Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II

Shop

Manual Manu al

MBHI M

diesel engne

Pub. No 97841-02003

602 ENGINE

Shop Manual

GROUP INDEX GENERAL

FOREWORD

ENGINE

This shop manual contains the specfcation, con strucion operaion, adjustmen and service proce dures o he Mode 6022 diese engine or service mechancs engaged in servcing o he Mitsubishi diese engnes. Please make he most of his shop manua to perform correc servicing and wasteess operations Noe hat some of he conents of ths shop anual are subect to change owing to improveents, etc. that ay be inroduced after pubcation o ths shop manual

LUBRICATION

..................... ................... ...

FUEL AND ENGINE CONTROL COOLING

...................... ......................

INTAKE AND EXHAUST ENGINE ELECTICAL CLUTCH

MAR 1989 SPECIAL EQUIPMENT

Applcable Engine odels 6022 6022-T 6022TC

.......   

m I       B

} Fo, industal use

n ine a ts ail o a ts one

E g

P r 2@gm

.c m P r .c

ph

: 269 673 1638

602 ENGINE

Shop Manual

GROUP INDEX GENERAL

FOREWORD

ENGINE

This shop manual contains the specfcation, con strucion operaion, adjustmen and service proce dures o he Mode 6022 diese engine or service mechancs engaged in servcing o he Mitsubishi diese engnes. Please make he most of his shop manua to perform correc servicing and wasteess operations Noe hat some of he conents of ths shop anual are subect to change owing to improveents, etc. that ay be inroduced after pubcation o ths shop manual

LUBRICATION

..................... ................... ...

FUEL AND ENGINE CONTROL COOLING

...................... ......................

INTAKE AND EXHAUST ENGINE ELECTICAL CLUTCH

MAR 1989 SPECIAL EQUIPMENT

Applcable Engine odels 6022 6022-T 6022TC

.......   

m I       B

} Fo, industal use

n ine a ts ail o a ts one

E g

P r 2@gm

.c m P r .c

ph

: 269 673 1638

ORGANIZATION

GROUP CLASSIFICATION

1. GROUP CLASSIFICATI CLASSIFICATION ON

This manual s orgazed to severa grops assfied accodg to e enge bas eemets.

Grop

No.

Description

name

00

eneal

External vew majo speifiatons engine outputs lassfed by ppltion, egne nmbes aton pae genea preons fo serving general bolts nd nts tightening torque tble

11

Engne

Engine proper !ylinder hed vlve meansm ams pston rnkshft tming ger lywhel speiiations serve standrds speil too, toublesooting

12

Lbriation

ubiation system (oil pump oil filter, oil ooler speifiations servie standards, speial tool, toblesooting

Fe and ontol

Fuel ystem (inetion pmp inetion nozzle, fue ter, pmp dive se, wter sepator speifitons servie standds, speial tool troubesooting

3

engin

4

Coog

ooing sysem (wter pmp temost rdor oolng system enng proedres fn speito servie stndds speial tool troubesooting Air lene trbohge fer ooer speiitions sevie stndrds speal too troublesootng

15

Inte and est

6

Engine eletrial

Stte, ltenator reeting system reys, ut6mti stop devie, spefitios sevie standards speil oo troublesootng

2

Clh

Clth proper being se, speftons sevie standrds, speia tool toublesooting

6

Speil eqpmen

A ompressor r pressure governor spefiation sevie stndards, speil tool

NOTE: Each group starts with page 1 .

2

ORGANIZATON - TERMS ND UNTS, ORGANIZATON UNTS, TBLE OF CONVERSON RATE FOR FOOTPOUND UNTS NTO S UNTS 2. TE TERM RMS S AND AND UN UNIT ITS S

The following terms and units ae used thoughout the entie texts of this manua (1) Font and Rea he tems "font is the fan side and "ea the fywhee side of the engine. (2)) Ri (2 Righ ghtt and and Lef Leftt he tems ight and eft sha be used to indicate the side as viewed om the ywhee side of the engine (3) Se Sevic vice e Standa Standad d ems ems •

Nomina vaue Shws the nomina dimensions, dimension of an individua pa standad ceaance between pats in an assemby o the standad pefomance of an assemby

•

imit Shows the vaue o a pat at which the pat is no onge seviceabe fo the peomance as we as stength viewpoits equiing epacement o epai

(4) ig ighte htening ning o oque que Ove- o undetightening of bots and nuts has citical efects on pefomance and functions ightenng toque is theefoe speciied o some tightening points A tightening toque specifications ay be consideed as dy uness wet is specified Whee no tightening toque is specified use a toque vaue specifed in the Genea Bots and ts ightening oque abe. (5) Uni nitts o ength weight aea and voume the SI unit (ntenationa System o nits) is used with the metic notation jointy shown in paentheses. empeatue is shown in centigade ( C). °

3 TABL TABLE E OF CONVERSON CONVERSON RATE RATE FOR FOOT-POUND FOOT-POUND UNTS NTO NTO S UNTS UNTS Sg of SI ut

Uni

S o foot-pod u

Conversion ate

Mass qaiy of maer

k 

lb oz

1  = 2.2046 b 1   003574 o

Dimension

m mm

f

 m  32808   mm  003937 



al

cc

o

Foce

N (Newo

b

1 N  048 b

Pessue

Pa (klopasca

bf 2

 Pa  0145 bfn 1 Pa  0953 H

Sess

N/cm2

lb/

1 Nc  145 b

Moet o fore

N 

bf f

 N m  07375 b 

Op

kW owa

P

 W= 134 P

Tempeate

"C

F

° C   18C + 3) 

Capacy

in.

1 1 1 1

   = cc = cc 

064 a (US) 00 a (mp) 0033814 o US) 0035195 o !mp

3

ORGANIZATI ORGAN IZATION ON - READ READING ING THE THE LLUSTRAT LLUSTRATION ION

4. REA READIN DING G THE ILLUS ILLUSTRA TRATIO TION N

(Ex. 1: Disassembly and Inspcton)

NV.L . Nomi iitnal Value mge discoloration

C4 os Damge bnorml we 06 Indictes the service standads

:� -3 ·o33 �P sVto08 pro1'7 t.oect· mm -

J

•oect V 02intmmog 0rod5 mmed ply L

Scrtcheson otop,otmeleteerid orphey, crcks discoored

1.0

ion tyo be madendibefcteoseidspect sassembl

ner o oto epeel  peedphey dmged corodd

\Indictes vis checs

er or oto epee r periedphery damged coroded mbers ssiged indicte a typicl disssembly seqence. ',

·g   Cg  rg @ P ©   g ® 2  g 2

 O g 7 S g 8 P  9 Cg 

Ipocede ndca\es hisexplthedisedssemb in they tet. C337C 4

ORGANI ORG ANIZATI ZATION ON - REA READIN DING G THE ILL ILLUSTR USTRATI ATION ON

(Ex. 2: Reassembly) Reassembly)

NV. omil Vue L iit Expnd spg b oron Psto proJon NV__ O 87 o  3

1age projctio i  V O o 8 mm I

s omprsson g ed gap dto

_

.

2nd compressi

ng d gap deto Rp 0-rig -rig

rg d gap cton

Gives sttio o obs to p rbber rig b doe t ssmby

4 m (5 kgfm p ok  � wsher Bd ok 2 =:'\ 1 -w�+

./

 m 5 m 8 kgm 2 km Wet Wt

I Spiis h ightig orq;

/

I

0r ;"' /� - _

st wth

aow ua

g

co

5 m (8 g) 10

14

Coeig rod Appy ege oi edNVpy or m gas   o 5 m  mm to ips

15

F o goove towrd sdig s. kst d py  NV 9 to  m   m

!wt ms t pt mst be tigteed i wt ste

dts  typ ssemby seqe

-

J

dits tt th ssmby prode is pd i t te C585 1 Iust Iustrations rations explode exploded d views views and assely assely dawdawings show a typica sevce pocedures if i is

identca aong vaous pes o avalae sses and unis 5

m·

GENERL CONTENTS

1. EXTE EXTERNAL RNAL VIEW •• •• •••• •••• ••• •••  2 2 M MJOR JOR SPEC SPECFIC FICAT ATO OS S  •• 3 2.1 MAJOR SPECFICATIONS • 3 22 ENGINE OUTPUTS CLASSIFIED BY APPLICATON    3

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Parts

3. ENGI ENGINE NE NU NUMB MBER ERS S AND AND CAUTON PLATE ••••••••••••• 4 4. GEN GENERA ERAL L PR PRECA ECAUTI UTION ONS S FOR SERVICING ••••••••• 5 5 GEN GENER ERAL AL BOLTS BOLTS N ND D T TS S TIGHTENING TORQUE ABE • 6

phone: 269 673 1638

00-1

GENERAL - EXER VIEW

1. EXTERNAL VIEW .

-· . 

-

-











A0243A

A0A

00-2

GENERAL - MAJOR SPECIFICATIONS

2. MAJOR SPECIFICATONS 1

  Engin model

6022

6022-T (urbcarg)

622C Trbochargd, wit afer cer

yp

Dies. 4cyce wacoe

Dsl 4cyc watrco

Ds 4cyc wacoe

Cmbuso e

Dret njecio

Dirc jcn

re neo

6 -le

6 iie

6 l

Item

N ad arangt f cylir Cylner boe x sok a isplacent

m

13

cc

1

X

4

13

49



X

14

49

13

X

14

1 49

Ege dmes

wihut a Ovea eg

mm

 39

 39

1 4

Ovea wdh

mm

898

872

882

m

 23

1 162

1 29

g'

98

 

1 5

Ova heigt py wg

,

• pty weig as easued accrdg o Mitsubs otos Cpa saad



G UU LD BY L e 622

622 (bcagd

622C (rbcarg wt afr cr

9 ( 46/1 5

16 216/1 5

79 24/1 5

App ee rat op

os rae outpt

kWHP/rpm

W (HP)/pm

29 73/1 8

186 249/1 8

27 277/1 8

4 89/2 

195 261/2 

219 234/2 

49 22 2

21 269/2 2

227 34/2 2

99 32/ 5

146 96/1 5

63 28/1 5

17 57/ 8

169 226/1 8

88 252/1 8

128 (171/2 

178 238/2 

199 (267/2 

35 (81/2 2

83 (245/2 · 2

26 276/2 2

Q:  he output (, gross) is corrected to standard ambient conditions based on  349  he continous rated output allows 10% (one hour) overload operation

00-3

• 3. ENGINE PLATE

GENERAL - ENGINE NUMBERS AND CAUTON PLAE

NUMBERS

AND

CAUTION

( 1 ) Engine Number

VALE CRN(ODlj IT 0r.16in) XHUS0W.24 F G  -53 L J MdB I 1 Valve clearance 2 Firing orde 3 uel injeton iming

E0143

The engine number s stamped on e position s llustaed. Ex:

6022 -1345

I

�-

Engine numbe

� Engine model

e engne number s mpoant n knowing te soy of te engine.

(2) Caution Plate

E75

e cauton pae is located as lusaed e cauton pae beas te valve clearance, fuel njecton seq ence ad timing

4

1

2

89012A

GENERAL - GROUP PRECAUTIONS FOR SERVCING 4. GENERAL PRECAUTIONS FOR SER· VICING

Beore startig the service pocedures check the vehcle or total time dive, use coditos. ad user's compats ad equests to now exactly the engine coditons Record iormation where eces sary To ensure you are doig corect and efcent service jobs observe the olowg precaos:

MITSUBISHI MORS �

L

GENUINE PARTS  Ao o G A        _   _

(7) The oil seals pacgs 0rgs and other rubber parts gasets and splt pins must be replaced wth a new one whenever they are removed or replace ment use Mtsubish Geune parts

A012A

(1) eore perormig the servce procedures gve n ths maual now the trouble spots and isolate the possible cause to deteme whether the remova or dsassembly procedure is reuired (2) Seect a lat surace or the servce job (3) When servcng the electrca system be sure to dsconnect the egative cable rom the battery (4) Careuy chec parts or ol leas beore cleag Aer cleanng t may become dcult to spot deec tve areas (5) eady and mae the most o the specal tools reured or servcng Use the rght tools (specied speca tools) i the right place to prevent damages to parts and persona jury (6) Mae aligmet mars and eep dsassembled parts neatly arranged to esure that they are reas sembled nto the rght positons • Speca care must be tae or assembes involv g a number o parts similar parts or parts dentical at rght- and let-had sdes to ensure correct reassembly • For aligmet ad punching margs select a poston that woud ot mar the appearance ad uncto • Cleary dstigush parts to be replaced rom those reused

A007A

(8) Apply the speced grease to pacngs o seals dust seas and beargs beore nstallaton (9) When wor reuires an assistant or two always mae sure o the saety each other Never play with swtches ad levers (1)Mae sure that your shoes are ree rom grease and oi especally when worng on a heavy tem (11)Whe checig or changig lubrcants wpe o grease ad ol rom parts mmedately wth a waste (12)Specia care must be taen n handling sesors and relays whch are suspectible to shocs and heat (13)Use care so that hands and ngers are not injured by sharp edges or corners o the parts (4)Wear saety goggles whenever hadling a grnder or weldng mache Wear goves as requred to ensure utmost saety



•

GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

5. GENERAL BOLTS AND NUTS TIGHT· ENING TORQUE TABLE

Unless otherwise specfed, the pats and equipment o vehie st be tghtened by the foowng stadad bots and nts. Tightenng toues fo these bots and nts ae shown beow

NOTE: 1 . Threads and seat surfaces must be in dry state 2 When there s a difference between the nut and bolt (stud) identification marks, tighten to the torque corresponding to the bot (stud) identification mark

Standad bots and nts Unit: Nm (kgf m) Dia. mm

Pitch mm

4T (Head mark 4 o O)

7T (Head mak 7 o 8)

BT (Head mak  o
5

0

20 to 29 (02 to 03)

39 to 59 (04 to 06)

49 to 69 (05 to 07)

6

0

39 to 59 (04 to 06)

69 to 10 (07 to 11)

7 to 11 (0 to 2)



1.25

 to 137 (09 to 14)

167 to 255 (17 to 26)

196 to 294 (20 to 30)

10

.25

16 to 275 (1.9 to 2)

343 to 539 (35 to 55)

44 to 5 (45 to 60)

.5

77 to 265 (1 to 27)

324 to 490 (33 to 50)

42 to 5. (43 to 60)

25

333 to 490 (34 to 50)

66 to 932 (70 to 95)

34 to 10 (5 to 11)

75

304 to 46 (31 to 47)

637 to 34 (65 to 5)

735 to 9 (75 to 10)

5

5 to 34 (60 to 5)

11 to 157 (12 to 6)

127 to 177 (13 to 1)

2.0

539 to 735 (55 to 75)

10 to 137 (11 to 14)

1 to 167 (12 to 7)

15

932 to 127 (9.5 to 3)

177 to 235 ( to 24)

19 to 265 (20 to 27)

20

3 to 11 (90 to 2)

157 to 216 (16 to 22)

16 to 255 (19 to 26)

12

14

16

Fange bots and nuts nit Nm (kgml Dia mm

it mm

4 (Head ma 4 o O)

7T (ead ma 7 o 8)

B (Head mak  o l

6

10

39 to 59 (04 o 06)

7 to 11 (0 to 12)

 to 137 (09 t o 14)



125

9 to 147 (10 to 5)

16 to 275 (19 to 2)

216 to 32.4 (22 to 33)

10

25

206 to 30.4 (21 to 31)

32 to 5 (39 to 6.0)

490 to 63.7 (50 to 65)

15

16 to 24 (19 to 29)

353 to 530 (36 to 54)

441 to 637 (45 to 65)

25

373 to 3.9 (3. to 55)

75 to 0 (B to 1)

.3 to 11 (90 to 2)

75

333 to 50 (34 to 52)

66 to 932 (70 to 95)

34 to 0 (5 to 11)

12

Identificaton mark of ut deifiaion mak o std 6T

4

®

@

Nmeical mak

®

deted mak

00-6

�

I

4T

8T

0 8 @

oched mak

(

Embssed mark

7T

A0066A

� < 

A0067A

m-

ENGINE CONTENTS

1 GR·A L

..........

2

2. SPECIFICATIONS •••••••..••••••• 3. SERVICE STANDRDS .................. 3.1 SERVICE STANDARD TABLE ..... 3.2 TIGHTENING TORQUE TABLE ... 4. SPECIAL TOOL .............................. 5. SERVICE PROCEDURES ................ 5.1 MEASUREMENT OF COMPRES· SION PRESSURE ........................ 5.2 CYLINDER HEAD ND VALVE MECHANISM .............................. 5.2.1 Disassembly ........................... 5.2.2 Inspection .............................. 5.2.3 Reassembly ............................

8 9 9 12 13 17 17 18 18 21 27

5.3

FLYWHEEL, TIMING GER AND CAMSHAFT ................................ 30 5.3.1 Disassembly .......................... 30 5.3.2 Inspection .............................. 34 5.3.3 Disassembl ...................._....... 38 5.4 CRANKCASE AND MAIN MOVING PARTS ........................................ 42 5.4.1 Disassemby ......................... 42 5.4.2 Inspection .............................. 46 5.4.3 Reassembly ............................ 56 5.5 INSPECTION AND ADJUSTMENT OF VLVE CLEARANCE ............. 62 6. TROUBLESHOOTING .................... 64

1-

•

ENGINE - GENERAL

1. GENERAL

(1) Combustion Chamber

Injecti zle

B076A

Pso

Fo moe effectve coong of the combuston cham be wate dectos whch diect cooan fow ae pesed nto the bottom of te cylinde ead

(2) Valve Mechanism

Valve c ·p Adjug cew B0375A

Rker haft _,-�/ baet

Vle ter Vle pig Vle pig

The combustion chambe is made up of the cylnder head and pston top. The injection nozze as wel as the nozzle tube s mounted to the cylnde head The nozzle tube holds the nozzle n postion and potects the noe sheathed by t fom coolant Since the utside of the nozzle tube is exposed o the wate acket, the top end of the tube is sealed off wth an 0-ing and the bottom end staked to peven t entance

iner

Lwer retaier ae tem eal Ve gde

Tppet

of wate Combustion s accomplished by compessng the fuel diecty nected into the combuston chambe

37A

The valve mechansm s of ovehead vave type and s constucted as shown above

112

m

ENGINE - GENERAL

(a) Both ilet and exhast vaves are made of suace-eated heatresst seel The vave seat agle s 45. A vave sem sea s povded o he em o vave to cotro the quaty o lbrcat o he valve ad vave gude sdg ortos (b) The vave sgs are eveytched srgs Two er ad oter srgs deet  coed decto are staled (c) The rocker ad rocker shat are suorted o the rocker shat bracket ad are deedety staed or each cyde Some rockes are sed or both et ad exhast valves, ad the ed sdg orto s queched The rocker shat s a hoow rod rod sead o by thrst ates at both eds The sde o the shat coses a ege o assage (d A stee ba ad cocave ece are resectvey weded to the bottom ad o eds o the sh rod ad both eds are casehardeed (e) The tae s o cydrca shae ad ts matg suaces wth the camshat are sherca The aet s removabe thogh the sde o the crakcase ( The cam oe o the camsha has a seca curve The srace s dctohardeed o mrove the erormace o the vave mechasm at hgh seed oerao ad mrove wear resstace

(3) Crankcase and Cylinder Liner

·  Ruber in�1 ' 0-g 8037

(b) The cooat ed  rom he water m a he et rot ed o he crakcase coos the o cooer te ows through the water jacket hoes ad arod a the cyders to coo them beore reachg he cyder head (c) The cyder er s o removabe wet tye ad ts to ad botom are ressted at the to o the crakcase ad the water jacke  crakcase resec tvey Rbber rgs ad 0rgs are staed at the to ad botom o cyder er o revet etry o cooat The water acket has a cooat throtg she or hgher coog erormace

(4) Piston and Piston Ring (a) Piston <602, 60-TC> Weight

<6022_T ;· �-a 'Size mark 1 d

I

. k

(A, B ) •

�L \e, ,

Srn mak

Pt

_� ·  CJ   /

/ 7;�, - · -.)

_ Pa nuber

If'� _-, ) /  . -y  _ l' 1 .

!

so rg insert

-

"F wh a aow fo he o mar

84205A

(a Seve camshat bshgs are staed to the camshat bearg orto o the crakcase To ac tate serto ad remova o he camshat rom he rear ed o the case he bearg ID s arrower toward the rot

B019E

The so made o amm aoy castg, has a toroda tye combso chamber a ts to

11-3

I

ENGINE - GENERAL

A Niresist piston ring insert is cast into the 1st piston rng groove to nease duabilty. Stamped on the top srface of the piston ae a sze mak (or ovesie dimension on oversize pistons) for selecton ft with the cylinder liner, a piston weght mark pat nmbe dentifcaton mark and the "F" with an arow fo the front mak showing the pston instaling diection. Piston pn fo connectng pston to connectng od s of fll-floatng type and s pevented from moving ot by means of a snap ing nstalled on each end of the pin ends. On the piston fo the 6022-TC a coong cavity is provided

5 Connecting Rod and Connectng Rod Bearing

602 > I , ·

I

(b) Piston ring

�  [1fsutl ckoemprysoees iotynpre)ng =-  ct type! (oX Oidual rlintype wth <6022. 6022TC> an expaner sprin 6022T ony>

compresso rig )2nd [taper faced iner I

B0374C

Thee are three piston rngs instaled: two compres sion ngs and one oil ing he sldng sface of each ing is hard chrome plated to mprove drablity he piston ings are shaped as shown in the figre.

4

39E

The connecting od s a die forging of  cross setion povidng hgh igidity A ead brone bshng is pess-fitted onto the sma end he connecting rod beaing of the big end is a split type pan bearing hrogh the stem of connecting od an oil passage is povided obliqely to lbricate the small end bshing On the top of connecting rod for the 6022-C an oil hoe s povided or cooling the pston he connecting rod and connecting od cap are coped wth for bots

m

ENGINE - GENERAL

(6) Crankshaft and Main Bearing

·-    

·-,

hole



  

· Ruber type (singe mass ; / Torsioal daer

�

/

I 

Jual sctin1 � Tr dpr Crk py

B wg 84206A

(a) The crankshaft is a high-rigidity die forging integ ral wth the· baance weight. An o hole n each journal s through to that n pin, feeding some of the main beaing ubrcatng oi to the pin for lubrication of the connectng rod beang.  



Flywhe ousing

9-ring

 

· Cf - r dmpr } _  k   1r 

B449A

he front portion of the crankshaft is a fange type to which the crankshaft puley s mounted wth ots A torsonal damper mounted to the puley absorbs the torsonal vbraton of the cankshaft

\ \

351

b he cankshaft gear divng tmng gear s ftted onto the rea end of the crankshaft Note that the cankshaft has an axal p type ol sea tted to each o ts font and rea ends

11-5

m

ENGINE - GENERAL

(a) Main bearing

The man bearng s a split ype pan bearng made of speca aoy pated kemet meta wth bakng meta The uppe main bearng has an nenal ol groove an o hoe whch concdes wh he o hoe n the crankshat Seven pas o man beangs are provded. Spt ype thrst paes are moned o he rear-mos beang  bear the hrs o he cranshat

Upper main bearng

Lower man bearng

Thrust plate

B0382A

(7) Timing Gars

Camsaft gea �3

Injec pmp ea =63

Ider gea "A 33 Crankshaf gea Z63

der gear C 8

Ier ea z47 O pump gea 53

The mng gears ae accommodaed n he flywheel hosng a he rear o the engne The gea ain s as 11-6

shown above.

B383B

m

ENGINE - GENERAL

Eac gar s a carbon stel hica a aving a g-prscsion oot suac macnd by t shav ng acn and vn srfac tan to pov draby. A ng a s stapd on ach tng ga Corc sng can b acvd by agnng t ng aks a rassby.  cansaf gar, pssfd ono  cansaft and d n poson by a dow pn, dvs a gars

(8) Flywhee

Pit brin

Cyir N. 1]

yr N  '

Idler gr "A Coa

 fyw s ad of cas on. T po bang of  cc saf s nsad a  cn of  fyw  ng ga wc ss w  sa pnon s snkagfd on  osd ppy of  fyw.

Crnkshft

Tu pl

8036A

8034A

T dr gar s, a on nd, ontd o t cancas w  dr saf bo, and sppord, a  ot nd, on  fyw osng A bsng s pssd no t d gar wc s on  d saf.

T ng gar  crss a ndcton-adnd o assr g daby On sd of  t s cafrd to a s a  sa pnon fts asy T cynd nbs and ang sca ar sapd on t otsd ppry of t fyw as sown n  fg

 bsng s bcad by  ngn o fowng og  nsd of  dr saf fo  crank cas o o

11-7

•

ENGINE - SPECIFICATIONS

2. SPECIFICATIONS Item

Specifications

Engine mode ype Nmbe o cyides aangeme Valve mecanism Combsto ambe Cylide boe x stoe otal dispacement

mm cc

Compessi ato Fiig ode

6022

622-T

6D22TC

Waer ooled, 4 cyce diesel 6inlne

Wate cooed 4cyce desel 6iline

Wate cooed 4cycle diesel

Ovehead valve

Oveead valve

Oveead valve

Diect ijecio type

Diect ijecto type

Diect injectio type

13 X 4

13 X 14

1 3 X 14

11 49

1 49

17 153 62 4

16 5362 4

149 15.5 153624

6inie

11

Cylide lie

Type

Wet type

Wet type

Wet type

Piston

ype

Tunk slppe skit type

Tk slippe ski type

 ·sppe skit type (Coolig cavity povded)

Pisto ing

'ty

ompession ng 2 Oil ing 1

Compession ing 2 Oi ig 1

Compesson ing: Ol ig 1

EnginePats2@gmai.com Pats pone 269 673 638

1-8

m

ENGINE - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1

SERVICE STANDARD TABLE Unitmm Descriptn

Nomal v;u

Lmt

Corecton and remak

!Basic diamet, I Cprss prssu

at 200 p) Roce to oke aft cleaace Oue valve sping

Fee length Load nstaled legt: 835)

I v spg

ee engt oad staled ength 035) Squaeness

28 003 to 008

0

Replace uhig

8938

8 5

Replace

0 N 6 kg

380 N 39 gf

6.0

620

1  2 g

00 N 02 gf

Diffeence betwee cylider wthin 039 MPa 4 gfc )

Replace

25 02

Replace tappet



05

Repace

00 o e

008

Coect o epace

30

98

Replace

et

.95 to 96

85

Replace

xat

191 to 193

Ps od unut Cylide head botto srface distotio Height fo op to botto uace of cylide head

Valve te to valve guide clearance

196 MPa 20 gfcm

-

Cacae tappet ole to tappet cleaace

Valve tem OD

2.7 MPa (28 g/c2 

35 006 to 00

nlet

2 005 to 009

Exhat

2 0.09 to 0

02

Replace valve gde

Replace vlve seat ie Sevce lit value when a new valve is italed - indicate projecto aout)

nlet

02 to 07

0

xhaut

05 to 05

0

45"

-

nlet

22

1.7

Exhast

2

20

Seat width of ae  

269 to 296

3.5

Coect o eplace

ccetcty o flywhee houing



02

oect instaled conditio

Depth of valve from cylinde head botto suface

Valve eat angle Vave agn

[email protected]

Replace

Parts phone: 269 673 1638

11-9

•

ENGIN - SERVICE STANDARDS

Uit:mm Nomnal vue [Bsc dm

Descripton

Fywh

Corcto d mks

-

0.2

Coct istd codto

01 o ss

02

Coct

48

495

Rpc

Btw ckshft g d d g "B

02 to 026

0.4

Repc

Btw d g A" d cmshft ge

03 to 026

0.4

Btw id g "A" d id g C"

03 o 026

04

Betwe jcto pmp g d id g C"

02 to 026

04

Ecctcty (ywhel hosg) ctio sc dstotio Depth fom cltch cov motg sfc to ficto sfc

Bcksh of tmg gs

Limt

d py of d g

01

to 028

0.4

Rpc thst pt

·'

Id sht A" to d g A bshg cc

40 003 to 006

02

Rpc bshig

Id shft C" to d g C bshig cc

46 003 to 006

02

Rpc bshg

d py of cmshft g

005 to 022

04

Rpc thst p

No  jo

65 003 to 008

025

Rpc bshig

No 2 o

6525 003 to 008

No 3 jo

6550 003 to 008

No 4 jo

6550 003 to 008

No 5 jo

6575 003 to 008

No 6 jo

6575 003 to 008

No  o

66 003 to 008

Cmshf jo to cmshft shg cc

It

883

83

It ob hght, 566; bs cic dmt 4334

xhst

882

83

xhst ob hght 56036 bs cice dimt, 426

Cmshft bd

005 o ss

008

Repc

Ccs top sfc dstoo

00 o ss

02

Coct

Cm pof c btw obe hght d bs cc dmt!

[email protected]

11-10


m

ENGINE - SRVICE STANDARDS

Ut:m Noal vue

Oes1pn

Limt

Crcti d k

[Basi d1mcl Cyn

34  54

0.

lner

yy (r b

Rc � c t sz.

2 or e

Pj f cs top uf

Po o yi

25

·-

O to 8

-

 78 o 2



  to 99

-

622C

 88 o 2

-

 rng

6 to 

25

622

5 o 8

5

622T, 622· TC

7 o 

622

Rp o p yr , o p po

 -

 - 6022T o )

Po g goov o g 

2n rig

 o 6

5

 o 6

5

Pojo of po ro op  o k

87 o 

-

Po p ho o po p ac

5  o 2

i g Po g op  

Fn o yr ir g uppotg r



o ckcs

Cong o

Bhng o pto p rn Bn  s E py

Cog o g

 

 g

Mor   

Rp Ch h p Rp io or st  Rp rn Rp hng



5 o 

Co or p

2 o 5



Rp

8 . o 

25

Rp rg Rp



L th 95

 py

9 to 2

0.4

At wt ovrz h pt

B

 o 



Cor or p

oro o o  p

 o 

8

G  o o d

Cyy o jor  p

6 o 



 

 8 o 5

Tion wh  Cht

5 2 o 5



p pto rig or ion

Rp g Rp



 h 65

I

0.4



Aj

Exh

6



Aj

To wh  Vv 

25

[email protected]


1-

• 3.2

ENGINE - SERVCE STANDARD

TIGHTENING TORQUE TABLE Descrption

Eg op

Cyler h bot

Tea ze 0. x Ptc mm M14

x

gteng toque Nm (kgfm

2

-

15

3 4 (3 .5)

Wet o tgng ocedr eer o 523 (6)

Roker sft rcket ot

MO

Rockr cover ot

MO

x

125

98 (1

Rocker justng scew ok u

MO

x

25

59 (6

 jet cec v

M12

x

75

3 4 (3 .5)

onetg rod nut

M13

x

125

115 (12)

Wet

Mn ing cp ot

M8

x

25

37 (38)

Wet

rnkst pue ot

M14

x

15

175 (18)

ms ger nt

M27

X

15

265 (27)

x

"A

M16

x

2

55 (16)

r sft ot "

M16

x

2

155 (16)

Ir sft ot

r st nt (o mouting cor!

M16

x

5

98 (1

Fw ot

M16



5

315 (3

Fwe osng ot

M2

175

69 (7)

x

[email protected]

1-12

Remrks

Wt

We


m

ENGINE - SPECIAL TOOL

4. SPECIAL TOOL Tool me Comrssio gug adt

Par No

Sh;p

U

MH0614GI

:�m
8500A

M0639

k gug

Masum o cno r

Adjustmen of val cr

80A Vlv lfr

Vlv 

M0666

ook

M06679

Rmovl a lo o vv o

Valve iftr

ID. 42

Hok

02A Nozl ub mov

MH06232

Rmovl o o  Damr 2.

�

�-

Dm 7 0A

 l

M0606

Rmov o   uy

Mxmm l  200 o  oo

07A Rmov   o o o· 

3-02900

0A

1-13

•


Tool ame Rocke bhing pue

Part No.

Shape

Use

MH061236

Reoval and ntalaton of ocke bng

B5311A Vave gude plle

30091-08100

Reoval ad talaton of valve de

B51A Valve eat ne calkng ool

Calkng ool body MH061360 akng ng nlet MH06160 akng ng exat MH06165

Intallaton and alkng of valve ea ne alkng too , body

0.

Ilet 59 Eha4 Daete 12

Vave lappe

B5202A

30091-07500

Lappng o vave

B5261A dle gea bhg plle

akcae abe

MH06228

Reova ad talao of le gea bhng (Idle gea "A)

MH06206

Reoal and ntallto of dle ge buhng (Idle gea 

MH06188

Meaeen of flatne o cynde le flange uppog fae on ankae

B180A 11-14

m


Tool name Cyider  xtco

,l No.

Us

Shape

MH06490

Remva f cyindr r

B513A Cyn r nstar

MH0179

Press-ttng  cynr 

Cntg r bushg pr

M0128

Rmva a ttn  ntng r bshg

B52A R  sa sg a

MH066

rsstg    sa sgr

Frn  sa sgr isar

MH068

rsstig  rt i sa sg

Dm \/ 5 '

B0585A Pn g

st g ap

M01

Psn gu r

M058

Piston gude clamp

Isr f ist

0. 13

Pso gude lever

B511

11-15

•

ENGINE - SPECAL TOOL

Tool name

Pa No.

Noz tub stap

MH061229

Nozz ub nstar fang

M061416

Noz b nsta bo

M061231

Shap

Us Istaation of o b

bwn cnts 46

Datr 8 51A Vav s sa nstar

ME067431

Prs-fng of vav st sa

ar 12

Dat 24 591A

11-16

ENGINE - SERVCE PROCEDURES

5. SERVICE PROCEDURES

5.1

MEASUREMENT OF COMPRESSION PRESSURE

Compresson pressure must be measured pro to sassembly of he engne. Measure the compresson pressure at regular nter vals an keep rack of s changes During he break-n pero or afer pars have been replace wh new ones, here s a sght ncrease n he pressure as the pston rngs an vave seas f snugly n poston As rough eges an frcton between pars are graually reuce the pressure comes own Measurement Procedure

•

NOTE: Cover the mounting holes and injection pipes to prevent entry of dust and dirt

NV

Nominal Vlue

L

imt

V 2.7 MP 1 kgf/cm') L 9 M 0 kgfcm 1) Dfferece betwee ydes 03 Ma 1 g/m) maximm Cmpess Gge At , MH0646

8556A 85554A

(1) Reghten he cyner hea bols to spece orque an le the engne warm up un he cooan eperaure reaches 75 C o 85 C 

°

NQTE In retightening the cylinder head bolts, observe the tightening sequence in (6) in 52.3

NOTE 1 Make sure that the engine speed is also measured as compression pressure varies with the engine speed 2 Make measurement fo a cyinders as wear and other conditions vary from one cylinder to another

v\ � . -·

,

'

.,� < . '·

(3) Insall Compresson Gauge Aapor (speca too) on he necon nozze mounng hoe ogeher wh a gaske an connec he copresson gauge (measur ng nsrumen). (4) To make sure ha he fuel s no fe uner pressure rom he njecon pump pul he stop lever o he necon pup al he way n he sop recton beorehan (5) n hs conon e he sarer run he engne an measure he copresson ressure a a roang spee o 200 rpm

- "

85560A

(2) Remove al njecon nozzles from the cylner hea 1-17

m 5.2 521

ENGINE - SERVICE PROCEDURES

CYLINDER HEAD AND VALVE MECHANISM Disassembly

Oil hoineg � , -ea We . dmged theds Waga eler ksls 19

9

Wer. dmge

23

Crbon scldepsie io, crcks depsin, dmge 18

bncns deposiion burn. dge, rdge wer

igsW leeerskses  2 3 4

5 '6 7

® 9

10

@ 2

Rocker cover Rocker backet ountng bolt Cynder head bol Thrust pate Rocke Se scew Rocke shaf Rocke shaf bracket Push rod Valve cap Vave coe Upper eaine

3 4

@

6 7 8

{)

20 2



23 24

Ouer vave sprng Inner valve spring Vave sem sea Lowe etaine nlet vave Exhaust valve Nozze ube Wate diecor Seaing cap Clnder head Cankcase sde cove appe

Fr dsasebly of s w  ecie ue, see lowing ies C1542A

[email protected] -


•


(2) Removal of Cyinder Head Assemby

Disassembly Procedure (1) Removal of the Rocker Shaf Bracket Assembly Rocker ve

Cylindr hea

Roer sha bckt mun1� l

y  gskt Knock pin

Cylid  l Ajg w 

B904B

C1543B

(a) Where the push rod is orcing the rocker up, the rocker adjusting screws should be loosened before al bolts are removed.

14B

he cylinder head is held in position by the dowel pins on the top surface of the crankcase o emove the cynder head lift it directly upward NOTE: 1. To remove the cylinder head, make sure that the injection nozzle is re moved beforehand (Refer to Group 13 Fuel and Engine Control.) If the cyinder head is placed on a workbench with the nozzle still installed, the end of the nozzle extending from the bottom sur face of the cylinder head will be dam aged. . When the cylinder head gasket is re moved use care to prevent damage to the cylinder head and crankcase (3) Removal of Valve Cotter

(b The rocker shaft bracket assembly is hed n positon on the cylinder head by spring pns. Lif it directy upward to remove t Vv Lfe , Hk MH061679

V f MH61668

Vv 

/ �

I 8522

o remove the valve cotter use speca tools (Valve ifter and Hook and compress eveny the valve spring [email protected]

Parts phone: 269 673 1638 11-19

m


(4) Removal of Nozzle Tube

Nozle Tub Rmovr MH061232

oe tue

C1527A

NOTE: The nzzle tube need not be removed unless water leaks, gas leaks, etc. are evident.

11-20

•


5.22

Inspection

�-





 - ·

C BO 28 NV 003 o 0.08 L 0

  

  

 





B  i Dm NV. Non Vlu  mt

Fre lh NV 898  85 oda gh NV 40N (61 kgf/ 8  380 N (9 f 8   NV 604  6.0

o isld  NV 1 N  0  100 N 0 kg0

Runot

L

0 . 5

Vv  D I vv NV 119 o 11.9  118

 p o o pp c  3 NV 0.06 o 00  02

S q   2

Ex v NV 1191 o 1193 18 

Vv gi o vv   Ex vv  vv  2  12 NV 0.0 o 009 NV 0.09 o 0.12  �2 02  Dp of vv fo boo f of   Ex vv  vv NV -00 o 0 NV 02 o 07   0 0

Vv   NV 22  17

Ex NV 2  2.0

Vv  i  wi NV 29 o 296   Doio o yn  oo f NV 007 o   008 Hi o o o oo f of i  NV 0 298  Vv  gl NV  '

[email protected]


2A

1-21

m


(3) Inspecton of Valve Sprng

Inspection Procedure ( 1) Rocker to Rocker Shaft Clearance

Sqaenss !er spring ly)

�

C701A

Measuring position

C2734A

If the limt is exceeded, replae the bushng in the rocker.

Mesure he free engh and installed load of the spring and replace if the measurement exceeds the m. For the nner spring check also fo squaeness.

(2) Replacement of Rocker Bushng

(4) Tappet to Crankcase Clearance

To emv

 stall

Measrn sn

C5A

Adjustng scrw sd

NOTE:

1. Algn the bushng and rocker ol holes. 2. Face the bushng jont toward the ad· justng screw

C273A

f the limit is exceeded, repace the appet.

[email protected]

11-22



(5) Runout of Push Rod

D

(7) Valve Stem OD

Measurg poitin

C2747A

30

Check for runout and replace if the reading on the dial ndicator exeeds the limit

Replace the limit

(6) Cylinder Head Bottom Surace Distortion

(8) Valve Guide to Vae Stem Clearance

valve

f the measurement is below the

Measuring poto

6B C315A

I the imit s exceeded, correct the distortion wth a surface grinder. NOTE:

aculate the clearance frm the valve guide D and valve stem OD f the mit is exceeded repace the valv guide [email protected]


Grind the cylinder head only to the extent that the height rom the top to bottom suraces is within the limit.

11-23

•


· (9) Replacement of Valve Guide

0

Vave Guide Per 3009-800 Vlve gd

God

Bad

Bd

C70A To nst

C311A

Using Va!.ve Guide Puller (special tool), eplace the vave gude NOTE:

When the valve guide is installed, make sure that the valve guide flange is securely seated on the cylinder head.

If ay unusua contact patte s ot coc  follows Mo faut: Lappg Seious fault Coect vave and vave seat

(11) Correction of Valve Face

Valve seat ang al .mari ,

(10) Valve Contact with Valve Seat Insert

-

�, · .J

le

C2708A

224

C0

Grind the valve face with a valve reface to obtan th specife vave seat agle NOTE:

(a) Apply an even coat of mnium to the valve seat nset surface  contact with the valve b Using Vave Lappe (specal tool), let the valve ht against the valve seat insert once NOTE:

1  When letting the valve hit against the valve seat insert, do not turn the valve. 2 Contact pattern should be checked when the valve guide is inspected or replaced.

1-24

1. Keep grinding margin to a mmum. 2. If the valve margin is below the limit after the grinding correction, replace the valve. 3. After the grinding correction, be sure to lap the valve and valve seat inset [Refer to Item (14) that follows.] [email protected]


m


(12) Correction of Valve Seat Insert

(13) Replacement of Valve Seat Insert Sne the valve seat nsert is instaled by expansion fit epace it by the followng procedures

C3127A Valve sikage

Vv margin

Vave seat age

Cu of.

5 o  211

(a) Grind inside suface of the vave seat insert to reduce the thickness and then emove it at oom temperatue Valv sa  Vave

C270A

(a) Using a valve seat cutter, cut the insert to obtan the specfed valve seat ange and seat wdth. Use 15 or 75 cutter first then 45 one. °





NOTE:

1. Keep the amount of cut to a minimum 2 If the valve sinkage after cutting ex· ceeds the limit, replace the valve seat insert (b) Afte correcton ghty grnd by holding about #00 sandpaper between the cutter and valve seat inset.

Had 0 7 + 

ead  52 +3 

(I de)

Exhaus sd) C8

all

Cakig

D

D

Caukig Too Body MH66

>-J

NOTE

After the correction procedure be sure to lap the valve and valve seat insert [Refer to Item 14) that follows.]

Caukig Rig l 665 au 665

811118

(b) Make sure that the cylinde head and vave seat insert are provded wh suficient inteerence (c) Immese the valve seat nsert in iquid ntogen for cooing it and uly heat the cylnde head. [email protected]


-25

•


(d) Insta the valve seat insert usng the Caukng Tool Body, Caung Rng and Cauking ool (specal toos) and cauk the perphery of the valve sert insert. NOTE: When the valve seat insert is installed, direct the chamfered side of the caulking ring toward the valve seat insert.

(e) Reface the vave seat insert so that the seat width and valve sinkage are up to specfcations.

NOTE: 1 Make sure that no compound stik  the valve stem 2 Use intermediate-mesh compound  20 to 1 5 meshes) first, then finemesh compound 2 meshes or more for finishing. 3. Addition of a small amount of engine oil to the compound helps make it easer to apply it evenl

(14) Lapping the Valve and Valve Seat Insert

he valve and valve seat insert contact must be even throughout their contactng surfaces hey ust be apped whenever eithe the vave o vave set nset has been corrected or replaced.

30

Compound

C2715A

(a) Apply a thin even coat of appng copound to the seatng surface of the valve.

(b) Usng Vave Lapper (specal too), seat the valve and valve seat nsert Whie turning the vave sighty at a time strie t aganst the valve seat insert (c) Wash away the compound n gas ol, etc. (d) Apply engine ol to the contactng surface to seat them with o. (e) Check to ensure that they are propery sete [email protected]

1-26


m


5.23

Reassembly -

�

·



  ·     

   

Cose-coiled end on the cynder ead sde 1

14 10

1

2

3 4

59 Nm 6 kgfm)

5

6

7

8

Coscoed end of o e yde ed sde

Lea es: No eas ae aowed w a 96 Pa (2 gf/cm' dauc pesse.

9

Appy seaa o noze ube THREEBOND 21 o equvae 21

4 Nm  gfm)

98 Nm  gfm)

3

23



22

24

Refe o em 6 seon 2 17

8

[email protected]


L+·�{,-87   32  T 23_ 752 Fo assemby o pas w an encced numbe see foowng ems C641C

1-27

•


Reassembly Procedure

(3) nstallation of Valve Stem Sa

(1) Installation of Water Director Water director alng cp Algn notch wth ths lne. Cylde head 6 mm

® �

2 mm

0g O

Vale t ea lide 

� ®o 0

G38 C642A

Instal the water diecto with its notch diected as shown.

(2) Installation of Nozzle Tube

he vave stem sea shoud be nstaed by apply engine oi to the ip and sting down Vav Ste Sea Instae (secial too) until it touche the cynd head NOTE:

1. Before the valve is installe, appl  small amount of engine oil to t tem 2. After installation check to ensre tha the valv stem seal sring has nt ben deformed or damagd

Nzzle Tube Insle B MH013

(4) Installation of Valve Cotter Aly engne l Aly elnt (HREEBOD 1  eqvlen) Vae ook M79

(a) Apply seaant to the end o the nozze tube and nset into the cyinde head (b Using Nozze Tube Fange (speca too, pess the nozze tube against the cynde (c) Appy engine oi to Nozze Tube Stamp (specia too and inset into the nozze tube (d) head Nozze Tube Instae Bot (special too) to push the stamp unti it can be emoved om the bottom of the cyinde head (e Ate instaation perom eak test to veiy wate-tightness

Ve oer

B5

Insta the vave cotter whie compessng the vave sping, usng Vave Lifter (secal tool NOTE

Install the valve srin wit the closely coiled ortion toward the cylinder head [email protected] Parts phone: 269 673 1638

11-28


(5) Instaation of Rocket Shaft Bracket and Cylinder Head

m

(6) Tightening of the Cyinde Head Bots

C6649A

Cylinder hea -�; gasket

\

A

Tighten he cyinder head bots  he seqece shown above to 175 Nm (18 gf) Ate tighteg eriy the correc torqe then r tighen 90 j . ?°

°

[email protected] Parts phone: 269 673 1638

Locaig p

B9014C

Seat the cylinder head on the crakcase, whle lning i up wih the locaing pin.

11-29

•


5.3

FLYWHEEL, TIMING GEAR AND CAMSHAFT

531

Disassembly

�o J S

10A

�'

Damage, usa wea n gea 9

4 1

3 Streas on wor srface, cracs taper wear

\ 5

Wea deeioraion

. 7 Oil leaks

1 Fywhee mountng bot 2 Plot beang @Fywhee © Oil seal etainer  Ol seal

(r Colar

7 Fywhee housng 8 Rea ol sea slnge ® Ring gear 10 Tachomete drve 1 A Speed senso

For disassemby o pats wih an encrcled nmbe see ollowng tems.

C1926F

11-30

•

ENGINE - SERVCE PROCEDURE �  -

NV N  V .

ck sga  B  Crnkshaft g a  e , NV  0.26   Lle g�: 0·12 "A 2a6 sha g NV 0 1 3 o  eLNV 00 413 A - C  IjNVio0o 412pu P ga d 9 L 04

o

L

-�·Timng cr b .

e

Limt

e r

o

O  as

20

e

c m

o Oogg

er ger

gear

e

o

e

r

m

-

ear "C

19

o 0.26

7

pay NVd  g a d 0 2 8  04 e

16

e r

W a dmg e

13

e

W a e

2

Wa

14

g 0a22d ply NVCasha D   L e

to

0.4

Camsaft F) Camshaf gear 3 Trus pae  4 Ider saf b  5 ust ae 6 de gea C" 7 de gear A 8 Ider gear B 9 Ider saf "A 9Ader saf "C" 20 Rear pate

*/ /1·

w p h,  d d   d  s  owg  F dpsass bdY ;  as a mus Th  o         o d uss d  '  d   ov h  sho     ,   w       a ma -    or

r

t

m m r

r e

o

b

c te

m e befor e

o

m

s.

ssem bly e

ets ae evdet

C27C

1-3

•


Disassembly Procedure

(3) Measurement of Gear Backlash

(1) Removal of Flywheel Threaded ole fr remva

C930A C1928B

Thread the mounting bolt into the emoving threaded hole to remove the fywheel

(2) Removal of Oil Seal Retainer and Coller

If th backash exceeds the imt ceck idler gear bushing and gears and replace pats as necessay.

NOTE: For a pair of gears, the backlash should be measured at more than three points to determine whether it is acceptabl. (4) Measurement of End Play in Idler Gear and Camshaft Gear

readed es   emva

Oi sea etane

C99D

•

o reove the oil seal retainer turn down the attaching bolts into the eoving threaded holes evenly, whie aking sure that the oi seal retaine does not have eccentricity remove the retainer with the oil seal attached. • Reove the collar y screwing M4 x 07 bolts into the reoving threaded holes.

11-32

C93

If the end play exceeds the imit eplace the trst pate


m


(5) Removal of Camshaft Gear

NOTE:

Do not strike the gears wth a hammer. Make sure that the gears are removed by use of a gear puller

Thrust plae Camhaf gear

(7) Removal of Rng Gear

Caha . Remove hrus plae his hoe /. r hu pe moung _ .J E bo

mounting bol through -1

C1932B

Accessing through the holes in camshaft gear, oosen he thrust pate atachng bolts. Then remove the gear togeher with the camshaf

Rg ge B356

(6) Removal of Camshaft Gear

Using an acetyene torch heat evenly he rng gear and ay a rod o the ring gear to ta i thrughout its erihery [email protected]

Lock 

Lock wahe


C933B

Remove he lock nt and oc washer fro the camshaft gear ad sng Gear Pler (secia tool) remove he camsha gear.

11-33

• 5.32

ENGINE - SERVICE POCEDURES

Inspection

Depth om cluch covr monig sfac o co sc NV 48 L

NV.. L

Nom V m

49.5

oo o ro sc NV 01 o ss L 02

C2758

1-34

m-


�

   -

BO . NV L

  

   



-    

Basic Dmetr Nomnal Vu t

Cra O 40 NV 3 o  6  2

a O 4    6  

C pf (dc bw o hgt a b

cirle damte)

O k vv a 88 !x vav ) 8 L

Cf j a  b c O  1  65 N   6525 o 3, 4  655 o    657 o. 7  66 N 3    

 w  g d ba c  3 B

NV 005 or les L .8


9

1-35

•


Inspection Procedure

(2) Correction of Flywheel Friction Surface

( 1 ) Distortion of Friction Surface Cltch cover mounig sufac

Frci sufce

C35098

Place the fywheel on a surface plate and move a dia indcator in the dametal direction of the flywheel to measue distoion. Use o a potable jack wll make it possibe to take a more accurate readng. If the distotion is n excess of the epai lmit, grind the fricton suface. NOTE:

If the ring gear shows and abnormal condition, replace the ring gear before measure ment. [Refer to 5.3. (7)

Corect the fricton srface with a surface ginde. Make sure that the friction suface is parae o suface A within 0 mm. f the dimension of portion B exceeds the evie limit, replace

(3) Idler Gear to Idler Shaft Clearace

Mesng posio

E

Mesg oso

+ 37

f the limit i s exceeded the bshing in the gear shoud be epaced.


11-36


(4) Replacement of dler Gear Bushing

rssur

Pressur

m

(6) Camshaft Joual o Crankcase Cam• saf Bushng Clearance

IBshing dl Garu MH06128 (for r g "A) MH062046 or  gr C � usng r g To remv

To instal

402A

C3808A

Replace the bushing by he pocedures shown in illustation, sing Idle Gea Bushing Puller (spe_cial oo). NOTE: 1. Insall e busng w camfered sde of gear I.D. nward. 2. Afer nsallaon, check o ensure ha he busng o dler saf clearance s wn e nomnal dmenson. f  s below e nomnal dmenson, ream e bushng. (5) Cam Profle

44A

 the lmits ae exceeded, he bushng n he cankcase shoud be· repaced. (7) Bend of Camsaf

Msrg poston Forwr 9.5

9.5

s c mr C401

Measue the lobe hegh and base crcle damee and eplace the camshat f he derence beween he two is below he lim NOTE: Te cam mus be measured a locaons sown as  s apered.

C4118A

Measue the bend o the camshat.  the limit is eceeded epace. NOTE Turn e camsaf a urn and read e deflecon of e poner usng a dal n· dcaor. One alf of e readng s e bend

[email protected]


11-37

m 5.33


isassembly

20

7

Moun inrgccond o Eccen  y L 02 Ben lock washe INVle gea en08pla 0. 1  o L 04 (765 kgfNmm) (we) Camshaf NVL 00.405t gea o 0en play 55 Nm (16 kgf 35(3 kgNmmHwe)  (098 Nmkgfm) m Appl hehuom engseagreaseneposol o 98Nm (10 kgm   (16 kgfNmm) Moun ng conon BackNV a0.sh1 o Backlash Runou NV 0  3  o L 0. 0  6 0  6  0.4  04 BacklNV a0s1 o L 0.046 10

12

16 /19A 15

5

8

19 15

9 3

BacklNV a0sh1 o 06  04 - 69 Nm ( kgm) �- Q199A@ •14 A 43_1  13  1   J l  of pars wh an encrcle umbe, see folowg FoFoemsassemb qupassembl men  of par make * efer o Goup 61 Speca -

11-38

B1902E

m



3) Installation of Camshaft Gear

 1) Installation of Rear Pate

If L�

264  '(27 kg Wet

Lock wase (o be be

C6230C I The botom of gaske instaled beween he rear pate and cankcase w prorude. Afe he flywhee hos ng has been insalled, c away he protrdng porton

847A

Install the camshaf gear so tha he sde havng stamped nmbers "4 faces font (4) Installation of Camshaft

(2) Installation of Idler Gears Crankshat gea \ Idle ga B

61 155 Nm (16 kgfm)

61D

Then, nsal he dle gea B so that s alignmen mark "1 s algned wth the alignment mark "1" on the crankshaf gea Next insa dle geas A and C so ha he agnmen marks "2" ae aigned Tghten he dler shaft bol to specfication

nsall he camshaf so ha the agnmen mark  on the camsha gear s aigned with the alignment mark "4 on dle gea A NOTE:

When the camshaft is inserted, take care not to damage the camshaft bushing. (5) Check camshaft ear and ider gear for correct end pay [Refer o Section 53 ()] (6) Check backlash in gears Refer o Secon 53 3) [email protected]


11-39

•

ENGIE - SERVICE PROCEDURES

(7) Installation of Rear Oil Seal Slinger

Loctg pin

Rear oil sel slnge

Theaded goove

(9 Installation of Flywheel Housing

C5529B

(8) nst�llation of Ring Gear

C6230D

Insta the fywhee housng and gasket so that they are aligned wth the loating pins in the rankase Cut the bottom portons of the gasket ae nstalato as they ae eess. Cut at the same tme the eess portions of the gasket between the ea pate and ankase

Rng gea

(10) Flywheel Housing Eccenticity Check

Flywee

237C

(a) Heat the ring gea o 3 minutes with piston heate (approx. 100 c) · (b) Fit the ring gear onto the fywheel wth the nonhamfered sde of the eeth end towad the flywhee °

ywee ousng 6233

Install the flywheel housing to the rankase by tightenng to the speied toque. Measue the mountng onditon (eentty) at the fywheel housng jont If the pointe of a dia ndato defets beyond the mt, oosen the bots and ghty stke the housing to orret the mounting ondition [email protected] Parts phone: 269 673 1638

1-40

I


(11) Installation of Oil Seal

(1 2) Flywhee Runout Check

Oil sa St oi sea nd o th rt postvy a u.

315 Nm (32 kgf) W)

/

/

/

/,

C6209A

When press-fitng an ol seal to the etainer, appy foce unifomy o the ene pephey.

Fw

C6236B

Install he flywheel o the cankshaf by ghtenng to he specfied toque Measue the flywheel ounng condition (unot) f the pone of the da ndcao defects beyond e  chec the bot ghtness o ounng suface

11-41

• 5.4 541


CRANKCASE AND MAIN MOVING PARTS Disassembly

4

amage discooation 7

0 � 56 0

�,

:  {�

Damage. abnormal wear

8 NV Piston toprojecti on

 • o p , me l t <     f o ;   : r a s c k 9 C  �-  _ -       ·>NV Conec g od ed play  2 o L 

Scratches on oute periphery,

:_ 10 Inner or oute peredphey damaged 3 cooded or peel 

NVL Nom Limi al Vale

Disassembly sequence Connecting rod cap 2 Lower connecting rod bearng 3 Upper connectng rod bearng © 1st compession ring  2nd compression ring

Inner o oute cooded or peelperedphey daaged

® -i ring 7 Pston pn ® Pston  Connecting rod *10 Connecting rod bot

sassemly of pars wh an encircled nume, see olowing iForPart temsdmar ked with * should not be removed nless deects are evServidence iems mared wt h shold be inspected beore disassembly 11-42

°'

C2337D

m


  

   



- ·            �

Oi hole coggg

26

5.4) Ma 18, n20bearg 15 19

12

11

Scatces secoos zeoplucacks gged oil dea oe o I -�·Ed00pl9 atoy 03  0

NVL Nom mt al ale

11

Torsonal damper

Cankshaft pulley 13 Font oil seal 14 Font cover 5 Front ol seal slinger 16 Main bearing cap

.,

'1

hrust plate 18 Lower main beang 19 Crankshaft 20 Upper main beang i Cranksaft gear

17

(i 2

'l

Fotemsdsassemby of pats w a eccld umbe, see foowg Te patmaked makedwt�• ms bed otspected befoedesssassembl y ae Pats soul be emoved def e cts evFodetspecto of te pat maked wt 2 ee to Gop 2 ubcato [email protected]

1

22

Cylinde iner

'2

23

Chec

valve

Ol jet 25 Ol spray plug 26 Crankcase

24

B0599G


-43

I


(3) Removal of Piston

Disassembly Procedure (1) Piston Projecton The piston projecton must be up to specifcation, as it affects engne performance and s also necessary for preventing nterference wth the vave.

�o Measuring pont 341A

When the withdrawing the pston from the crankcas by pushing up together with the connecting rod C2339B

(a) Hod the dia ndcator to th top surface of the crankcase and make zero adustment (b) Find the top dead center of piston with a dia indcator (c) Measure three points on the top surface of piston to find the average vaue (d) If the proection is out of specification chec the connectng rod, bushng pston pin, connecting rod bearng, etc and repace defective parts

NOTE: When remoing the pistons, use cre to preent damage to the cylnder liner (4) Separating Piston from Connecting Ro

Snap ng

(2) Connecting Rod End Play

Remove the snap rng and using a rod tap pston pn off If however the piston pin is hard to reove heat the piston wth a piston heater or n hot water

C340A

Measure the end pay of each connecting rod If the mi s exceeded repace the connectng rod or cranshaft

1-44

m


(5) Removal of Piston Rng

(7) Remova of Main Bearing Cap

_ Slide hammer

Piston Rg Tool 391-02900 8010A

(6) Crankshaft End Play

03

The eamost main beaing cap is hed n positon by dowe pns Remove it by se o a sde hamme

(8) Removal of Crankshaft Gear R oi sa ng

I

I

/ Canksaf ga

B011C

Beoe removing the main beaing caps, measue the end pay n the crankshat. If he end play exceeds the mit epace the thst plate with an ovesize one [Refe to Secton 5.43 (3)]

(a) Remove the ea oil seal slnge fom the can shat by cutting it with a punch (b) Remove the cankshaft gea om the canshat using Gea Pule (specia too)

NOTE: Do not attempt removing the crankshaft gear by striking with a hammer or prying with a lever. [email protected]


1-5

m 5.42


nspection

Clearance B 50 NV 0.01 to 0.02  01

learance B 50 NV 002 o 005  0.1

Bend or torsion L 0.05 or less

0  0

pen en clearance NV 04 to 06 L 1.5

Pson ring groove o pon rg clearance 1s ing NV 006 o 011 L 025 2n rng NV 005 o 008 <622> 007 o 00 622-T, 622 L 015 i ring NV 0.0 o 006 L 05

Clearance B 0 NV 018 to 0204 622 017 to 019 622T 0.188 o 0214 622TC

Distortion of top surface NV 00 o less  02 Fatness o cyer liner flange suppong surface L More han 0.1

B NV L

Projection o cyline liner rom op srface of crankcase NV O o 008

Basc iaee Nonal Vaue Lit

Insie iameter NV 130014 o 130054  13025 u of rounness of cylinricity NV 0.02 or ess

i clearance B 84 NV 00 to 01  025 ension wen ee L ess a 05

[email protected]

Parts phone: 269 673 1638 C2760C

11-46


m

Bend NV 0.04 or less L 1 Ou of ode V 00 o e L 008 Cyidicity V 0006 o e Teio whe fee L Le tha 06

D  aic Diamee V  omia Vae   Limi

Oi ceaace D 00 V 008 to 05 L 02

B0599F


(2) Crankcase Top Surface Distorton

 1) Flatness of Cylnder Liner lange Supportng Surface on Crankcase

Meaeme poit

C4417A

Measure he crancase op surface dsoron. If  exceeds he ms, correct he dstoron wh a Replace the crankcase wit new one f the m s exceeded.

srface grnder

1-47

GINE  SERVICE m ------ �        E

PR O CIDURES

:=  NOTE:

crankca�e is ground, make sure that the piston proection does not exceed the no·mal value. [efer to te (1) ' ection 541] (3) ylind When the

  (4) ylinder L",ner Flange Projecton

er Liner I.D

�m �

. ra nkshaft d'.ection t ght-a gl di ectio:f

A- C

B: Cran ksh

n

e

.  ou of specifcation  repace th If the proJecton cylnde ner or /ran kcase (For rep! acemen of th cylnde liner refe to Item S

c"'

_Y nder lner D at ".x postons as shown in he gh fgu If th Db s moe an he ,e  e line o oe t o o ers ' ace he y d imits rep v  (Fo eplacemen of he cylinde ne refe o Iem Measurn the c 1·

(5)eplaceent o ylinder Lner (a)eoval Cyinde Li E xtracto MH06149

IS.i

CB

11-48


e i. CMHl6d1e75L9 I e e

(b) Instalation

-

S i z e a r k P i s t o n Cyld ie

m

1

C27B C4813C

1 When replacing the cylinde lne, use a cynde line with th same size mak as tha of he piston to be selected. Size ark of pstn

A

8

C

Size mark of cylind 

A

8

C

0-pRucbgg> eppd  0

3 Secely seat the cylinde ne on the cankcase by lightly stiking the fange potion, sing Cyline Line Installe {specia ool. NOTE:

1. Apply soap suds to the crankcase and cylinder liner fitting prtions and make sure that the rubber paking and O,ring are not twisted when inserted 2 After installation condct the leak test to verify air-tightness Apply thrust force to cylinder liner flange [email protected]


C4426

2) Afe a new e pacing and 0-ng have een nsaed to the cylnde ine, slowly nse the cyinde ine nto he cankcase

1-49

m


(6) Selection of Piston and Cylinder Liner

(b) Oversize piston

A pison may be sandard or oversze, depending on whch he cylnder ner is to be seected as foows.

Boe he cyinder ner as foows accodng o the ype of piston  +05 0.75  .00 mm)

(a) Standard piston

<6D2> 6D22, 6D22-TC Weigh "T ark Weght � Sze mak : /-

J f Se a

/ � Part number

'

(

Cynde lne I.D. Se a saped o30 oe _ 1

-

Pa,< orbe

o oe 70

Ovese son OD

al deco of  A: Axasha 8 Doeo ansafa gh angles C42A

OD. easung poson Cylnde ne

Pson

C44A 842210

1) Seect the piston wth he same sze mar as ha stamped on he cyinder ner. 2) Make sre tha the weght of pisons for one engine (sx pstons) s in he range of± 0 g of he weigh samped.

NOTE: Whenever the piston is replaced, replace the piston rings.

1) Deermne he amount of mea o be bored fro he cynde ner by tang into account the poo whch weas mo wth eference to the measre ments of .s of a cynders. 2) Bore and honefinsh he cynder ner to obta the specifed cearance between the oversze pso and cyinder liner

NOTE: 1 Even when only one cylinder require boring bore a· cyinders to the sam oversize 2. Replace the piston rings to those corresponding to the oversize. (7) Piston to Cylinder Liner Clearance If he cearance is ou of specifcaion repace he piston or cynder ner [Refe to Iem 6)]

-50

D


(8) Piston to Piston Ring Clearance

(9) Piston Ring Gap

Ps '-



.

0

Pson ring

Cyliner lne

C806A

Measure the piston to piston ring clearance. If the limit is exceeded, replace the piston rings or piston ,

NOTE:

1. After carbon has been removed, mea· sure the clearance all around the pston 2 Replace the piston rings as a set.

807

Measure the pston ring gap with the piston ring hoizontally pushed into a standad cylnde ine or actua one in the crankcase with a piston. Replace the piston ring if th gap exceeds the imit Standad cylinder liner ID: 30 ± 0 NOTE:

Use the pston to push the pston rngs horizontaly nto a standrd gauge. ( 10) Piston to Pston Pn Clearance

Thickness gauge

Pso

1st ompreio rig

E

Saig edge

Pison pn 4815A

The 1st compesson ring should be measured by pressing the rng against the pston wth a straght edge

48A

If the clearance s o piston

over

the imit replace the piston pn

NOTE:

Whenever the pston s repaced, be sure to replace the pston rngs [email protected]


-5

m


(11) Piston Pin to Connecting Rod Small End Clearance

Connecting rd

�

(a Ag the o hoe o the ushg wth he o hoe o he coneg od ) ress he ushg  rom he chamered sde o coecg rod ed c Aer he bshig has ee pressed  ser the pisto p ad check o esure hat t turs ighty whout pay

(3) Connecting Rod Bend and Twist

Pis pin

®

4812

If the clearace is over the imt, repace the ushig i the coectig rod.

(12) Repacement Bushing

of

Connecting

Rod C0A

Repace the ushg y procedures show i iustra tio, usig Coectig Rod Bushg Puler specia too

wst

Ii

52

00

·. -91/ 0

Pio n Connctn o an Conncting Rod Bushng Plle .- MH063

To emove

C07A

/Bushng '=_ ;Oi I ho · , Connctn rod

Measure the ed ad torso o the coectig rod wth oectig Rod iger easurg strumet 

o nsa

 he readig s  excess o the m repace or correc wth a press T:

522

11-52

1. Install the bushing and connecting rod bearing to the connecting ro before measurement 2. Tighten the connecting rod and connecting rod cap to the specified torque before measurement

m


(14) Tension of Connecting Rod Bearing and Main Bearing when Free

(16) Main Bearing to Crankshaft Journal Clearance a ol O Mesing deto

5209

esn poso

552

If the ensor'is lowe han he m eplace he uppe ad owe beangs as a set. NOTE:

Do not use the bearing by artificially expanding it.

Ma bag I

(15) Connecting Rod Bearing to Crank shaft Pin Clearance rankshaft pi O.D

Measuring decto

Mesug oo

C3A onectg od beag D Meag eto

Mesg oo

24

f the lm s eceeded, eplace the ppe ad oe beaigs as a set.

14

 he mt s exceeded, eplace he ppe ad lowe beags as a se

11-53

•


(17) Crankshaft Roundness and Cylindri cty Roundness

Cylriiy

Measrig rectio

Measrg posio

(9) Correcton of Crankshaft to Undersize f the ournal o p is damaged o sezed gd the cashaf y the followg pocedues Replace the bearg wth a udesized oe 42.0

540

+g- 2

H

0 +I  "

C5223A

Determine the out-ofroundness on the bass of the crankshaft journal and pn O.D. measuements If the mit s exceeded, gd to undersze. [Refer to (19)] (8) Crankshaft Bend

5527A

(a) When the crankshat s ground take care not to chage the center dstace of oua and pin (b) Gind the cankshaft  such a way as not to chage the wdth of oual and pn (c) Fsh the fllet smooth to the specfed R (d Check for groud cracks by the magnetc partcle inspection method The suface hardess (Hs 7 or moe) shoud also be checked to confrm that t has ot decreased. [email protected] Parts phone: 269 673 1638

C26A

Measue the bend of the crankshaft. If the imit is exceeded corect wth a pess or gind to udersze NOTE:

Read the crankshaft center journal runout wth a dal ndcator. One half of the read· ng s the bend

54


Grincg

•

Fsh

Westoe o ad pape Cksaft

C5509A

(e) To grind he cranksha wth grnder, he gnder and cankshaft shold be urned cockwse as viewed from the crnksha fon end. (f) To fnsh he crankshaf wth a gndstone or sandpaper, rn the cankshaf conecockwse Unit: mm Joural O.D ih dimeson

Pi 0.. i dimenso

russ

yid icit

025

0·08 997   00

83.  006  0.09

001 o le

0006 or e

050

008 9950  010 

830  006  009

05

 008 99 5  0 0

8    006  0 09

100

 008 99 00  00

800  006  009

dersize

O-of

11-5

• 5.4.3


Reassembly

-   -      - 

 Cyr ner fge ro NV O o 00

[21

2- 5 43· 0•19 7 �  8  6 }

-· 2 1

 �

a97s4 ,o_ ,£  For emy of pr with n eied ume ee foowng e. 0 Exer rg e

ocg 

 comreon rg e

Be ock wer

23 3 N (35 kgm) 24

2 -*!�\ ?,YU 1 �+¥-'

Lg eo

Po ojeco NV 08 o 33 8

22

Ag g reco

14

30 Nm (3 kg) (We)

5  ( gf We)

/ 0·

ce row e 

20

Locg NV L

ce e w o groove ow g rfce

11 16

Ay  e gee o 

No Ve L

19

Coecg ro e y NV 0 o 05  0

17

Crkf e y NV 00 o 03 L 0

C583F

56

m



(3) Installation of Upper Main Bearing and Thrust Plate

(1) Installation of Oil Spray Plug � --

  - 

ug Up r main earng



\�

:

;_·.•1,

.I

f�is

:_ -;' · (/   I Thunshtrupgtappnae   g g  o  e        0  g  o  e   C5837 C23 5B  ' �-"( ,. ·-1 I  I  'I nly •   Jj 0 ,/

•  ' o,

r

.( �'/ ; 

 ' - « ��r :, ·  i :

Install the oi spray plug wth the arrow stamped on the pug toward the top of the engine.

(2) Installation of Oil Jet and Check Valve

]\ heck vmaLlovcek washe bending poro Atbaebtne.r aosemwabfs41hnegrN,� ) C586B

0 '

0

6

,r·

NOTE: 1. Instl the thrust plate with the oi grooveless side toward the crankcse. 2. Line up the ug of the min bearing nd the groove of the crnkcase. · The pper min bearing is one with oil holes Take care not to confuse it with the ower one. 3. Oversize (0.15, 0.30, 0.45 mm) thrust plates re vailabe for adjusting the end play in crankshaft [refer to Item (6), Section 5.4.1]. If any one of these is used, ensure the correct of the thrust pate to be installed to the min bering cap [refer to Item (7)].

Dowe n

(4) Installation of Crankshaft Gear

(a) nsta the o jet, whle makng sre that ts ocatng pn fits n the cankcase (b) Mont the ock washer in sch a way that ts bending porton wll fit the end of the ol et c Afte the check vave has been tghtened to the specfied torqe bend the lock washer to fit the hexagona portion of the check valve

r a  k s h a  

rankshat gear

(a) Heat the gea to about 100 C sing a piston heate etc °

1-57

•


(b) Locate the gear so that the dowel pn of he cranksha wi  n he noch o he gea and  he gear by ghy sikng the gea end wth a so hamme. (c Insta the ea o sea snge. [Ree to em (7, Section 533] (5) Installation of Front Oil Seal Slinger

(7) Installation of Lower Main Bearings and Main Bearing Caps

Foow he prcedue given beow

�l

o t

o

�7

Crankshaft

�{

Oil Seal Sger Istaller MH06187

Axial directon of c,aksft

Dowe p 817A

a Drve he ocating dowe pns nto the eamos main beang cap n the drecon shown. 80596A

nsta the ron oi sea singer using Oi Sea Singe nstaer (specia too (6) Installation of Crankshaft

5A

C533A

 he cankshat wth chan bocks ec. Whe keeping t in horizonta position sowy ower t nto the crankcase

Ma bearg ca embed numer

I�

engine 0



0

r �

·1

JL,

-=

-

42A

(b Mate he owe man beain wih each ma beaing cap makng sre that the g in beang is ed nto the g goove n cap 1-58



m

(c) Only to both sdes of the earmos man bearing cap, nsta he hus paes acng he o gooveess sde owad he cap.

(f) Check to see f the end pay of the cankshaf s whn nomna vae [Refe to tem (6) Secon 541.]

NOTE:

(8) Installation of Connecting Rod Bolt

tBeari , ustngplacapte fot Bea ngplacapte ea   st �

-/  ·,_�t  -� ,

0

,

.�

'

(

•-

·

Fae top goove iside. Pess-f Max 5i9t wkN(6a00pess kgf) Appy engine oil

Use t h e same ·�f , '. r . i \� size

Cankase ea us plae

C5838B

If an oversize thrust plate is used, use the bearng cap rear thrust plate of the same sze as that of the thrust plate in the crankcase rear end [Refer to Item (3)]. Note however, that the bearing cap front and rear thrust plates may be of different sizes.

8907A

Afer checkng he connecng rod for damage and br n the bo hoe, appy engne o to he conet ng rod bot and pessf  no he conncg 

(d) Insta the man beang caps makng sre that the sde wh he g grooe paced on the rght-hand sde of the engne and hey are nsaed n the order of embossed nmbers fom the fon of engne e) Tghen man bearng cap bos to specfed torqe hen, tghen man beang cap sde bots to spcfed orqe. Afte he bos ae tghened make sre tha he crankshaft s fee to rotate by hand

9

•


(9) Reassembly of Piston and Connecting Rod

Aow shwing frn

 Ptn

(1 O) Instaation of Piston ing

I :�; Ends

Cectg d

Sap rg

M mark tamped

C5841B

 p

Eced cylnde N. Smed  etce wegt ak Dec lug gve _-, m wad n

Samped lgme m

C5840

Connect the piston to the connecting rod with the pston pin so that the Font mark on piston ad lug goove mak in connectng od ae paced on the same sde. If the piston and pston pn ae had to nset, heat the  pston with a piston heate o n hot wate NOTE:

The parts for an engine must be of the same weight mark.

Weight maks Heavy-     Light J K A B C D E F G H

160

Using Pston Rng Tool (speca too), nstall the psto ngs in the folowng seqence  Oil ng 2 nd compesson ing 3 1st compess on ng

·1


(11) Installation of Upper and Lower Connecting Rod Bearings

Lower thes.o t1_g   Aig ee od beaconet ing g -�· lg Uppe od eag  , v  ; n

. J

.

'

_,



I

'

.

Rl '·  I

NOTE

1 Make sure that the sze symbol of the pston s the same as that of the cyln der liner 2. Make sure that the piston ring open end drectons do not change. 3 Put a vinyl hose or something else on the bolt of connecting rod for protec• tion of the crankshaft pn against dam• age by the bolt

.



Usng the Piston Gude Clamp and Piston Guide Lever (specal tools) 

.

apConetng od

Pisto Gude Camp

B4223A

Instal the uper connecting rod bearing, making sure that the bearing ug is algned with the lug groove in the connecting rod. Insta the ower connecting rod bearing making sure that the bearing ug s algned with the ug groove in the conecting rod ca NOTE:

Note that the only the upper connectng rod bearng has an oil hole. (12) Installation of Piston and Connectng Rod

sMH06658 Pee on Guide

Adjotsting

Pisto Gde ee

B91C

ine u the Piston Guide with the ston skt and set the ever into osition. Then turn the adjusting bot so that the cam 10 equas iston .0 Afer the adjustment ay engine oi to iston outer surfaces Pston Gude inner surfaces and cyinder ner inner surfaces Afer these rocedures have been cometed ft Piston Guide onto the iston so that it is fush wth the istonhead sng a maet or wood bock ta iston into osition with care not to damage it [email protected]


C5834B

Using Piston Gude Cam and Piston Gude Lever (secia toos) insta the iston and connecting rod so that the front mark on iston head faces the front of engine

11-61

•


(13) Installation of Connecting Rod Caps Connectng rod ap

.

55

INSPECTION AND ADJUSTMENT OF VALVE CLEARANCE

The vave ceaance shoud be checked and adjusted as descrbed beow whe the engne s cold

Frot of enine

)8  -c

Algnment mark

I

-

C584B

I 

'

- _

\-

I

_.-

Make sur� that the alignment marks and lug groove maks on the connecting od cap and connectng rod ae aigned. (14) Check the connecting rod end play.

[Refe to Item (2), Section 541] (15) Chec the projection of the pison

Refer to Item (1, Section 54 (16) Installation of Front Oil Sea

on ol seal

Press- Ol seal ange

3A

(1 Cank the engne to agn the ponte of the inspecton wndow of the flywheel housng with the nscibed mak 6 of the fywhee Check the push rods and the pston whose push rod s not pushng up the ocker s at the top dead center of the compesson stoke. (2 When the No 1 cynder pston s at the top dea cente on the compesson stoke check and adjust the cearnce of valves maked "o" in the folowing tabe When the No 6 cynder piston is at the top dea center on the compesson stroke check and adjust the cleaances of valve maked x". urn the cank shaft though a rotaton and make sure that al cearance nspection and adjustment ae perfome for a of the sx cyndes 1

Cylinder No. 17A

Vave

2

4



6



n Ex. I x  x  x  x  x

arrngemet

Eveny pess the oi sea throughout ts ente pephey to prevent t fom tting Press-ft the o seal nto the font cover unti the oi sea fange is hed tight up against the font ove.

1162

No 1 t TDC o th compess soke No 6 at DC on e cps son stoke

0





0

X

X

0



X

X

X

X


- .             1 Valve clr
O 4 m

Exhaust 0.6 m

Tickne gge MH1359

m

(3) Measure the ocke m to valve cap cleaance with a tickess gage to deermine wether the clearance is up to specificaton. If e thikness gauge of the secified thickness is soewhat ard to move, the clearace is good. f the clearance s ot of specfication, loosen the lock nt and adjst with the adusting screw Afte adst ment tun down the ock nt to ock the adstg screws NOTE:

8574

After the lock nut has been turned down, echeck the cleaane.

11-63

•

ENGINE - TROUBLESHOOTING

6. TROUBLESHOOTING Probale cause

Sympom Engie wl o sar

Iadeqat ol vscsity

Remedy Rplace

Re grop Grop 12 Gop 13

Icrrec fe  se Lw compressio ressue •

Icrec ale cearance

Adjs

•

Deece head gaske

Repace

• Wor valve ad valve seat, car depos •

Deeoraed ave sprig

• Wo  damaged pis g

• Wo  damgd piso g goove • Wor pis ad cyld lie

Chag o ez

Defecive preheaer •

Defecie sae swich

•

Defecie heaer elay

corec eci img

Correc r replace

Grup 6

Adjs

Group 3

Crrec r repace

Grup 3

Cec  replace

Gr 14

Replac

Grup 

lsicie ijeci amu •

Defecie ijeco pump

•

Icoec njeco o

Cig sysem  fucioing pperly Rgh idle

Iadeae il iscsy

Gup 3

crrec el  use Defecve cg syem

Correc or epace

Goup 4

Adjs

Goup 3

Crrec o repla

Grop 3

Replace

Grup 3

Crrec  replace

Grp 

Core or rel

Grop 5

Correc r eplac

Grop 3

Low compression u (See "Ege wil t star.)

Icrrec ijecio img Defecive fel sysem •

Defecve econ pmp

• Defecie jcto le  Air rapped i fel sysem Aorma exhas gas colr

corec fel  se Coolg sysem o fucog ppery Iae/exhas sysem  fucg propey •

Cogged a cl

• Clged mffler •

Oil leas o iaeexhas ppes

ow cmpesso pressre (See Egie will  sa Defece el sysem •

Deecve jecio pump

•

Defecve ijecio le

Icorrec ijeci mg

Adst

Excesse egie 

Adjs

Bidig f major mig pars

11-64

Correc r eplace

Gup 

m

ENGINE - TROUBLESHOOTNG

Pobale c,\1e

Sypo Low oupu

Indeque oi vscoty

Reedy Repce

Ref. goup Goup 2 Goup 3

Incorect ful i s

Defecive coong em

Corec o epce

Group 4

Coec o epce

Goup 5

Coec o epce

Goup 3

nke/exhu ye no uncioning popey • Cogged a canr •

Cogged uffer

Low ompsso  See "Engne wi o .)

Deecive fue ye •

Deecive injectio pup

•

Deecive njcon noe

• A rpped n ue ye norc injecion ing

Lge o

Adju

O ek fo ubicion ye

Check nd coec

Goup 2

onpon

Oi ek fro engne nd eed p •

Defecive gke nd o e

Repce

Oi enered o cobuion ce fro pion de • Won cyinde ine nd pion

Corec o epce

• Won dged o eized pion rng •

Cogged pon nd o ng o oe

Repce   e Cen

Oi eneed o cobuion che fro vve ide • Wr vve e nd vve guide • Worn

Abnor ngn os

Repce

vve  e

Noie poduced fo round e engine •

ooe pping or oing connecon

• necion pup enor o ohe uy uni defecive or incoecy ouned •

ooe o dged V-be

Check nd coec Ceck nd dju Repce

• Cnkf puey incorecy ouned

Ceck nd du

• Ai cene ue no funcioning popey

Coec o epce

Noie poduced fo ound ocke

Goup 

Goup 5

cve

• ncoec vve cence

Adju

Defecve vve pring

Repce

•

Goup 3 nd 6

• Defecve ocke h nd bcke • oo ubicion in ocke hf

Ceck nd coec Ceck

Noie poduced fo ound ywhee ouing • ncoec iing ge bck •

oo ubicion ound iing ge nd de hf

Repce Ceck

1-65

D

ENGINE - TROUBLESHOOTING

Prbable cse

Symptom Abnormal engine ois

Remedy

Nise prodced fm cyde head or crakcase •

Lw mpess pressure !See "Ege w  s I

•

nce jeco img

• correc spray condii • Worn connectng rd small end bsg ad pisn pin

Ads Correc r repace Repace

• Wo r dmaged cansh pi and cnecing od bg end beang • Wo or damaged crans oral and mn berig •

xcessive cransaf, to cmsaf end py

• Worn ppe ad cmsha

11-66

Ref. grup

Repace rust ple Replace wrn pa

Gro 13

m

LUBRICATION CONTENTS

1. GENER·AL •••••••.••.........••••.••• 2 2 SPECIFICATONS •••••••••••••••.•..•• 10 3 SERVICE STANDARDS ••..•••••••• 10 31 SERVICE STANDARD TABLE •.. 10 32 TIGHTENING TORQUE TABLE .. 11 4. SERVICE PROCEDURES •.•.••••••••• 12 4.1 REMOVAL AND INSTALLA TION 12 

4.2

DISASSEMBLY, INSPECTION AND REASSEMBLY •••••••••••••.••.... 13 4.21 Oil Pump 3 4.2.2 Oil Filter •••••••••••••••.•..•.•.. 16 4.23 Oil Cooer ••••••••........•.•. 1 7 42.4 Reguator Vave .••••...•••••• 18 42.5 Check Valve .....••.•••.•• 18 5. TROUBLESHOOTING ••••••••••••••. 19 ..

12-1

l

LUBRICATON - GENERAL

1. GENERAL

Engine lbrcaton is accompished by oced uba tion sstem sng gea pmp. The engne ol in the oi pan s dawn p thogh the oi straine by te o pmp and foce-fed to the o iter and oi cooer to lbricate a parts

O pressue guge

0-�

Waig lamp "OIL

O pessue gauge  O pessue wtch Man o aey

Water pum Oil sy plug

-oil

O pa B1539F

12-2


(1) Oil Pump l m gear

Oil pump der ga Drv gea r ger From l sn

5

At the time the engine oil is drawn in from the sucon side by the negative pressure produced as the gear turns along the nsde of the pump case, and is carried along the gear and case nsde wall to the delivery side he ol stainer at the suction port prevents entry of

 pmp (wth blt-n eef valve)

foreign matter n the oil pan and air The engine ol is routed to the crankcase by the oil pipe connecte to the delivery port 81540A

The oil pump, of a gear pump type, is mounted in the rea bottom portion of the cankcase drven by the crankshaft gear. An ol straner is mounted at the su ction port of the oil pump; an ol pipe at the deivery port he crankshaft gear drives the oil pump idler gear and o ump gea to transmit rotaton to the oil pump drive gea. In the oil pump, the ol pump drve gear is n mesh with the o pmp diven gear When the oil pump dive gea is drven the o pump driven gear is turned n the opposite drecton

Ree vv 42A

Since the oil pump s drven at speeds poportional to the engne's, the delivery pressure of the oil pump increases dring starting n cold weather A reef valve is provided in the oi pump to make sure that no excessive pessure acts on the ubrcation syste.

12-3

•


(2) il Filter

·

- Oil flter head

Eemnt

Oil fir cas

!Bypass 

C bo

Di lug

Fu-w i

85448 81543A

The oil filter s a double ol fite consisting o a ull-fow lter made integral with byass ter. Ele ment s a filte aer eement Engne oil ed under essure rom the oil pu asses through the o hole n the cankcase and ows from the oi flter head into the ufow te and , byass lter. The engine o teed though the ull-ow ilter is outed om the oi filter head though the crancase o hole to the oi cooer The engne ol tered though the byass te etuns to the oi an.

12-4

When the oi ter element s cogged and the dfeence n essue between the fltered and unfi tered oil exceeds the limt secified the valve in the oi byass aarm moves aganst the sng foce allowing the unteed ol to flow to the fiteed o ath he o byass aarm has eectrc contats that are closed to turn on the lot am warning the drve of clogged element when the vave is oened


m

(3) Oil Cooler

Oil coer mnt

Ca� T a l galy

81545A

The shell-and-plate type (multi-plate type) oil cooler is monted in he cooant path on the left side of he crankcase. Egine ol forced through the oil flter flows isde the oil cooe eleme; whereas he coolant forced from he wae pump flows arod the elemet. he egine ol in the eeme is then cooled or heated be�oe t fows o he main oi galery.

(4) Bypass Valve

T a  galy 8530A

Whe he oil vscosty is high at low emperaes or when the eement has high resisace o flow becase of clogging, the bypass valve istalled a the oil cooer opes o allow engie oil o flow o he man gaey bypassng he oil coole

12-5

D

LUBRICATON - GENEAL

b) Camshaft

(5) Regulator Valve Main ol �1llery

Regultor valv

81529A

The regutor vave is mounted in the man o galery n the crankcase to make sure that no excessve pressure acts on the ubrication system.

847

Lubricaton o the camshat bushings is accompished by the o fowing through the oi hoes rom the outside periphery o the crankshat man bearng to the ndvidual camshat bushng

(6) Lubrication of All Parts The engne o routed to the man o gaery ubrcates a parts as descrbed n the foowng

(c) Valve mechanism

(a) Main bearing, connecting rod bearing, and connecting rod bushing ck shf b 

/ Piston

Caksha ma bearig

.-  Coectg od Ro f

Fom ylind 

 Conectg rod earig Cakshaf  815468

The oi hoe extends rom the man oi galery to the crankshaft main bearing to ubricate the main bear ing Part of the engne o that has ubrcated the man bearng passes through the oi hoe in the crankshat to ubricate the connectng rod bearng, and then through the o hoe n the connectng rod to ubricate connectng rod bushng On 6022-TC there is a hoe provided n top of connectng rod from whch o spurts out to the pston

126

15A

The engne o that has ubrcated the No 7 camshaft bushing ows through the o hoe provi ded at the top of the crankcase to each cynder head

LUBRICATON - GENERA

Engne ol ed to the cyinder head ows through the ol holes n the rocer saf bracket and rocer sha to lubrcate each ocer bushng. The engine oi s also sprayed out o the rocer arm oi oes or lubrcaton o the sldng suraces o vave cap and vave sem as well as the sldng suraces o push rod and adjustng screw The ol then ows through the push od hoes n the cylnder head and crancase to ubcate the tappet and cam o the camshat and retuns to the ol pan

(e) Cooling the pston (ol jet)

(d) Tmng gears

Check valv

Oil spray ug

85358

-Cmshaf bn secto

Ma  ey

81549A

The ol et provded nder the man ol gallery or each cylnde sprays engne o aganst the reverse srace o the pston to cool the pston The ol et s eqpped wth a chec valve whc opens and closes at speced ol pressure, peventng the decreased amont o · ol at ow ol pressre and oss n ol presse On the pston or the 6022-TC a coong cavty s provded The ol nected om the o et entes the coolng cavty to coo the pston

he tmng gear dler shat ae lubrcated, as shown n the gre, by engne o lowng throgh the o holes outed rom the man ol galey and the cranshat man bearng n the rear end ach gear s brcated by the engne ol sprayed rom the ol spay plg

12-7

•


he injecton pump and ai compresso are ubricated as follows:

(7) Lubrication of Turbocharger

Oil m ain gallery

m P  e t  i n _ p u �- _ 'n  _ _ c  I� o Ar in=

Cakcase

_ oer co  il    l�_ _  

i om p esso

Gea tai

Pston ng

Exhaus

B436A

Part of the engine oil s dectd through the oi pipe om the ·�rankcase into the tubochager. The engne o passes through the ol hoe in the turbocharger beaing housng to ubicate the bearngs It s then etuned through the oi outet at the bottom of the beaing housg back to the cankcase and to the ol pan. A piston ring is nstaed on the outsde of each beang, serving as an oi sea (8) Injection Pump and Air Compressor

12-8

Oil a

  

m

LUBRICATON - GENERA

(9) Lubrication of Water Pump

To oil pan

A

' Fom an o galery 052A The engine oil drawn by the oil pump is roued hrough the crankcase oi passage to he water pump. The engine oi deivered to the wae pump fows

he egine oi is hen forced back from the dain por o he crankcase and retuns o he o pan

hrough he oi hoe of the water pump and ubricaes he bearings

12-9

m

LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS

2. SPECIFICATIONS Secifcatos

Iem

Qualy

Eng oil

!Withot trbochage AP\ cassifcaon lass CC o ete IWih bochage! AP\ cassificaio Cass D o bee  Fo geeal owe Aox. 27 i

Fo conso machiey

Oi pa caaciy Oi fie caacity

4 o 45 i

4 o 45 i

Ao 25 i

Foce bcaio by ol 

Lbicaio ehod O  Ree valve

Tye

oce bicao by gea  (wh bi- eef vave)

ye

Bal vave

ye

Fie e ye

Oi fie fow it leet Byass fie eee

ye

Fie ae ye

O byass aa

ye

Piso vave ye wih b eecc coacs

ye

She a ae ye (ate ye

Tye

Pso vave ye

ye

Pso vave ye

y

Pso vave ye

Oi coole O byass vave Regao vae Oi je heck vave


SERVICE STANDARD TABLE U: Descito

Ol esse A le (O ee

Noina ae !asc aee!



145 kPa 5 g2  o oe

49 Pa (05 kgf/c 

295 o 490 kPa 3 o 5 kgf/c 

195 kPa 2 kg/c 

Coecio a eaks seco

ature 

0 o 90"

A a see

Oi 

Backash bewee cakshaf gea a o  e gea

013 o 025

04

Reace

Backash ewee ie gea a oi  gea

0 to 04

04

Reace

Dfeece bewee  case eh a gea heigh

005 o 01

015

Reace

Gea ooh i o  case ceaace

01 o 0.8

02

Reace

Dve gea shaf

20 004 o 00

015

Reace

laan

Dve gea shaf o ive gea ceaace

0 004 o 00

015

Relace

e gea shaf o e gea ceaace

22 003 o 005

015

Relace bshig

12-10

to covr

Ajs

m

LUBRICATION - SERVICE STANDARDS

Descripton

mit

Nmal v1

Coeco nd mrks

!Bc <,atl O ump

Re vv vve opng u

180 P 2 f:)

eef vv s od (Inst ngth 463

50 to 6 N 53 to 169 k

pce png.

O bypss m vve open ss O st pese

34 o 390  3 o 4 kfm'

pc

O ooe bypss vve op 

75 o 2 k 8 o 22 kfm

pe

360 o 420 k 37 o 43 km 1

pe.

o vve

Vve oen  Spng od sed eg 483

265 to 32 k 27 o 33 k/m

hk vve og 

3.2

76 to 80 N 78 to 8.2 gf pe

TIGHTENING TORQUE TABLE Dspo

Ted sz  x h mm

h oq m kfm

O pmp de  hf 

M2 x 2

9 o 78 6 o 8

O yps m

M20 x 

44 o 4 4 o 

O fte ee bot

M6 x 

9 o 69 6 o 7

O oo bypss vve

M27 x 5

 o 20  o 20

o vve

M27 x 

98 o  0 o 2

O p dn p

M8 x 

69 7

O jet hk vv

M2 x 75

·34 3

mk Apy LOTE o 262

12-11

•

LUBRICATION - SERVICE PROCEDURES


At dle V 145 kPa (.5 gf/c') or moe L 49 ka (0 gf/ A axiu speed NV 29 o 490 a 3 o  gf/ 9 Pa ( gf2  

NOTE: 1 To remove the oi cooler remove the injection pump beforehand 2 After the element has been installed start the engine and check connections for oil leaks (2) Oil Pump Oil Strainer

V  onal Vale  

8906A

With he .ol pressure swch removed and pressure gauge staed, worm up the ege uti he o temperature reaches 70 C _to 90 C Measue the ol pessure a dle ad maxmum speeds If he measureme s beow he mt ovehaul e lubricatg sysem °

4.1



REMOVAL AND INSTALLATION

(1) Oil Filter, Oil Cooler

Bol gheg sequee :- 1  !J Afe e salao has bee oleed, ae se  e ol p gea oaes soly whe ed y a.

3 4 5

Oil pan O staer O ppe O pump Da pug

0

NOTE: 1. Measure the backlas in advance f removal of oil pump. 2 The oil strainer and oil pipe should be removed together with te oil pump unless anything wrong is evident 3 After the oil pump has been installed, verify tat the backlas is within te specified rane.

Reguao vae

CD

12-2

2


4.2 4.21

DISASSEMBLY, INSPECTION AND REASSEMLY Oil Pump

(1) Disassembly and Inspecton

Cernce betwee ide sha  de ge D  NV 003  005  05

'Bcklash NV 0.1 o 024 L 04

Reef ve peig pressue

NV 1 80 P ( kgf/cm) Ised d f spg (Ised egh: 463) NV 50   N  53  9 g)

W  dge  ece bewee shf to cove

gged  e

D 0 NV 004 t 007 05  

6 W bushg  w  ged  sce

�\, 9

4 2

Cgged  ccked BD  NV  

t sfce  w busg

Worn sig Ceace BD 0 NV 004  007  05 asc Dee N Vue 

Cece betwee gea  p   pup cse NV 0  08 i

L

0.2

Deece ewee  pp  cse dep d gea hegh NV 005  0   05

Oil staier () Oil pump over 3 Diven gear 4 Dve gear shaft 5 _ dler gear shaft

Idler gear 7 Sea 8 Spig 9 Ba 10 Case ad gear assembly 6

F dssseby f ps wth n ecce ue, see wg es The p ked • s be speced befe dssseby

NOTE:

1.

2

Do not remove the diven gea shaft unless it is faulty. Removal of the shaft may resut in loss of alowance for tightening the oil pump case. The case and gear assembly is a non-disassembled type. Replace the assembly if it is defective

[email protected]

Parts phone: 269 673 1638 8

12-13

m


Disassembly and Inspection Procedure (a) Before dsasembly, measure and ecord he backlash beween he o pump gear and he dle gear.

C91

) Measure he clearance beween he dve and dri\en gea tooh end and the oil pump case with a hckness gauge Oil pump cover

C9519A

(b) Remove the oi straine and dve out the oi pump cover wh a plasc hamme ec NOTE: The oil pump cover is located by the dowel pins installed to the oi pump case. (c) Before the drven gears are emoved measue and recod the followng ems

C96

(d) Measue and ecod he outsde damete of each of the drve gear shaf drven gear shaf and dler gear shaf Then, measure and record he nsde damete of each of the oi pump case cove and drven gea bushngs Caculae he cearance be ween each shaf and bushing If he sevce lim is exceeded, eplace the asseb C920A

1) Measue the dffeence between the dve and dven gea hegh and the o pump case deph wh a thickness gauge

12-14

•


(2) Reassembly

Bcklsh between rive ge d le ge NV 0.1 o 024 L 0

Shaf o hoe sou be  hs e

Reove o o geses o hede e n he pply ote 262. 59 o 78 N 6 o 8 kgf

6

Appy se o he poo o be fe  bshg (Moly bdem bse gese)

5�

-



C Alg o hoe wh  arow

UP ak p

Algn ol holes  e se shod e flsh wh se en sae 7

I

1 (Wetl

/

2

3

4

9

< Asseby seqee> I0 -�             3     NOTE: 1. Before reassembly, apply engine ol to all parts unless otherwise specfied. 2 Temporarily tghten the oil strainer, taking into consd· eraton its nstallation t the crankcase.

C92

12-15

m 4.22

LUBRICATION - SERVCE PROCEDURES

Oil Fier

Cracks

Cloggg, defomtion

- 4

Ccks fomo

2 3 4 5 6 7 8

Dra plug Ceter bo Washer O fier case O fier eeme Eeen reaine O er hed O byass aarm

C9705

Inspection of Oi Bypass Alam



/

Pssu gag  � _    Vv opnn rr NV 345 o 0 k 13. to  kgf'I

U000C With no air pessure appled, check fo continuity acoss the ermnas as hown and epace the o bypass aarm if there s continuity. Next, wth the a pressue apped and graduay ncreasng, measue the air pessure when there is contnuty If the measurement s out of specicaton, epace the o bypass aarm

12-6

m


4.23

Oil Cooler

Damge, cracks scle oil leas 3

Ccs scle Oil cooer element 2 Bypass vave 3 Ol oole cover

0

@  @ �   2 . � Bypss vve pen .

"

"

pessue NV 175 t 215 P (1.8 o  f/c')

NV  Noinl Vlue C9804C

( 1) Cleaning

(2) Air Pressure Test

(a) Chek for abon or sludge deposited  the oi passage of the oil ooe element and bypass valve. If ontamination is evdent wash in a eanig oil (b) f there is muh sale on the eement and over, wash with tap wate (peferably hot water).

To hek for oil leaks de to a broken o aked element air pessre test shold be performed Apply 1470 kPa (15 kgf/m ) a pressre to the element to hek fo eaks If ai leaks or other efets ae evident eplae te eement 2

NOTE: Make sure that the specified air pressure is not exceeded

2-

• 4.2.4


Regulator Valve

98 to 15 m  o  kgfm)  Set load (set ength: 48.) NV 76 to 80 N (78 to 82 kg) Lost tension 3 NV .. Nomia Vaue

Opening presse NV 60 to 40 kPa (7 to 4 kg/c')

1 2 3 4

Snap ring Valve Sping Body

C9902A

4.25

Check Valve

I

�

�2

. After assebing,  bend ock washe  tab against check = -1 34 Nm (3.5 kgfm) (onted on cankcase) vave.

NV . Noina Vae

Vave opening presse NV 6 to  ka (.7 to . kg/c)

Check valve 2 Lock washer 3 O jet body C9951B

Fo the check vave mouting posio, efe to (e) 12-8

i 6)   Geera ad 2) i 5.3  Group  Engin e

LUBRICATIONS - TROBLESHOOTING

m

5. TROUBLESHOOTING Pobal cause

Symptom Oil pressue dos nt icra

Rmdy

R. goup

Anorma oi v •

Oil laks into cooat Ol

as

Coct and f to spcifd 

Ire l vsy

• O out o f

Rpac

Fu i oi

Rpac !caus)



Oi pssu swch no uctoning popy Loadd oi t mnt oadd o sraer, lse oi ump joint, cackd pp

Rpac Rpac mt Coc o pac

Ri a ypass a not functioning popy Wo o damagd o pump pop Excssi o m

Oi

as om gin

Oi as om caksat ont o a oi sa

Rpac Coct o pac

Goup 1

Coct o pac

as to cooing sysm •

Dcti oi coo wat jac

Aoma compssion pssu

Coct o plac Cc

Goup 

12-9

FUEL AND ENGINE CONTROL CONTENTS

2 1. GENERAL ............. 2 SPECIFICATIONS ..... 22 3 SERVICE STANDARDS ......... 23 3.1 SERVCE STADRD TABLE .. 23 32 TIGHTENING TORQUE TABLE .. 25 4. SPECIAL OOL ...... 27 5. SERVICE PROCEDURES . 30 51 NJECTION PUMP ....... 3 5�11 Removal ...... 31 512 AD Type njectio Pump .... 32 513 P Type Injetion ump . 40 514 Adjustment after Reassemby ..... 49 55 nstallatin ............. 57 5..6 Bleedng the uel Systm 60 51.7 nspectin and Adjustmet of uel njeton Start Timing 6 5..8 nspecton and djustment o No-load Mmu nd Mxmum Sped ............ 62 5.2 GOVERNOR ...................... 64 52.1 RSV Type Governor ....... 64 5.2.2 RD ype Goernor ....... 67 5.2.3 djustmen after Reassembly 0 5.2.4 nspection ad Adjustment of No-load Minimum nd Mximum Speed ............... 80

5.3 FEED PUMP ................. 5.3.1 Disassembly, nspetion n Ressembl ................ 532 es nd Adjutmn ........ 54 AUTOMATIC TIMER ..... 541 SA ype Automt imer  ...... 54.2 SP Type Automa mr 543 Test nd Adjustment ... 55 PUMP DRIVE CASE ........... 55.1 Rmoval and nsalltion .... 55.2 Disassemby nd nspec· tion

553

81

8 82 83

83 88 9 3 93

.

93

Reasembly  INJECTON NOZZLE .

94 95

.6 561 Removal and naltn ....... 5 5.62 Disassemly ........ 95 96 56 Cleaning nd Inspection 5.6.4 Rsembly n Adustmn (1sprng zz) .................... 97 5.65 essembly nd Adustmn (2·spng ozze) ...................  57 FUELLTER .................... 104 105 58 WATER SPARATOR  TROUBLESHOOTNG ............ 106

13-

D

FUEL AND ENGINE CONTROL - GENERA

1. GENERAL

Injection pie

-

eion ozze Fe feed um

Governor

e fier

Fuel eak-of ie e feed e

ie

Fel feed

Fl eun

pump

pipe

We seo (Oio! Fe 

NOTE: he ige sows he AD imoved eo ieio m. B215A

The fuel system consists of he injection pump general assembly (njection pup pope, govenor, tmer feed pump and coupng) fuel flte water sepaato inection pipe injecton nozze fue eak-off pipe etc. The njecton pump is drien at onehaf the engne speed.

132

FUEL AND ENGINE CONTROL - GENERAL

( 1) Injection Pump Proper (a) Injection pump

AD type -6022> -�

'

Dlivery valv le Delvy valve sprng

 tye <6022· T, TC

elvry valv holder

Dvery vv sa Dv av sat

Puner barre Control rack Contro seev

O smp Cotro o

Low srng sa et Cm cam Cmsf 8902A

he camshaf driven at half the engne speed s suppoted by taper olle bearngs at both ends. he camshat has a cam fo operatng the punger and a cam for opeating the eed pump A tappet operatng wth the pump housng as the gude s n contact wth the camshat The tappet chnges the otary moton o the cam to up-anddown moton whch is tansmtted to the plunge he P type njecton pump ofes the olowing featues 1) The pump housing is a totay encosed type. 2) he punge barel has an obque hoe made to etun the fuel that has leaked to the ol sump to mnimize the leakage of the fuel nto the cam chambe

903C

3 To prevent the fuel n the ol sump from leakng nto the cam chambe, an 0ing s provided on the oute crcumerence of the punger barre, thereby mantanng ts tghtness 4 A defecto s provded on the oute crcmfeence o the punger barel to pevent eroson of the pump housing that may be caused by counter low o el at the end of an nection.

1

m


The plunge as n obiqe goove nd  vetic goove, wile te plunge be hs 2 inlet-otlet hoes. Pessurized feeding of fue ol begins wen the punge pushed p by te cm of cmshft coses the netoutet holes of pnge bel Wen the punge is fute pshed p fel o is dischge tog te vetic goove of punge fom te netotet hoes

(b) Plunger

Fuel daw n

Beging of preue feed

Pessure feed

End f peue feed

82204A

AD type injecton pump

P type inecton pump

Ct d Plnge bel

Plge

onrol leeve Dvng fce

8222A

A defecto s instled on the pephey of the punge be so tht hgh pesse fuel oil dscged fom · net nd otet pots wi not eode the pmp hosng Fe njecton vome s contoed by the goveno wich moves te conto od (o the contol ck) et nd ght nd ottes the conto seeve

134

8226A

whch engges wth the conto od (o the conto ck nd pinon). Snce the dvng fce of punge meshes wth the contol eeve t the owe pt theeof the pnge tns with the otton o onto seeve nd necton vome s contoled though te cnging of the effectve stoke

D


A delvey valve stoppe provded on the top of the delvey valve sprng lmts the ft of the delvey valve to pevent the surgng of the vave durng hgh speed opeaton It also educes the dead volume between the delvey valve and nozzle and stablzes the njecton rate

Ef Pctive sk

(d) Overfow valve

B2205A

The effective stoke means the length of the punger stoke fom the tme when the uppe end of plunge coses the nle . t-outet hoes of plunger barrel unt the oblque goove of plunger opens to the net-outet holes When the effectve stoke stands at zeo, t ndcates that no fuel njecton takes place

pp

Sl ball

B8A

(c) Delivery valve

Suon o

Bgg o Ij 

Sprg

When the fuel pessure n the necton pump exceeds a pedetermned pressue the steel ball n the ovefow vave s pushed up to let the fuel fow out from the njecton pump and eturn to the fue tank, thereby stablng the fue temperatue and tempa tue dstbuton n the necton pump and mantan ng the njecton rate nto each cynder constant

d o d    (bgg o u) B2207A

he fuel hghly pressurzed by the p lunger pushes the devey vave up and gushes out When devey of the fuel under pessure by the plunge s completed, the delvery vave s pushed back by the devey valve spng and closes the fuel passage to prevent counte flow of the fue The devery valve s further brought down untl t s hed aganst the seat suface tghtly he amount of fuel correspondng to the stoke durng the peod s drawn back fom above to nstantly owe the resdua pessure n the lne between the delvery valve and nozze The drawback effect mproves the cuttng of fuel from the nozzle and prevents afe-njecton drppng 135

D


(2) Governor (a) RSV type govenor Supporting leve Guide lever shaf

Governor ousin

Tenson leve  spn

�ono k

cke -Adjusin leve Cono lever Goveno spn

Cmsf

Flywe

Unec sprin

op ever llod sopper bol

The RSV type governor is a centrifugal type a-speed governor couped to the camshaft o the injection pump. he governor not ony conros the maxmum and minimum speeds but aso automaticaly conrols the engine speed a any intermediate speed poston.

lider

Gude leve

ie

13-6

Govenor sleeve

uppoin s ywei

82C

82657

he governor, as shown, conssts of fyweighs mounted to the injection pump camshaft When the fyweghts turning on the yweight suppqrtng shat open outward the roer mounted to the end of yweght arm pus hes the end of he seeve n he axia drecion. he governor seeve being made inegra with the contro bock through a bearg moves ony n he aia drection he contro bock mouned to he guide ever hung on the supporting ever shaft of he governor cover prevents rotation

D


Sa sping

rack

Cotol eve

Gude eve

Sppo eve

Re sp

Sop leve

B2659A

The control lever is mounted to the mddle of the guide ever by the shaf with the bottom end as the fucrum, whereas the top of the ever s coupled through the shackle to the control rack. The start sprng attached to the top end of the control ever aways pus the contro rack n the drecton that fue s ncreased

When the governor sprng receves tenson the bottom end of the tenson ever touches the adjust abe full-load stopper bolt When the angle of the adustng lever s changed the angle of the swive lever s also changed and the tenson of the governor sprng changed hs s because the turnng center of the swivel ever and the mounting poston of the governor sprng nstalled to the tenson lever are eccentrc to each other as mentoned above. An adustng scre s aso mounted to the swive lever Adustment of the scre changes the tenson of the governor sprng thereby makng t possible to adust the speed reguation An Unglech spring s provided n the bottom porton of the tension lever Adust the tenson of the sprng by adding or removing shms An dlng sub spring adjustabe rom outsde s provded in the mddle of the governor cover. Durng idlng the spring always keeps n contact with the tension lever to mantan a constant ding speed he stop lever mounted through the supportng lever to the bottom end of the control ever returns the control rack to the stop poston th a sight pressure rrespectve of the adusting lever poston 1) Start of engine Aj eve S p

Coo Ajs eve

Aj sew Ge eve

Goveo sp

Swve eve Fu-o oppe bo

B370A

he turning shat of the swvel lever s ftted into the bushing of the governor cover and ts center s eccentrc with respect to the mountng positon of the governor sprng instaled to the tenson lever The governor spring s nstaled to the end of the swve ever.

B660A

When the adustng ever s moved to the start poston (untl it touches the maximum speed stop per) the swvel lever whch moves wth the adjustng lever pulls the governor sprng and moves the tenson lever unt t touches the fulload stopper bolt

13-7

D


At that time, the flyweights are statonary, and the start sprng wth weak tenson pulls the cotrol lever in the directon that fuel is increased. At the same tme, the control block ad goveror sleeve push the flyweght roller to the let. As the result, the tenson leer and control block are spaced that much apart, and the correspondng amount of fuel is supercharged to facltate startng

3) Maximum speed control - 

 



�

jsng eer

2) Idling control Start spring Shfer F-oa stopper o

Goveor spng Conol

Teson ever Idng sub <� sprg

8261A

Once the engne s started and the adjustng leve returned to the idlng postion, the tension of the governor spring is drastcally reduced Now the flyweights can move outward even at a low speed so the tenson lever is pushed back untl it touches the idling sub spring and places the control ack at the ding positon In this state, the centrfugal orce of the flyweghts and the weak-state goveror spring and idling sub spring achieve balance and maintain smooth idling When the speed falls, the centriugal force decreases, the flyweights move nward, and the idling sub spring pushes the tension leve to the left and moves the contol rack in the drection that uel s increased. I the speed alls radically, the start spng wth weak tension acts and moves the contol rack n the drection that fuel is ncreased to maintain the dlng speed

13-8

822A

When the adsting lever s moved to the fullload positon, the tension of the governor sprng is in creased and pulls the tension lever until t touches the full-load stopper bolt When the engine exceeds the specified speed the centrugal orce  lyweights becomes larger than the orce of the governor sprng pulling the tension leve. So the tenson lever s moved to the right and moves the cotrol rack n the directon that fuel s educed thereby preventing the engine from exceed ng the specifed speed  the spee further ncreases, the centriugal orce of yweght creases and pushes the tenso lever to the right ad als o compresses the idlng sub spring to pull the control rack back to the no-load maxmum speed posito, thereby preventin g overspeed opera tn o the ege The RSV type govenor controls the entre speed range from dlg to maxmum speed I load in creases of decreases at a certan speed determned by the postion of the adustng lever the governor automatcally unctons ad maitains the enge speed constant at all times


4) Ungleich operation

jectoatons se aWhenlow-max. speedinnoper \ wteton nmattakecedrae Inecton/soke AA'.-,--�-1TI BB' When max. injct o s s t g-pd r Engne speed I 82663A

The Ungleich devce contols fue injection in such a way as to match the engne peforance (the e qred injection varies with engine speed).

t

R2 R1

D

he ai intake ate of the engine falls as the engine speed inceases he njection pup, on the othe hand, inceases the pe-stoke injection as the speed inceases even with the conto ack at the sae posion. heefoe if ful load is set at point A to derive enogh outpt at low speeds, the injecton wil each Bas the speed nceases and the engne wil podce black soke If fl load is set at point B' to pevent black soke the low speed injection wil coe down to A allowng cobustion of oe fel So the ngleich devce accoplishes the function of setting full load at pont A to deive the lagest possible toqe n the ow speed range and changng it to adjst the njection to pont B' in the high speed ange

 E z

WUghoutech effect

a : 0 f

N2 N1 Pump spee (pm) 

N2 N Engne pee (pm) _ 664A

When the engine speed s low and the centfuga foce of flweight salle than the pessre of the Ungleich sping the contol block is oved as ch as the ngech stroe to the left, so the contol ack oves in the direction that fuel is inceased to ncease the toque of the engine at low speeds.

13-9


5) Stopping of engne Full oad Adjusting leve Tension ever Conol rack

Shifter

Sop

82665A

Sop lever

As the engine speed increases, the centrfugal foce of flyweght ncreases. If t becomes larger than the pressure f the Ungleich sprng the Unglech sprng s sowly compressed befoe the start of high speed control, and the control rack moves in the drecton that fue is educed The ngeich stoe s completed at the postion where the conto bock drecty touches the tenson lever



When the stop lever s moved to the stop posito, the control ac s moved to the stop postion to stop the engine regardess of the poston of the adjustng lever

6) Operation of torque spring [Option]

t

C

I

D

E

D

.

Governor opeat ane



0

-� ·.

0

a

-

A

5



5



u

0

A

P1

P

2 Pmp speed (rpm) -

P2 Enne peed rpm)

-

8667

Constucton machiney engines ae often subected to a large load during opeaton and reduced speeds 13-0

often ead to stas o pevent ths a toque spng is provded.

D


When the adjsting ever s fxed n the eve set poston, a sdden ncease of oad, f no torque spng s povded, w move the contol ack aog the 8-D curve as the speed fas. The rotatona dspacement at the tme may be epressed as P 1  If a toqe spng s provded, the contro ack moves aong 8-C, and the rotatona dspacement at the tme

At the tme he tenson eve pn pshes the bottom o the torque conto eve and the eve moves wth the pn "A" as the fcm whereas the poton 8 s pushed to ght As the esu, the toque sprng

may be epressed as P2 Therefoe age changes occu n P 2 and engne speed and because of ncreased fe necton, the engne toque nceases, and age combuston nose wans the opeato of the

(b) RFD type governor [Option]

nceased oad enabng hm to take pope acton to prevent stoppng the engne.

pefoms the fncton of edcng movement of the tenson eve.

overor Stop ever Guide cover  eve \, Tenso .'   lever  · ' ong   _   ever k

oveor / hog  � oeo  pg

/

Swve eve Camaf Seed oo ver

Idg prg Soke  djg Foang bo ever

yweg Sdg ever

86

The RF type govenor s a mnmummamum governor whch contos ony the mnmm and mamum speeds.

Ful-oad stpper 8266A

In an abpt ncrease of oad occrs when the engne s nnng at contnos atng the engne speed as So the yweghts are moved nwad and the tenson eve ped to eft by the contro sprng casng the contro rac to move n the decton that e s ncreased

The RD type goveno make t possbe to ncease o redce fe by the oad contro eve whch opeates the conto od Any desred speed can be set as a dspacement of the speed conto ever changes the tenson o the governo spng. Because o the constcton descrbed above the RD goveno can be opeated as an aspeed goveno by hodng the oad conto eve n the UL poston and opeatng the speed contro eve On the top of the govenor an engne stop ever s povded whch ceates a nofe necton state fo stoppng the engne A cance spng s povded to make se that when the eve s operated no nde force s apped to the n

13-1

D

FUEL AND EGINE CONTROL - GENERAL

1) Start of engine and control of iding

Increas. jctio a - Dcs

Incras� Injctio a - Decra

Flatg lv Tnsio levr

/N•r>:� Lad c I lv

C

Lad  lv

dlg spg

Idg pg

B265A B2603A

When the engne is stationary, the flyweiht s in cosed poston, pushed by the governor sprng dln sprng and start sprn. If, n ths condtion the oad contro ever s moved al the way to the FUL position (in the directon of greater fuel delivery) the start spring and dlng spring wi cause the control rod to move to the fuel ncreasng poston

13-2

If the load contro ever s paced to the dlng postion after the engine has started, the floatin lever wl move the control rod back to a poston where a fue njection rate suitable for the din speed s avaae wth the pont B as the fulcrum As the enne speed ncreases the flyweghts wil move outward by he centrifual force and wil shift the shfter y the point A unti the shfter compresses the dlng spring At this time the fucrum B w also sghty move toward the tenson ever and wi move the contro rod bac n the drecton for reducn the fue nection rate As the engne speed decreases the centrifuga force of the fyweghts wll decrease and the fyweghts wi move nward so the point A wl return toward the pump housng Ths w set the shfter n the free state pushing t bac toward the pump housin by dng spring force


A he same ime, te fulcm B wl aso sgy move towa he mp hosg o sh he conro o back · he deco or eceasg the fe jeco rae. I hs ae he g see s maae stabe by sgh asme o he jeco ae 2) Normal speed operation

m

As e ege see creases he cega oce o he ywegh wl cease a he ywegh w sh he she. I he oma see age howeve he shte w have oy a hs eogh o comessg he g sg a w o be abe o sh he eso eve o by ovecomg he eso o he gove sg I hs mae he e eco ae s cease o ece smy by oeao o e oa coo eve whch moves he coo o 3) Conrol of maxmum speed

Inras  Ijectio ra . Das

as -  a � as

Sd cotl ev

Ts lv

Eccentric shaft

Idg pg

82606A

I he coo eve s move owa FULL ( he eco o geae e evey) he eccec sha coe o he oa coo eve w case he sg eve o  wh he o D o he eso eve as he cm I ao he oag eve w sh he coo o bac  he eco o geae e eco ae wh he o  as he cm

Flyweight

Sfer

67

I he ege see excees a eeeme max mm see becase o chages  ege oa he cega oce o he ywegh w ovecome he eso o he goveo sg a w sh he eso eve ogehe wh he she

13-3

D


Movement of the shier wll move the pont B, and movement o the tension leve wil move the pont D, and wi aso move the point C wth the point E as the lcrm. Movement of the point  and movement o the point  wi combine to p the conto od back in the decton o less fue njection ate thereby peventing the engine speed rom inceasng. I an engne conto mechanism which opeates the speed contro lever adsting the tension o the governor sprng s empoyed the governor can be opeated as an a-speed goveno which maintains a desied engine speed constant

With smoke s'e asebly Wou soke se

,)'mblv Rack poson ()

4) Start booster (smoke set assembly)

P seed r) 8264

1

As ndicated by the governo chaacterstcs show above when wthot the smoke set assemby the sher and loatng eve are pshed back by the idng sping orce movng the contro ack towar e increasng diecton when pmp speed eache N Namey, N s the smoke mt in ths case When with the smoke set assemby the sprng oce o the smoke set assembly ovecomes that o the ding spng so that the loating ever motion  nhibited nti the speed eaches N hs the smoke mit deceases om N to N It s aso possibe to sece ack postion Rs needed at time o sta 82763A

The smoke set assemby instae to the ea o the goveno has a spng wth settng oce and a stoppe as nctona parts. t aso has seeve stoke adstng nt sping adsting nt and cap

134

D


5) Engine stop

Stop lever Normcl psitn

he loatig leve A pushed by the floating lever link turns i such  way as to make the cancel spring bend ove the sha B So no load is placed on the loating lever C blocked by the idle stopper bot outside the governor Operation o he ungleich device is the same as the RSV type governor

(3) Feed Pump

/ Pm u

Cono od I

Foatig ee nk

8260A

To stop the engine, fuel is cut o by operating the stop ever n the top o the governor If the stop lever is operated, the internal ever pushes the pawl of the oating lever ink to force the contro rod out to the no-injction position. Since the amount the contro rod is moved by operation o the stop lever exceeds the operating range o the loating lever mechanism damage to the link and allied parts is prevented by the cancel mechanism shown

'

Ite ee  so  

J�

�I

O chek 

To fe te

e eck ae

Fo e k

3006A

Supply o fue to the inection pump proper is accomplshed by the eed pump mounted to te side o the inection pump proper and driven by the cam o the injection pump camshat provided for the pur pose he priming pump mounted to the eed pump makes t possible to lift uel manualy when the engine is stationary

oti ee k

ono o

sg

163A

13-15


Ouet

hen e pressure of the pressure chamber or the divery ressure exceeds specification the piston cannot be brought back by te pressure of the piston sprng so the pump action stops and the fuel pressure in the fe fiter does not rse more than necessary

Piston prg

(4) Atomatic Timer

Pressu

S

fd

83002A

The feed pump feeds fuel under pressure as foows. Wen te pston s pused up by te cam of te camsaft' the fue n te sucton camber opens the outet check vav, so most of the fue is forced out and drawn nto te pressure camber. Wen te cam is moved away by rotaton of the camshaft te pston is pushed back by the pressure of the piston spring At te tme the outet ceck vave closes and the net check vave opens So fuel is drawn into the suction chamber wereas te fue n te pressure chamber s forced out

Te nterva between fue njecton nto the cynder and its gnition s caed te gniton deay nterva he igntion deay interva s constant regardess of the engine speed If the gnton timng is aways constant changes n the engine speed wi vary the reaton between the piston postion and ignton tmng, makng t mpossibe to obtan te best engne performance To mantan the reaton between te pston poston and gntion tming constant at al tmes the injecton tmng must be canged to matc the engine speed. The automatic tmer s a device wc automatcay canges the njecton timng accordng to the engne speed

(a) SA type automatic timer [6D22]

ywih

Flang

Timer case

Flyweh hld

310

13-16


The wo lyweighs have a hole a one end. he pins of he flyweight holder i in he hoes. he flange legs ouch he curved surfaces o he flyweighs imer springs ae mouned o he ywegh pns and flange legs. Roaion o he engine s ransmied o he lange and from hee o he lange egs, flyweighs and flyweigh holder and o he injecion pump camsha

S

m

At maxiu advance agl

A ig 

81A

Flang lg wt yweigh older p

A lw s 8321 lA

Dung ow speed operaion of he engine no ceniugal oce acs on he yweighs so he imer springs have he onges nsalled engh

When he engine uns a a high speed a cenrugal foce acs on he lyweighs and causes hem o open ouward wih he pins of he fyweigh hode as he ulcrums. he ange legs ae pushed by he cuved surfaces o he yweighs n he direcion o he ime spring compression bu hey canno be moved because hey ae coupled o he drive side As a resul he pns of he lyweigh holder are drawn in he urning drecion while compressng he imer springs and move he camshat of he pump n he urnng direcion o advance he njecion mng If he engne speed changes rom a high o ow speed he cenruga orce o he lyweighs wl decrease and he yweighs will eun o her original posions A he same ime he pins of he lyweigh hoder wll be pushed back by he ime sprngs

13-17

•


(b) SP type auomaic mer [6D22· T, TC]

Oil sea

0-rng

Cov

Spg t

Tm hung

B321A

Two flyweights are fitted on the pins of the timer housing and are held n the tmer housing. On the other hand, the injection pump connecton side fange has a curved suface and the role fitted on the pn instaled n the flyweght touches the crved sface

138

imer spings are hed between the sprng seats ftted on the tme housing pins which extend though the fange and fyweght hese parts ae hosed n the tme hosing and ae totally encosed wth a coer, 0-ng and o sea


�- 

 

  

m

(5) Coupling



[For AD ype] Timer sng

Fla

ss coupi Drv coupg

A copo rksh

Advance gl Cupng plt

otte bol 345A

[or P type

rss l "·

Dv oupl 83202A

When the engine is unnng at a low speed, the timer sping pessure is stonger than the centfuga orce o lyweght so the olle o yweght s hed down by the ange ceatng no advance state. When the engine eaches a hgh speed the centug a oce o lyweght becomes stronge the oller o lyweght pushes the curved suace o  ange with the tmer housing pin as the ulcum and the yweight opns outward whie compressng the time spings. In ths manner the ole nstaed on the lyweght moves the ange n the turning diection and adv ances the njecton timing

rksft,  oo

tr bl 3A

The couping which transmits drve powe rom the air compressor canksha o inecton pump drive cankshat to the automatic tmer s a aminated couping consisting o thn plates placed one upon anothe. he amnated couplng thanks to the revesibility o the pates absobs excess orces other than the torque thereby povdng protection aganst applca tion o oces other than necessay to the inecton pump Adustment o the uel inecton stat timing is made by changing the instaed condtion o the diving couplng

13-9

D


(6) Pump Drive Cas

he gh pesse fel whch has foced the neede valve p s ncted fo the ofce  the end of the nozzle nto the engne combston chambe Soe of the hgh pesse fe lbcates the neede valve etc and s retned thogh the fuel eak-off ppe to the fe tank he necton pessre of the njection nozzle s adsted by changng the tension of he nozzle spring wth the adustng screw (b) Hole type (2spring nozzle) [Option] B419A

The pum drive case is monted on the fywheel housing on the eft side of the engine and is driven by the timing gear of the engine at half the engine speed. The pump dve shaft, with ts end connected to the coupin of the njection pmp dves the njection pmp (7) Injection Nozzle

Adjstig scew ok 

Pref dig shm Sper

(a) Hole type (1-pring nozzle)

No. 2 pusod . Noe ode Ve opeig pesse adi  No 1 sping No  ps od Nozze Reng 

Adjusing rew B346A

Nozl olde

Noze ping

Neede vave

Noe

B3407A

The fue deiveed from the injecton pump enters the nozzle hode and has a pessre higher than the specified pressre So the fe overcomes the nozze spng and pshes the neede vave p 13-20

he fe devered fom the injection pump entes the nozzle holder and overcomes the No 1 and No 2 spings depending on ts pressure, and pushes the neede vve p The hg pessre fue whch has foced the neede vave p is propery nected from the orfice at the end of the nozze into the engne combston cham ber Some of the hgh pessre fel ubrcates the neede vave etc and is retrned throgh the fe eaoff pipe to the fel tan The injecton pressure of the njecton nozze is adjusted by changng the tenson of the nozze spring with the shim and adjstng screw

FUEL AND ENGINE CONTROL - ENERL

(8) Fuel Filter �

D

(9) Water Separator [Option] 







To inject pum

Freedom p fuel

cver

� 1

�Eleent 

51A

B3501A The fuel filter s a spin-on ype. So he eemen is easily replaceabe The fue fe separaes he waer conained n he fuel fed unde pressure fom he feed pump of he njecion pump and removes dust and dir by the elemen

he sedimener ype wae separaor separaes gas ol and wate cenifugally by taking advanage of thei dfference n specfic gravy he fuel ha has flowed in from he inlet conneco s squeezed by he fuel pah of the head o increase he fow veocity and spins he separaed waer s sedimented n he case, wheeas he water-separaed fue s drawn hough the fuel pah in the center of he head nto he feed pump he wate separator sedments not ony waer but also mud componens. A ed foa goes up and down wh he waer level n he semanspaen case, makng t possibe to visually check he waer quanity.

13-21

D

FUEL AND ENGINE CONTROL - SPECIFCATIONS

2. SPECIFICATONS Iem

Specifaton

Desel k o, d odc \62[

[6D22[ njecon pump proper Type Model urig diecio (as vewed fom drie side) Pluge

Dameer

Govero

ype

mm

6D22J

(Sadad

(Opo

(Sadd)

(Opo

Bosch ne ype

Bosc -e y

Bosh inle ype

Bosh ie ype

AD

AD

p

p

p

Cocwise

Cocwise

Cokwse

Cowise

Cocwe

105

105

2

12

2

Minimum

Al sped

u

Al speed

maxmum mechanica

goeo

mamm mehaa

oveor

A speed goeo

oveo

RSV

Mode Feed pump

Mode

Automai mer ype

oeo

RS

RFD

KE

KE







Mechanica

Meaca uoc mer

Mehaa aomai imer

Mecanca auomaic mer

S

S

S

SA

SA (Sandad

eo oze oe ype (spig nole)

ype Mode No. o oes Oie diamee

Ieo pessure Ma (kg/cm' Waer eparaor

ype

Sandard)

Opon

A

A

A

LA

A

A

4

4

4

4

5

5

036

06

037

037

0

037

54

4

54

54

50

50

216 (220

26 220)

1 80

26 (220)

26 220

1 10)

Spo ype Sedme rap ype

[email protected]

13-22

(Opo)

Hoe ype oe yp Hoe ype Hoe ype oe ype sprig ozze) (2spn ole spg ozze) (1spring noe) (2sprig oe

mm

Orie age

Fue e

RS

RD

Mechaica

uo e uot er

Mode

Bos ine ype


FUEL AND ENGINE CONTROL SERVCE STANDARDS

3. SERVICE STANDARDS

3.1

SERVICE STANDARD TABLE

( 1) njection Pump Unit: mm Nominal value !Basic dameer

Decriptio

Fe njecton sart imng IBDC

Dependen o

Limt

Correction and remarks

-

Adjs



Adst

efo

Eccecty wh respec o ar compesso craksha o pmp drve saft

0.2 or less

econ spacing

nectio pmp poper

Presoke

60"  30'

Overfow valve opeg presse

Ads Adst.

AD ype

4.5

005



P ype

48  005





02

Repace



epace

Overa tappe cleaance ,



t

622 (for geea powe applcao)

155 ka 16 kgf/cm 2 

622 fo

2 kPa 26 kg/cm 

ouco



machey 622-T, 622C d pay of camsha

01

-

Slidg resstance o contro ack whe staioary

AD ype

5 N o ess 150 g o less

Slidg resstance of contro od whe statioay

P type

3 N o ess 30 gf or ess

appe ceaance

AD ype

Backas betwee contol rack and pio Dimenson

fom goveo ousg





AD type

015

0.3

RSV type

19 o 192



D ype

33 to

o ser

33.4

Adst ss Ceck Check Adst

0.3 or mor

21 o more

 sroke of cotol ack o contol od

Governo

002 o 006

Ceck Repace Adust ss



13-23

FUEL AND ENGINE CONTROL SERVICE STANDARDS

Unit:m Descripton

Feed pp

Tghness wen 195 kP (2 kgf/')   pu s pple iting apaity

 f stres reqired bere ltig wen perated at 60 t 00 stres per inue

Delivery (iI fr 5 sends 

00 p

500 p

000 p

500 rp

Noial value !Basc ete

Liit

O i.

-

Crei ad mak

Repae

25 stes r ess

KE type

60

K type

60

KE type

340

K type

260

KE ype

405

K ype

50

KE ype

430

K ype

520

Repae

(2) Injection nozzle tm esriptin jeti nze ineti p

inal vale Basi daete

ne-sprig nle

26 Ma (220 g/'I

Twspng nle

17 Ma (180 g/ 2)

iit

rei and 

Adjust r replae e

00 ± 002

Adjust

-spg reguated pressure pe pessure

24. t 254 Ma 253 t 29 g/'I

Adjust

sprig regulated pressure ver pressue) wit a 005 needle valve lif

23 t 3 Ma 235 t 240 g/'I

Adjust

reli

13-24


3.2

TIGHTENNG TORQUE TABLE Descripton

Ijti pump backe

njecon pump

Thead sze 0. X pc Imm)

gtening oque Nm lkgfm)

M1 x 15

35 o 53 36 to 54

Devy vave or

AD ype jet pmp

64 o 69 65 to 7

Loc pae

44 o 59 45 to 6

Fange eeve 

P ype neti pump

39 o 44 4 to 45

Deivery vave or

1 o 115 (11 o 2

Govenor ywegh nu Ron nu

83 o 98 85 to 1O

S tpe automac tme

Ro nu

125 o 145 13 o 15

Cap ce

29 to 39

(For AD type injecton pump)

= �c B

to 4

A ot

49 o 54 5 o 55

B o

29 o 34 (3 o 35

C o

29 o 34 (3 o 35

A o

74 o 83 75 to 85

B ot

59 to 64 (6 to 65

C ot

59 to 64 6 to 65

f

�



(3

22 o 24 22 o 24 ·

Cove mounting o

·'

9

ighte ee tme to the pecie toe

49 to 59 (5 to 6

SA type automaic tme

-

Remark

B

B348A

Fo P type njecton pump

�

(,. (· 1� ·

B ,'

�·( ,/

C

I I

I

B

B341A nection nozze

ne-pring noe

o-prng nozze

Reanng n

M22  5

59 o 78 (6 to 8

ne onnector

M14 

69 o 78

1.5

(7

to 

Cap nt

M14  1

39 o 49 (4 to 5

Retaining nu

M19  1

59 to 78 (6 o 

Set cre

49 to 59 (5 o 6

oc nt

2 to 25 (2 o 25

Cap n

M22  5

39 o 49 4 to 5

ne connector

M14  5

69 o 78 (7 to 

[email protected]


13-25

D


Thread size 0. X ptc (mm

gnng orqu Nm lkgfm

MS x 125

 

P yp

M4  5

9 3

AD yp

M  5

9 3

M  5

9 3

MS  

98 o   o 

M4  

 

Descriplon

Injcton n bt ! tcng to cyinde d) Injcton pip non n

On pmp d

On n d Lk o pp y o

-�

F 

Connor o

W

Rng n

-

9 o 7 8 6 o 8

Drn pug



9 o 39 3 o 4

A pg

MS  

8 o 98 8 o 

Cnnco o

M4  

 

 n



 o   to 

Fu d d pmp



 o   to 

 d pmp propr



 o 9   3

F ovow



 o 9  o 3

AD yp



98  3   3

P typ



    to 

AD yp



  8  to 8

P yp



 o 9  o 3

M4  

 

ato

Incon pmp ppng gnng yo

rcn n

Lrcnt 

Incton pmp gr monng nut o pmp drv c

13-26

Rmrk

FUEL AND ENGINE CONTROL - SPECIAL TOOL

4. SPECIAL TOOL Unit: mm Tool name Ijeco pup ceterig ol

Par No.

Shape

Use

MH01270

Cenen o backe of AD ype injecion pump

B5032 M06340

Centen o bace o  type necton pump

B503A Fiter wench

M052

Removal o ue fite element

85222

Diesel Kk roducts (1) D ype njecton ump roper The pa nmbes ae the DEEL KIK pa numes pecia Too Name

at No

Use

D type necton pmp specal tool set

05790-060

isassembly and eassembly

nivsal vice

057940090

Mouning base

Tappet pn

57937320

ppotin o tappet

Measin devce

052430

Measuement o camsat end play

Wench

59020

Removal and insallation o scew

Guide

59205400

otecion o oil seal

Rolle pnces

5923020

Removal and installation o tappet

Tappe pinces

579320

lune pnces

59220

Removal and insalaton o plune

Wenc

5940500

Removal and installation o delivey valve holde

xtacto

5925520

Remova f  c

579250520

Remova o ote ace (tme sde)

57925020

Remova o ote ace (oveno side

579304620

Coection of pump hosin

Reame

13-27

FUEL AND ENGINE CONTROL - SPECAL OOL

The pa nubes Special Tool Name

Prt No

Stad

105781-0430

Measurng devce

1057826010

are the

DIESL KIK par bers.

Use est d adjusmet o inectio pp

1057824020

Hode

579314400

Nozzle ode wrench

1579168220

(2) P Type Injection Pump Proper he par nmbers ae the DESEL Speca Tool Nae

Par No

Use

P type nectio pmp special tool

1057907050

Disassebly and eassebly

ivesal vce

1057940010

otig base

Fittig plae

1579443620

nstallation

Plate

157943820

appet ode

57934700

Sppog of tappe

Backet

1579209900

Removal o bearing over

Extractor bearig

cove

579207720

appet montg device

1579218020

Removal and saaion o tappet

Plge ser

1579214820

Reova ad installan of plge

Plnger cap device

1579215620

Remoal ad installatio of contro sleeve

Etactor

105790030

Removal of plnge blok assembly

ittng plate

157943520

Disasseby and eassebly o plge block assebly

Socket wrenc

579140500

Removal and istlatio o delivey ode

pecial wech

1579156500

Reovl and istaatio o screw bshing

Inner ace extcto

579257120

Removal o ne

, Oer ace exactor

1579252020

Removal o oter race

0-ig iset

1057920000

nsallation o rng

late easig

157828·7200

ostioig o govero sde tape

Cashat easng device

1057824140

easreet of casat ed play

Fiig stad

1057810170

es ad adstet o ectio pp

easrig device

105782420 057824270

13-28

rce

role

berig

IKI part

mbes

FUEL AND ENGINE CONTROL - SPECAL TOOL

(3) RSV Type Governor Th pat umbrs a h DISL Pa No

Spia l Nae

KIK

pat mbs.

KK

a mb

Us

Hanl

15790-120

Sct w

57940500

W

5950100

Rmva nd istaao of rou 

Exta

59265320

Rmva a saa  fywg

Sa wh

5962620

Ajsm f Agh

Rmva a alla f lk t

(4) RFD Type Governor  pat nbs a t DS Pt N

Spal  Na

Us Rmva ad saa f k 

a

59020

Sk w

57940500

Sa w

595000

Rmva a saa   

xat

59265320

Rmva  fywg

Spa wch

5962620

Ajsm f  sp

G sw

596310 0

Ajsmt f ak lm

(5) SA Type Automatic Timer Th a mbs a h DS KK ar mbs Spa  Nam

at N

S y omc e pecl  s

0590500

Dsassmby a assmby

Sa sa

5965320

Rmva a saa f  

xa

592660

Rmva

G b

59240200

Dsassmy a assmbly

Bas

592400

a pe

596620

Rmal a sala f m as

s bsg

5924500

saa f  sal

G shg

5924200

Bk

59240800

G shg

5924300

G

59240900

S

5932000

G

59240400

rs busg

59240500

Isaa  fag

O sa g

5940600

s f m cas

Us

Isaa f fywg

13-29

D

FUEL AND ENGINE CONTROL - SPECAL TOOL, SERVICE PROCEDURES

(6) SP Type Automatic Timer The pa numbers ae e DIESEL K pa nmbes pcal oo Nme

Pr N.

S yp omi ir speca oo st

05790-5050

Dsssemby ad esseby

Box spaner

5952320

Reova a salain of rn n

Bx wenh

1596-2800

Speia spanner

1596-5320

xrar

15926220

Base

5924-2520

Spea spanner

5968320

Use

Reva an insaaion

Dsasseby n reasseby

(7) Injecton Nozzle he par nbes are e DS K par nbers ar N

peia  Nae

se

Nzze eaning o

05890010

Ceanng of noe

Noe eser

0585-010

Ajsen an esing

Asng eie se

05890500 ( •: Copnens)

Asng ee

'589-0220

Dal gage

5954-3800

in

I

= 50

5892-200

n



 605

*589200

Conneor

5892-320

Base

5892-800

Gaske

'5892-500

Reaining n

5892-420

Gaske

026508-40

Asen an esng f 2-spring noe

-


Wherever possible, test the fuel system parts before disassembly to precisely know their conditions. Select a clean ste for dsassembly and reassembly work as even small dust partcles on the fuel system parts can adversely affect engine performance When disassemblng the njection pump eep work ench clean and dsassemled parts neaty arranged for each cylinder. Use special care to ensure correct combnation o plunger and plunger barrel and of delivery valve and delivery valve seat

13-30

Scrupulous care must be exercised whe disassemling and reassemling critical parts se the specified special tools for disassemly a reassembly; never apply excessive force or handl parts carelessly Before disassembly test the system to know exactl the trouble spots

FUEL AND ENGINE CONTRO SERVCE PROCEDURES

5.1

m

J M

5.1 1

emoval

3

5

Fuel hose Injection pipe 3 Overfow pipe 4 Oi pipe (5J neon pmp 6 neon pmp bake 1

89147A

2

Note: Never remove the injectio pump backet unless t is uavoidable due to cracks, ec.

86120C

(1) At emoval, first loosen bots dicated by aows n gue o coping.

B953C

Wooden block

C096A

2) Use a wood block to stoe njetio pp est excess foce ght be appied to tier

3-31

D 5.1 2

FUEL AND ENGINE CONTROL SERVCE PROCEDURES

AD Type Injection Pump

( ) Dsassembly

NV Nominal vaue L . im

Damage, worn eat Damage, ezre end ooh broken *Sdngatonary) resisance (when 15 N (05 kgf) o e Backash NV 015mm mm  03 Overfow vave openng prere NV 155 kPa (16 kgf/ c m' Remarks Fo genera power appcaion NV 25 ka kgf/cm) mahnery Remak or (6 conrcon 1 2) 3 ( 5 6 7 8 ® 0

@  13 4 5 16 17  19

13-3

Housng cover Scew Screw Bearing cover Oil sea Camshaft Taper roe bearing Center bearng appet Shm Plunger Lower spring seat Punger spng Uppe spng seat Control sleeve Pnion Lock plate Delivey vlve holde Stoppe

1�;'! :'"I C

0



�

,.�

5

4

 ofamage wear eiure cam sace End play to 006 mm < NV 00  thread   0 mm Crack, damaged � -- -  Broken too Sere 8 wear peeng  acks deeroration Daage,of apped ere,rface goss  �

' ;

3

f:

e,o

�: 0   3 4 5 6

amage, break

Devey vave sprng Deivery valve Devery vave seat Punger bare Screw Conto ack Pump housng

or dassemby of pars w a encrced nmber see foowng tems Te par marked • ms be npected before dasemby

D15668

FUEL AND ENGINE CONTROL SERVCE PROCEDURES

-

 � 



m



-· 

Tapet Pin 157931-320

B908A '

     





(a) Insall he injecon pump n Unvesa Vce (se ca tool). (b) Remove he feed pump (c) Remove he couping and auomatc mer [Refe o 41.] (d) Remove the governo (Refe to 52. o 5.2.2)

() emove he housng cove. Inse appe Pns (speca ools) no he appe hoes o al he cylndes  sace he appes aay fom he casha

Msurng Dvic 10840

2

157

(e) Measure he sldng essance of he conol ack wth a sprng balance Turn the camshaft and measure the sdng esstance n a o the rsng and alng postons of the cam I the readngs are n excess o he nomna value, the olowng causes are probabe. 1) Damaged contro rac abnormal teeh ) Abnorma teeh o pnon contac wh housng 3) Overtghened devey valve hode

(g) Measre he end play o the camshat wth Measung evce (special tool) If the end pay s n ecess of the m adust by usng shms o replace the beang Shm hckness: 010 02 0.14 0.16 018 030 00 .00 mm : elect timer and governor side shims so that their thicknesses will be about eqal.

3-33

FUEL AND ENGINE CONTRO SERVICE PROCEDURES

,-



--





--

-

i

Wrench 15790-20

8903A

(h) Remove the screws at the bottom of the injecton pump with Wrench (special tool

805A

() Push the tappets up om the bottom o th necton pump with Roe Pinces (specia too) an remove the Tappet Pins (special tools).

Tapet Pincers 1571-620

804A 0

(i) Inset a screwdiver into the goove in the beang cove to emove the bearng cove and oil seal ·NOTE:

1. To prevent damaging the oil seal, re· move the woodruff key from the camshaft and put Guide (special tool) on the threaded portion 2 To remove the camshaft, direct the first cam lobe on the removal side of cam shaft toward he top of the pump to prevent the camshaft lobe from touching the tappets, and then lightly strike.

13-34

(k) Hod a tappet n appet Pinces (speca tool) remove the Roer Pncers (speca too), and then tak out the tappet and shim

lugr  21-6120

() Remove the punge togethe wth the lowr sping seat using Punge Pincs (specia tool) (m Measure the backash between the control ack and pnion.  the backash is n excess o the imit epace

m

FUEL AND ENGINE CONTRO SERVCE PROCEDURES

(n) Use Wrench speal tool to remove the delivey valve holer. NOTE: Immerse the delivery valve combined with delivery valve seat and the plunger com· bined with plunger barrel in gas oi without changing their combinations.

Wrench 15794-000

B908A thUosecsoRirnega,moedrrm{e1p5alg7ec30. -p4u6m20p) Ar tihtes (' "   Sl g  �  / " OvLelapme ere  ('•:

(2) Inspection and Correction

,_

'"-. "

-

r � ; ? ) (-

t� �·!

() u

- i\

8

BNLV  B ismDlVeltue    °

(a) Punger and punger barrel

Afe leanng n gas ol, hek o see ha he punge falls smoohy n he punge bae unde s ow weght Chek by he olowng poedue 1 Tlt the plunge bare approx 60  2 Pull he plunger about 20 mm ou 3 un he plunge and hek seveal ponts

A 3-35

D

FUEL AND ENGINE CONTROL SERVICE PROCEDURES

d) Replacement of taper roller bearing

(b) Delivery valve

Inne ace

Exc 57925-65

01525A Clean theyave and vave seat portions of the deiver valve n gas oil and check worn condition. Sea off the bottom of the vave seat portion with a fnger tip and press down the vave porton with a fnger. If the valve porton bounces back when reeased, the vave porton is good If it does not bounce back the valve portion s badl worn. Repace the deiver vave (c) Tappet

Pin Bushing Roler Tappet boy

To remove use Extractor (speca too To instal put the rng and shims and then nstal the taper roer bearng Outer race

Berig ove ./ Beaig oter ae trto  side)sie  (timer (goveno

0153 0156

Hod a dial gauge to the roer portion of tappet and check the overa cearance b movng the roer p and down If the overa clearance s n excess of the imit repace the tappet assembl

13-36

915

he bearing cover sde outer race shoud be emoved b use of Outer Race Extractor (speca too) To nstal put a new o sea in postion ad then instal the outer race. [email protected]



m

(3) eassembly

 ., ·  4.5 -        to .8   Nm          17 �jq-· (0.4  06 kjl  18 64  68 Nm J . _ 19 6   7 gfm -

21, l-20 ',l)

.

"X '

�!-:\ / 

7 =, • L�-\ 7 . {� 2 4_/: r\� ' r(if;  ,." ,. 2 =   I ·> :·g 1' Sidig  ressance  r  !y J  • _ '�\'{; J l£_\ NV wh st, o yl \    � E p   � <-�  N  g   )  ? 26  -i NV 0  0 06  3/ L  m      Asseb seque> i ", 4 6  2 8  7 2                2   8  7  � ·2 Fr re  s with  [� 0 NV . Ni Vu   t i: ' 2 9 D7 0

5

'

,

encircld umb, see follwg item.

Positionng groove

7A (a) Mount the pmp hosing in Unversal Vice (speca too). After the contro rack has been inseted, thread the screw nto the back of the pmp hosng Check to see  the contro rack lghty operates

DA b Insert the pnger barre into the housng NOTE: 1. lign the notch of the plunger barrel with the dowel pin of the housing. 2. o not lightly strike the plunger barrel but securely push in by finger.

3-3


!-� Manufcturer mrk isibd

Plug mb iib

89109A

(c) Place the pump housing on its side and set the contro rack so that the punched marks of the contro rack wl be postioned the same dmension away rom the ends o the housing. After the pinon and contro seeve have een coined, put the pnon in mesh wth the teeth o the contro rod

9A

NOTE

Istall the plunger with the stamped model numbe toward you (the housing cover)

Tappt icer 79362

NOTE:

1. Install the pinion and control sleeve so that the joint of the pinion and notch of the control sleeve will be faced toward you 2 After each pinion has been installed, move the control rack to confirm that it can be moved the same amount to ight and left

89096A

(e) Hod the tappet and shm n Tappet cers (speca tool) and nsert nto the housng

Pluger incs 5792-620

Tappt i 79720

89097A

(d) Insta the lower spring seat and punger together usng unger Pncers (specal tool).

8909A

() ush the tappet nserted nto the housng up wth Roller incers (specal tool) and nsert Tappet n (special tool) into the hoe n the tappet

13-38

FUEL AND ENGINE CONTROL SERVICE PROCEDURE

� --

       -

-



Wnh 157910-120

Inscribed lin

8914A

NOTE:

when the camshaft is inserted, face the inscribed line on the end of the camshaft toward the timer.

(g) Confirm the following tems. 1) End pay of camshaft [Reer to 512 ()(g)] 2) Siding resistance o control rack [Reer to 512 (  He). I Check after remova of Tappet Pn (special too)

9093

(h) Install the screws, using Wrench (specal tool) () Install the folowing parts Governor (Refer to 521 or 522) Feed pump Atomatic tmer (Refer to 54) Copling (j) After the reassembly has been completed adust the njection pump

3-39

D 5.13


P Type Injection Pump

(1) Dsassembly      -      

  

 �

16

Rotating condiion 1 I

Craks, 33 amage

7�

Oveflow valve opeing pessue NV 255 kPa (2.6 kgf/m')

1 2 3 4

® 6 7 8 9

@ 

© 3 14

 6 

Overfow vave Botto cove Scew pug Shm Beang cover Ol sea Center bearng Camshaft Roler bearng Tappet assemby Lower sprng seat Punge Punger spng Uppe spng seat Contro sleeve Cover Nu

(� 9 20 21 22 23 2 25 26 27 28 29 30 3 32 33

Punge bock assemby Deecto Devery vave hode Stoppe Devey vave sprng Delvey valve Delvey valve seat Punger barre Dstance ng Fange seeve Scew bushng Pn Bushng Contro od Bushng Pup housng

Fo isassembly o pas wih an enicle nmbe see foowng ems.

3-4

01568A


(a) Reove the feed pump. r

  

     

· - 









�

  

157

b) Insal Fing Plae specal ool) n Unversal Vce specal ool)· 





e) Reove he screw plg n he casha o place he appe a he op ea cener poson an nser Tappe Holer specal oo) ino he screw plg hoe o space he appe away ro he casa ) Reove he oplng g) Reove he aoac er Reer o 542) h) Reove he governor Reer o 521 or 522)

D1504A

c) Ulzng he hreae hole, nsal Plae specal ool)

) Reove he bearng cover, sng Bracke an Bearng Cover Exracor specal oos) NOTE:

D505A

1. When the baring cover is removd, use care not to los the end play adjustng shims. 2. Check the ol sl and do not remove t unless defctive.

) nsal he njecon pp n Unversa Vce spe cal ool)

3-

FUEL AND NGINE CONTRO SERVCE PROCEDURE

.-



) Reove he ger ung Plunge nset (specal oo!)

· 

NOTE:

Put the removed plungers ordery in a ray containing clean gas oil.

Plunger Camp Dvic 15792 ·60

(j) Install Tappe Mounting Device (specal too) to the pump housing. Then operate the ever to push the tappet up, remove Tappet Holder (specia tool) and take out the tappet assembly (m Remove the uppe spring seat and conto sleeve The contol sleeve can be easly removed by use of lunger Clap Device (specal tool) NOT

The control sleeve anno be removed unless the ball mouned on e flange of the control sleeve and e appet guide goove n he pump housing are n aign· mnt

(k) Remove Tappet Mounting evice (special ool) nstall a wire in the hole of the lowe spring sea pull t togethe with the plunge until the lowe sprng seat can be emoved and remove only the lower spring seat

Extrto 109-0030

7A

(n) Mount Extactor (speal tool) to the delvery hoder and emove the plunge boc assembly

0153A

13-42


Fittng Plate 157944-3520

(o) Disassemble the plunger block assemby by the folowng pocedue. a) Mount Pitting ate (special tool) in the vice

(q) Remove the goveo side scew bushng with special Wench (specia tool) and emove the pin and bushing Then emove the contol od and bshng om the tme side NOTE:

1. Arrange all removed parts orderly by cylinders 2 Be sure not to change the combnaton of the pared plunger barrel and plunger and that of delvery vale and delvery alve seat

Socket Wrh 794-0500

D159A

(p) Secue the pnge bloc assembly to the Fitting la,te specia too) and oosen the delivey valve holde wth Socet Wench (pecial tool).

13-43

D


(2) Inspection and Correction

The ispection procedure is the same as that for he AD type except e folowg.

Sdg codto hek

NV. L 

Nominal Vue Lmt

Over tpet cee of oe oo 02 m  D1523C

Replacement of taper roller bearing

Outer race

Inner race Bearing ov Bearg uter ace Oe Rae Extractr 15792-202

051A

Reove e ace by use of Ie Race Extactor (speca too o sa, use pess

13-44

Reove te bea cove e oue ace by use o Oute Race Etacto (speca too) o sta sta a ew oi sea a e sa e oue ace


(3) Reassembly

Control rod slding resstace (when stationary) NV 1.3 N (03 kgO or less

16 Alg guide groove wt

4

9

1

I 33

.J�

7� A

End play adjustng sm amsa end ply NV 002 to 006 L 0 NV  Nomnal Vae   mi

veral clearance f oller area  02 27-25223222Q26 9 8

y 73

33 32 303 2928 ·_  ' 79�432  6 For dsassembly of pars w an encrcled nmbe see folowg tems -



D15698

3-5

FUEL AND ENGINE CONTROL SERVCE PROCEDURES

11 to 115 Nm (11 to 12 kgfm) (Tight i hre sage.)

D140A

(a) Mount he pump housing n Unversal Vce (spe cal too Then ns bushngs and conro rod, pn and screw bushing wih Specia Wrench (speca ool Check to see tha the contro rod ghtly operaes.

(c) Using Soce Wrench (speca ool) tghten the deivery vave hoder o the speced orque (tighen in hree sages) 

If the tightening torque is smaller than the specified torque, oil leakage or damage to the related parts could result If the tightening torque is excessive un smooth plunger movement or damage to the related parts could result

0-ring Ise 15792-

D1537A

(b) Instal he 0-rng on he upper side of he plunger barrel, and inser he ower sde 0ring ino he pump housng wih 0ring Inser (speca ool) :

Make sure that the lower side 0-ring is not set on the plunger barrel and slided along the wall surface of pump housing.

113A

(d) Moun he punger o Plunger nsert (specia oo) and nsert t ino he punger barre. [email protected]

13-46



-



 

 



(e) Mount Tappe Mounting Device special tool o the pump housing. Then nsa  he appet by operang he appe Mounting Devce A this ime, compress the pnger spng and insert the mt poon of he plnge no he guide goove in he control seeve and inset appe Holder (specal ool nto he scew plug hoe he operaion of inserting the mtt poron of the plunge into the guide groove of the contol sleeve can be easily peformed by inseing the mit potion while moving he contol od to ight nd eft.

g) nstall he governo housing At his tme perform the following opeaion Mount Measuring Plate spe cal tool to he timer sde aper poron of the camshaf and nstall and poson the governor side taper rolle bearng oer race n the rng so that the dimension from the end of he pmp hosing o he end of the Measrng Plate wil be 1385 ± 0 mm.

nsalaion o he aper oller bearing ouer race wl poduce a clearace beween he goveor housing and aper oller bearng oute ace. Change shms o emnae he cearance (f Inser he camshaf from the timer side. When the camshaft is installed face the inscribed ne of he end of the camshaft toward the time side

Shm thckness: 06 1.2, 1 18 20 mm

-47

FUEL AND ENGINE CONTROL SERVICE PROEDURES

0155A

(h) Measure the camshaft end play. Instal Camshat Measuing Devce (speca to) t the timer' sde f the camshat t measure the end pay

Bearing cover Shm DA

,I the camshaft end pay s ut f the nmnal vaue adjust by changing shims between the beang cve and pump husng Shim thicness: 010 012 04 016 018 030 050 mm

3-48

(i) Insta a sprng baance t the cnt d and check t see that the cntr d sides smthy ver the entire stre wthut exceedng the standard sng esistance vaue Reme the Tappet Pn speca t) bee checing () Insta the fwing pats Gvern (Ree t 2 r 522) Feed pump Autmatic tme (Refe t 42) Cuping () Afe eassemby has bee cmpeted adust the inectin pmp


5.1.4

Adjustment after Reassembly

For fuel ijecio rate adjsig saad, see Sevice Inomatio publishe sepaaely.

(1 ) AD Type Injection Pump

Total stoke of conto ack NV 21 or moe

Injction tat itva V 60 ± 3' °

(a) Isal e pump o e ijecio pmp ese Fixig Sad special ool) ad secue i

NOTE: Make sue that the cente of couping is aigned with that of injection pump so that the couping and injetion pump tun smoothly

apt caane NV .3 o mo

B9143A

NOTE: 1 Supply oil to the injection pump cam chambe. 2. · Adjust the injection amount afte ad justing the goveno njection sequence 1-5-3-6-2-4

13-49

FUEL AND ENGIN CONTROL SRVICE PROCDURS

(c) Checking stroke o control rack Move the control rack to confir that the tota stroke is over the specifed vaue In addton check to see that the start sprng and idling spring soothy move the contro rack in the axium inecton direction

Measuring Devce 105782-610

34A

(b) Setting positon O of contro rack Mount Masuring Devce (special too) to the injection pump. 1) Keep the pump running at 750 rpm 2) Loosen the stopper bot and pul the adustng ever toward the non-inectng drection 3) Press the end of the easurng device all the way toward the governor and adjust the positon o pont "O" on the scae of the measuring device ) Fix the load contro ever at the idng poston 2) Let the pup run at 500 to 600 rpm and tepor ary fx the speed control lever so that the governor w begin to provde control at the speed 3) Press the end o the measuring devce a the way ,toward the governor and adust the poston of pont "O" on the scale o the easuring devce

Measuring Devc 0540

45B

(d) Adustng prestroke ) Pu the contro rack out to the total nection poston and secure it there 2) Pace the punger of the No 1 cylnder in the bottom dead center postion and mount Measuring Devce (specia tool) Set the contactor on the tappet 3) Coupe the nection pump and tester nozze

NOTE:

If the injection pump is not running at the speed mentioned above, position O won't be obtained even if the control rack is pressed with a strong pressure, and there will be danger of damage to the link mechanism of the pump.

Nozzle hlder wrench 157916-8220

4B

4) Send a hgh pressure ue into the inection pup to et he fue fow out rom the overfow pipe of te nozzle hoder

1350


NOTE:

The pressure of the fuel forced into the injection pump must be higher than the delivery valve openng pressure. Insd e of timer

92A

b Slalic njeto gng

D3427A

5) Slowly tun the camshaft until the uel ceases to flow om the oveow ppe of the nozzle holde (untl statc njecton begns).

7 Ate adjustment o the pestoke check to see that at the statc njecton begnnng, the nscrbed lnes of the ponter and tmer ae n agnment If they ae out of algnment, estamp a ne on th e atomatc tme

NOE

Make measurement by turning the camshaft clockwise.

Angle scal

9

Preslok

89144A

6) Read the pestroke om the bottom dead center to the pont whee the fe ceases to fow (statc njecton begns), sng a dal gage If the prestoke s out of speccaton adjust by shms [Ree to (e).]

(e) Adjustment o njecton stat nteval 1) Cope teste noles to a the cyndes o the njecton pmp as n the case of adjstment of the prestroke 2) Force el nto the njecton pmp to et the el fow out om the teste noe 3) On the bass of the statc njecton begnnng o the No  cylnder measre the nterva when the e ceases to flow ot accodng to the njecton seq ence, sng an angle scae NOE

Inecton sequence 1-536-24

13-1


 Mease th stoke of the tappet from the top dead cente to the pont where the punge bae is touched 4 If the tappet ceaance is ess than the nona vale adust within the extent peitted by the inecton stat inteva f coecton wthn the pemtted etent s ipossbe set the pestoke of the No  cylnde to the aum of the set value and eadust

Holder 57931-4400

D3478

4) If the prestoke and njecton stat inteval ae out o specificaton, inset a Hode (specia too) between the tappet and lower seat and then adust by chang ng the shm thckness. Shi thckness: 02 to 160 mm 29 types in 005  ncement

Contol sleeve

034728

g) Adustment of fue inecton aount To check whethe the inecton amount is up to specfcaton at the specfied ack position and speed measure wth a measuing cylinde. f the nection amount s out of speciication adust by the folowng pocedues.

 Plung iig fce "Ajstig shm Tapet

D3522A

(f) Adustent of tappet ceaance ) Pace the tappet n the top dead center postion 2) Raise the tappet with a scewdve etc. unti the divng ace o the punge touches the botto end of the punge bae.

3-2

1) Loosen the scew of the pnion 2) Whie blockng movement of the conto ac tu the contol sleeve wth an adjustng od ) Tghten the scew of the pnion. NOTE:

1. A maladjusted injection amount will produce marked effects on engine performance. Make sure the injetion amount is carefully adjusted


2. The injection amount varies on diffe rent nozzles and pipes. Make sue that the measuring conditions are observed. 3. Injection amount uneven ratio Maximum injecAverage injec tion amount in  tion amount of each cylinder each cyinder Uneven ratio (+I

Afte the governor has been adjusted, measue the fel injection ate adaptabe to the engne. (i) Inspection of fue and o leaks •

x 100 (%) Average inection amount of each cyinder

Uneven ratio()

(h) Adaptation to engine

•

Fue leaks from deey valve attaching positon and other parts Oil eaks from o seals and other parts

( nspection of parts

Minimum inec Average inec• tion amount in  tion amount of each cyinder each cyinder x 100(% Average inection amount of each cyinder

Check pats for unusual nose and beaings for excessive heat

(2) P Type Injection Pump

Adjustmen of inco ar vl NV 6' !:30"

Asen o peroke NV 4.8 ± 005 

NV 

Chekng soke o oo o NV 21 o oe

No Ve

NOTE:

1. 2,

Suppy oi to the inection pump cam chamber. Adust the inection amount after adustment of the governor

B9146A

13-53


With RD governo ) Fi the oad contro lever at the dng poston 2) Let the pump un at 500 to 600 rpm and tepo ay f the speed contol ever so that the governo wil begn to povide contro at the speed 3) Pess the end of the measung devce a the way toward the govenor and adust the poston of pont "O on the scale of the easring devce NOTE

(a) Mount two Fxng Stands (special toos) to an injecton pump teste. Secue th� necton pump fimy to the speca tools. NOTE:

1 If the position "0 of the control rod is set by operating the load control lever there is danger of damage to the link mechanism and other parts of the gov ernor Do not set the position "0 by operating the load control lever 2 When the position "0 is set remove the damper spring beforehand.

To make sure that the coupling and injection pump rotate smoothly, align the cen ters of the coupling and injection pump accurately. Strke 21 mm or r

410

D3409A

(b) Settng poston "O" of control od Mount Measuring Device (specal tool) to the injection pump. 1) Keep the pump unning at 750 pm. 2) Loosen the stoppe bolt and pull the adjusting lever towad the non-njecting diection. 3) Pess the end of the measurng device a the way toward the goveno and adjust the positon of point O on the scae of the measurng device.

354

(c) Checking stoke of contol od Move the contol rod to confm that the total stroe s moe than the specifed vale. Chec o see that the contro od s oved smooth in the maxu necton amount diection by the start sping and idling sping

m


I

5 Sow tun the flywhee o the pump teste cockwse ut the uel ceases to ow out om the ovefow ppe util statc necton begins)

Prestoke

03518

(d) Adjustment o pestoke 1) Remove the governo side No 1 cyinder delivey valve holder; spng, delvery valve and gasket. 2) Mount Measung Devce (specal tool) to the lange sleeve 3) Tun the lywheel o the pump teste to detect the bottom dead center o the plunge wth a dal gauge

044A

6) Measue the pestoke o the plnge rom the bottom dead center to the point whee the ue ceases to low out (static inection begnnng)

09 0342A

4) Wth the conto rod set in the ul postion oce a high pessure uel into the nection pump to let the uel low out om the ovelow ppe

7) I the pestoke is out o speciication adust by changing the shim thckness between the ange sleeve and pump housing hm thickness: 00 to 197 mm 9 types n 002 ncement  the pestoke s smaer, incease the thckness  the pestoke s age reduce the thickness NOTE: To install the plunger block, apply grease to each 0-ring. After inserting the 0ring in the lower part of the plunger barrel into the pump housing in advance, apply grease to the skirt portion of the plunger barrel and then install the plunger barrel

04A

-


Satic njto begng 07A

8) After adjustment of the pestroke, check to see that the inscribed lne of the tmer and that of the ponter are in agnment If they are out of agnent nscribe another ne on the ter. When the automatc tmer was repaced wth a new one proceed in the same way

) owy turn he fywhee of the pump tester clockwse unti the fuel ceases to fow out from the tester nozze. Read the rotation angles (inecton start intervas) where th fue ceases to fw according to the njecton sequence. 4) f the necton start interva is out of the standard ange, adust y the sae rcedures as for prestroe adjstment NO

Injeco qence: 1 - 5  3  6  2  4 �-

· 







Pressue fd stke 03426A

(e) Adustment of njecton start nterva 1)

Set the static inection beginning position of the No 1 cynder on the pump tester scae pate. 2) Force a high pressure fue into the injecton pump to let the fue flow out fro the overfow ppe of the tester nozze. NOTE:

The pressure of the ful forced into the njection pump must be higher than he delivery vave opening pressure.

13-56

05A

(f) Adusten of fuel nection amount At the specfed rac positon and speed easue the nection amount and uneven ratio with a measurng cyinder to check whether they are up to specifcation. f the inection amount is out of specifcation adust by the folowng procedures


1) Loosen he two ns ighening he lange sleeve. 2) T he lane sleeve by ighly sikin 3) ihen he nus o he specied orqe o sece he lane seeve [9 o 44 Nm (4 o 45 kgf] Peo he operaons epeaely NOTE:

1. A maladjusted injection amount will produce considerable effects on engine performance. Make sure that the injection amount is carefully adjusted 2 Since the injection amount varies on different nozzles and pipes, make sure that the measuring conditions are observed 3 Injection amount uneven ratio Maximum inecAverage inec tion amount in  tion amount of each cylinder each cylinder

D

Minimum inec- Average inec tion amount in  tion amount o each cyinder each cyinder neven ratio (1  x 00 (%) Aerage inection amount of each cyinder

() Aaaion o enine Ae he oveno has een ajse, ease he el njecon ae aaae o he enine (h) Insecion o el an o leaks • •

Fel leaks o eivey valve aachin oson an ohe as Oil eaks o oil seals an ohe as

(i) nsecion o as Check as o nsa noise an eains o excessve hea

Uneven ratio ( ! I Average injection amount of each cyinder

51 5

Installation

4

2

G Inecon  acke  necion   Oi ie  Oveow ie  necon ie 6 e hose

B9147A

13-57

D


(1) Adjustment of Injection Pmp Bracket �

 -





·

[P type

[AD type]

eco um eeg M61340 oo

Injectio Pump Cenerg Tool MH06127 \

' ·,

Ar comressor

A comessor

- eco  acke

neco um bracke

C063A L

_



_







(a) Place Injection Pump Cenerng Too specal too) on he njecon pump backet, hold a dal ndator to the andre of he centering oo and pero 0-pont adustment

597

13-58

814

b) Sde he dia ndicato o the ceneng oo towad e a cmpesso (o necton pump dive) and measue he posiions o he copesso can haft or njecon pump dve sha) shown in he llusaton wth he dia ndcao.

FUEL AND NGINE CONTRO SERVCE PROCEDURES

Keyway

OGO

c) If the eccenticity between the mandel and ai compresso cankshaft is in excess of the nominal dmension, djust by adding o emovng njection pump backet shms. Shim nsetng Conditon • The number of shms nseted into a sngle point mst not exceed thee. • he front and ear shms mst be eqal n nmber. • he diffeence n nmbe between the top and bottom shms mst not exceed one

(b) At this pont check to ense that the keyway of the cankshaft of the ar compesso (or njection pmp drive) s in the uppermost position f the keyway is not in the ppermost positon tn the engine cankshaft.

(d) After adustment tghten the tightenng bots to the specified torqe befoe confmation.

(2) Installation of Injection Pump line 8619

(c Algn the pointe of the necton pmp and th nscbed mak of the ato tmer. (On engnes wth no auto time align the nscibed mak n the pump beang cover wth that on the pump sde couplng

)

C0599A

(a ank the engne to adjst the No 1 cyinder to the fel njection tming. For ths ppose agn the ange scale nscrbed on the oute pephery of the flywhee wth the ponte of the nspecton wndow of the fywheel housng.

13-59

FUEL AND ENGINE CONTROL SERVCE PROCEDURS

C r s co u" pling/·- �  Dvg ouplg (3to 3.5 kgfm) <,� 'f 1 Aicra c;o m p e s so  � \t I {/(?�\ \' V  I >

(AD type]

"/� ?-

2 9to 34N m



\

/Nf· /y,A\ I /J; .

.

l

!( l

shaf



Co u p l ng pl at e 7 (5to49tot er 5_54bo lNm5tk gfm)

"

83405C vng couplg

(P type

Coss copin·g (6to 59to 664Nm 5 kgm)

(2to 20to 329kgNmm) \ (: t 3 2kgf0tom 29Nm   � '  (20to 30 kgfm) 1 fl. Jrl :i� ,- ,s�-.'[   • fL_ ,  _ . '1 - I I Jc � l 4'9\  (

AD yp

9 8 1 3N m 2 9N m ( 3 kg fm l . to

"

.

c·r� z _\' \- ,./ }

i ,



5c

L_

15to5to 11Nm (2to 20to 2.255Nm (  kgf m 84390 kgf m  20to0to 293Nm (2 (220 0ot 290Nmkgfm  J  0 kgfm  29Nm (3 kgfm) j  � " Jy d  (2.20to0to 293Nm 0 kgfm) ( type

"

Acak  compa esso sh f

t t er b o l t, C po a ute p ing� C 7o4to 3 Nm

(75to 5 kgfm)

�c, l1L1tr�I '  � (2 20to0to 22N5kgf7· m -\ "� 

<

(

2.5 kg m B   (1.2to2to 15Nm 15 kgfm  (2 20to0to 25Nm

B 

(d) Install the driving couping on he cankshaf of the a compesso, and pu it a tle owad the a compesso. Insal the njection pump on the inction pump backe Move the dving coupling owad he coupng pae and ghten i wih he tmng adusng bot Then ghten he cotte bo o he specifed oque to 'educe the cleaance beween the dvng coupng and coupling pate to less han 05 mm

(e Tghten each ppe o the specified toue 51 6

Beeding the Fuel System

Bleed the fuel system as descbed beow

NOTE:

After the injection pump has been instal· led, be sure to check and adjust the fuel injection start timing (Refer to 5.1 7 )

B (1) Loosen he a plug of he fue fite (2) Tun the pmng pump knob of the nection pump countecockwse to et the knob foat up [email protected]

13-60


m

FUEL AND NGINE CONTROL SERVCE PROCEDURES

 7

-   

,;\ /

. 'f .'·f/! l _,

I· -/ , iJ '\ -r I

  �

\

)

J

._ ,

Inspection and Adjustment of Fuel Injection Start Timing

I

 , -r .

8590A

(3) Move the priming pump knob up and down by hand to orce the fuel out unti no ai bubbles come out om the air pug. (4) Afte air bubbles have ceased to come out in the uel, imly tighten the ai plug 5 Move the priming pump knob seveal times up and down and tun down the knob while pessing it down NOTE: Make sure that fuel split around is thoroughly wiped away. (6) Opeate the starte to exhaust the air rom inside the injection pump and inection pipe NOTE: Do not operate the starter continuously for more than 1 5 seconds

C

(1) Cank the cankshat moe than 180 in nomal direction to align the ue injecton start timing ange scale nscibed on the periphery o the lywheel with the pointe °

NOTE: f the engine is reversed (by cranking or when it is stopped), the automatic timer will stay operated in advancing direction and will not readiy return to normal even if it is made to resume normal operation by turning the engine in normal direction for a while. Make sure that the crankshaft is cranked more than 80 in normal direc tion by hand. °

86118

(2) If unde the conditon o Item ( the pointe of the injection pump and the inscibed ine o the automatic time ae in aignment the injection stat timing is corect

-6

D


51 8

[AD type injection pum)

Inspection and Adjustment of NoMaximu load Minimum and Speeds

( 1) RSV Type Governor

Il posit  F ee oi  7, \,; ev SboterA" /  1   e ' - �   =  bo 8 o

o

\-r

/J

to

ontrol

r

L

j

to

, .�

86120A

P tye co pm

c�i=: ·

  e� ve o

Adj59 usti64ng Nmb  (6  6.5 kfm) o

to o

117

(3 If he e co sat g s ot corrc, loosen  wo m dg bs and adj  mg by ng e atomac er. Tig  adug bolts o e spcfed qe Rcheck th fu cton s tming by  oce dre descibed in tem (1 nd (2. NOTE: Do not loosen any other parts than Ue adjusting bolts.

13-62

�'I

3

(a ncto and adusmen o idli R   a id nd cec to nse at the co v c  s bo "A", nd a  g s a e m.   dg sd s  wn h secid imts adj w  sop b A ( scon ad adsm o no-od axmum sd h  c ever n i ouce e tppe t B If  ge sped is ou of h maximm p lmi, dj w he soppr bo B. NOT Afte iling adjustment, quickly move the control lever from the full load position to the idling position to verify that the engine does not stall and no hunting occurs f abnormal condition occurs make adjust ment as far as the specified idling limits allow f adustment is impossible dis assemle and inspect the injection pump

FUEL AND ENGINE CONTROL SEVICE PROCEDURES

(2) RFD Type Governor

(e) n the above condton d) measure the maxmum speed to detemne whether it is wthn the specified iit f) f t i not within the specifed its, adust the fied postion of the speed coto ever with the stopper bolt

Idle stopper bol

NOTE: Sopper bo

Ful loa oppe bol

m

Spee conol lever Load onrl lever 863128

(a) Check to ensure that the load control ever is touchng the' de stopper bolt (b) In the above codtio (a), measue the idlg speed to detemie whethe t s wth the specfied lmts. c) f it is ot within the specified imits adjust wth the de stopper bot (d) Operate the oad contro eve to the f oad positio (unt it toches the fl oad stopper bot)

1. If the fixed position of the full load stopper bolt is changed, the amount of fuel injection will change Be careful not to change the fixed position 2 Check to ensure that even if the load control lever is quickly returned from the full load position to the idling posi· tion the engine does not stop and is free from hunting

13-63

D 5.2


GOVERNOR

5.21

RSV Type Governor

(1) Disassembly, Inspecton and Reassembly

Cracks, detrioraion 23

Cracks, deeroraion 6

18 � 7

Daaged osurface unevely worn contactng Wo sher chrome porion pang of

. -�

� 29

12

Cosing cover @ Ungec spng capsue Iding subsping capsue Torque spng capsue Governor cover Star sprng Round nu ® Fyweght Goveno housing Pug 1

24

Tension eve shaft Cono ever Coar Sm Govenor sping Tenson ever Guide ever assemby  Seeve oatn eve nk Snap rng



2

2

22

3

13

23

4

14

24

5

5

25

6

6

26

7

7

27 28

9

9

29

0

20

30 31

For disassebl and reasseb of arts wi an encrcled nbe, see folowing es. For eassebl, reverse e order of disasseb

32 33

34

Bushng O sea Swve ever Sop eve Shm Sprng ap Return sprng Bushng Sidng eve Bot Snap rng Spring oque cono eve Adapter B9150A

13-64

FUEL AND ENGINE CONTRO SERVIE PROEDURES

(b eoval o lyweght

NOTE:

1. Do not disassemble the shackle and governo sleeve from the guide lever, unless replacement is necessary. 2. Do not remove the governor housing unless removal is necessitated for cor· rection of oil leaks, parts replacement, etc Before removing the housing, use Tap· pet Insert (special tool) to separate the camshaft from the tappet

sng eal Wrench (speial tool remove the roun nt tightening the lyweight. At this tme ho the rive sie to prevent it rom trning

Extracor 157926-5320

D0A

Thread Extractor (special too nto the yweght Ater the bot end has toched the camshat, lighty ' strike the bolt head an tn down the bolt to remove the flyweight

Handle 15790-20

NOTE: B915A

(a) Removal of ungleich spring assembly Usng Socket Wrench (specia too, loosen the nt tghtening the nglech sprng assemby to the tenson lever and remove the ngeich sping capse.

Do not attempt disassembly to remove the swivel lever except when replacement of parts is necessary or when nsmooth op eration is evident In addition, disassem• bly of parts for the stop device and torqe spring mechanism of the governor is not generally required [email protected]


Specia Wrech 157915-0100

B92A

13-65


Shm

Sleev

Baring

Sht Chom platd sufac 81357A

(c) Repacement of sleeve or guide ever assemby 1 Remove the beang fom inside the shifte, usng a pess 2 Usng a pess emove the shfte of the guide eve assembly fom the beaing

19 to 19.2

0254A

6 When the shim has to be epaced, assmbe all elated pas coecty and seect the iht shi thckness to make sue that the dimension fom th end of the housing to the shfte compies with th specfed value Shim thickness (6 types: 0 03 04 05 10  mm

NO: Measue the assembly dimension without lifting the flyweights

835A

3 4 by 

Instal the beang n the seeve. Then nsta the shifter of the guide eve asse in the beaing Check to ensue that the seeve otates smoothy.

NOTE: 1. Do not replace the shim, as it has a thickness determined by adjustment of Item 6). 2. During the removal and installation operations, use care not to damage the chrome plated surface of the shifter.

13-66

m


5.22

RFD Type Governor

(1) Disassembly, Inspection and Reassembly -

     �  -              

21







23





a, eteati

Cracks. deteiaton Ol ea



14

1

9

6

4

5

Damage tatig uae a L� �8

as amage

9

 16

0 @ 4 5 6 7

8

 10

@ © 3 4

Govenor cover Lock nut Idling sping assemby Cap nut Lock nut Damper sprng Governor cove Start sprng Tenson ever plg Tenson eve shaft Gde lever assemby Seeve Floatng lever lin ension lever

Governo sping 16 Load control lever 17 Bushing 18 Lever sha 19 Sliding ever 2 Speed contol lever 2 Snap ing 22 Bshing 23 Swvel ever  Round nut  Flyweght ® Governor housing 15

F iflasemb ytems a easemly f pats with a eile mbe see l  w  g i  eassembly evee te e  aemby

89155A

3-67

D

FUEL AND ENGINE CONTRL SERVCE PRCEDURES

NOTE: 1. Do not disassemble the shackle and sleeve from the guide lever, unless replacement is necessary 2 Do not remove the governr housing unless removal is necessitated fr cor rection f oil leaks parts replacement etc Before removing the housing use Tap pet Insert (special tool) to separate the camshaft from the tappet

(b) Reove he lywegh by he wng prcedure Usng Specal Wrench (specal l, remve he nd nt f he flywegh 







-

-

-

  -

Extrato30 579

Usng Exrac (speca  remve he lwegh

Handle 20 15790�

--



86A 

(a) Remve he lck nu wh Scke Wrech ad Hadle (specal ols). Furherme, remve h idle srg cape.

NOTE: Check the speed setin leer f ee is nothing wrng o nt disassemble it

I

Tappe P320n 793  ppt 4o700deo P type pp A 157931 -



(c) Remve he gvernr hsng by he flwng pcedre Usng Tappe Hder r Tappe Pn (speca l dscnnec he appe fm he cashaf Then emve he gvernr hsng gheng b and remve he gvenr hsng whle srg w a pasc hammer ec

Specia 0W100eh 1579158A

13-68

NOE D not remove the stop lever assembl o the top of the gvernor housing from th governor housing


-



   

Sim



Sleeve Wshe

Washer Being Snp ing

223A

33 to 33.4

225A

(d) Replacemen of sleeve or guide lever assemby

(e Assembly dmenson of shter

To dsassemble the shfte and seeve, remove he snap rng n 't he seeve and he shter and seeve can be separated.

When the she and sleeve are assembed, be sre not o change he adjsng shm, as he assembly dmenson o the shte has been adjsted by he shm. I eadstmen s necessay, assemble all reated pars coecty and seec the rgh shm thckness o make sre ha the dmenson om he hosng end o he shfer comples wth he speced vale

uig Sift � Com pd fc 0224A

Shm hckness (6 ypes: 02 03, 04 05 10, 5 mm NOTE: Measure the assembly dimension with all flyweight lifted.

Use a press o remove he sher and bshng NOTE: When the shifter and bushing are installed, use care not to damage the chrome plated surface of the shifter.

-9

D 5.23


Adjustment after Reassembly

( 1) RSV Type Governor For governor performance curve, see Service In ormaton pblshed separately.

Adjustmen of torque sprig Adjusme o hg speed conol Adjsmen of edng spng or g ch sprng

Adjusme of sopper bo NOTE:

�®(Adjusmn : of nermea

� '--

-

speed coro

-

-

B9163A

,

E E

(

" a

Ng N Na N N N Ne Pump speed (rpm)� D34748

Adst he relatonshp beween pump speed and he rack poson o speced governor performance crve by the olowng procedre.

3-70

Suply egine oi to the jecto m cam hamber Lose the adstg eve soe bot Remo the g sb sg D o w the Ugeh sg o g sb sg  toqe srg to wrk

--

Ugec srg a R1 - R g  b C j d Rg / conro Hgh speed  Re -·· e R

C 0 ·; . 0 a

1. 2 3 4

-

-

--

--

�

(a "O poston seng of conro ack [Heer o tem (1) (b or (2 (b) ecton 5.4] (b) nstal he ange scae plae for fxng he adjsg lever


Ful positon

Sc Wenh 15796-2620

Maxm peed ppr b

89169A

(c) Temporay adjustment of high speed contol With the adustng eve n ul poston adust the maxmum s' peed stoppe bolt so that hgh speed contro stats to wok when the pump speed is "Nd".

8964A

8966A

(e) Adjustment o Ungech sping (goveno wth Ungleich sprng ony) 1) Keep the pump runnng at a speed whch s a itte owe than "Na" (speed at whch ngleich sping starts to wok) 2) Fx the adusting ever at the u position. 3) Usng the specal tool Specal Wrench tighten the Ungech spng so that the ack wil move om "R" to "Ra" x the sping wth ock ut 4) Check that the pump speed is "Na" ad "Nb" when the rack postion is "Ra" and "Rb" espectivey.

E 

Re

K

0

(d), Adustment o intemediate speed contol

0

Wth the pump speed at "N" ( c point) which is a itte lowe than "Nd" adust the ull oad stoppe bot so that the ack is positioned at "R" Pp peed (p) 8070A

() Adustment o dlng sprng (goveror wth dng sprng ony) Adjust the iding sping so that the ack stats to move om "R" to direction to ncease ue rate at point k

3-7

D

FUEL AND NGIN CONTR SRVIC PRODURS

g) Adj Adjust ustmen mentt of of low low speed cotol

·

---

 



80A  

89167A

1 Adus .tmet tmet o stopper bot Adust the stoppe bolt so that the rack is positoed at "Rg" whe the adustig eve s set at idig posto wth the pump statioay

   

 

  

 

i) Adj Adjs se ett of pee peed d egla eglatio tio  hec tht the ack is plled back to postio Re whe the pump speed s creased om Nd to Ne" Goveor sping

Swvl  Adjut bo D342A     - -

8A

2 Ad Adust ustme mett o o d dg g sub sub spr sprg g Adust the dg sb spg so that the ack is positioed at R whe the pmp speed is N" . Check that the rack s postoed at Rh whe the pmp speed s fuhe iceased (h Adustmet o high high speed speed conto Adust as  (c ad fx the maximum speed stoppe bot  posto

13-72

�         

If he pup ails to todo so, adjst tighteing amount o the swive eve adjstg scew Tihteg gs bete speed eguatio Looseg gies pooe speed eglato Speed rgulation

Ne - N d

X 00 (%)



NOTE:

1. If th spe sped d rgul rgulati ation on is poo poor, r, th ngin wi wi   xcd th spifid maimum sp t no load and will ntr a hzardous ondition 2 Th mai maimum mum tnt tnt to whih whih th a justing srw an b loosnd is 20 noths (5 tuns) from th fully tightnd position Loosning it any furthr an  dangrous 3 If th adju adjustin sting g srw srw is adju adjustd std th tnsion of th govrnor spring will hang and th high spd ontrol start point will hang B sur to radjust th high spd ontrol in aordan with (h)


.

"

'" Stop [_/ posion Normal poso 0

0

8917A

D

1) F the the adustin adusting g lever lever at the full full posto poston n and and set the pup speed at "Nk". ) Sr Srew ew in until until the torqu torque e spring spring con contact tactss the the lever and f temporarily 3) Ad Adjjust the torque sprng so that the rack s positoned positon ed at "R/" when the pup speed s lowered to N ". 4) Che Check ck that the pump speed s "Nj whe when n the pump speed is lowered to poston the rack at "R" "R"  5) Afe Aferr the adjus adjustme tment, nt, check that the rack rack posito positon n is as specfied at each pump speed f the rack postion s out of specfcaton readjust the torque spring and ful load stopper bolt.

(j)) St (j Stop op eve everr opera operati tion on chec checkk

() Adustment of adaptation to engine

Wth the adjusting ever fixed at the full positon, pull the stop levr al the way to the stop side and check that the rack s positoned at O mm.

After the governor has been adjusted measure overall necton amount at the same lever angle as n the hgh speed contro and n accordance with the adustent standard and reajust as necessary

(k) Adj Adjust ustmen mentt of fu fu oad oad

(n)) Lo (n Lock ckng ng wt wth h wre wre

84055A 837D

1) Ins Insta tall ll the leve leverr to to the the governo governorr cover cover 2) With the adjusting lever at the ful positon, adjust the fu oad stopper bot so that the rack is postoned at "R" () Ad Adu ust sten entt of torq torque ue sprn sprng g

After adjustments, lock the governor wth wres NOTE:

Locking of the sections marked with * must be done after adjustment of no-load minimum and maximum speeds.

t�f -      f f -

- k

E E

C 0

U0  (



N N Nk Pup ped p)-

89728

-7

D

FUEL AND ENGINE CONTROL SERVCE PRCEDURES

(2) RFD Type Governor Governor For goveror perormace, curve see Serice I fomao publshed separaey.

Adj ustmen high peed corol arofpoi Adjsmen of dmper sprig

I Adjsme of lig k

' --- ·,._

., Adme of idlig prig I

Adjstme of opper bol Load onrol leve agle Adtmet of flyweght if '

       

   

NV Nom Vue NV                 -  -         

NOTE: 1. Rem Remove ove the dam damper per sp spin ing g 2 Rem Remove ove th the e idlin idling g sprin spring g 3 Kee Keep p the the stopper stopper bolt of the the speed speed control lever loosened ' 4 Keep the stopper bolt of the load load con· trol lever loosened. 5. Supply engine oil to the the inject injection ion ump ump cam chamber

E _ C

:�

3-74

R R R R R RR

S    R' H _        P  

03486C

B9174A

   �

Adju e eato bewee pmp speed d he rak poso o speied goveno peoane ve y e oowg poedue (a) "O osio osio sei seig g of o oo oll ak ak [Ree o e  1 b o 2  eo 54]  sall e e agle agle sae plae fo fxg fxg he oo lever

FUEL AND ENGINE CONTROL SERVICE PRCEDURES

1

m

Ra

.g ·;

' t

0

Nu 700 o 800  Pmp sed lrm

406A

(c) Adjust Adjustment ment of of flyweight flyweight ift and ful oad posit position ion Divide the fyweight ful it nto the it necessary fo high speed ·contol and the lft necessay for idng contol

95

3) Low Lower er the the pump pump speed speed to to "Nu "Nu and adjus adjustt the the hgh speed ift  wth the stroke adusting screw d) Ad Adust ustmen mentt of high speed speed conto contoll

1) Wit With h the the load cont contol ol eve eve fix fixed ed at the the fu fu oad oad positon, teporariy set the speed cntol lever so that high speed control works when the pump speed s 700 to 800 pm.

9A

1) Adu Adustm stment ent of hgh speed speed cont control rol start start poi point nt

196A

2) Inc Incea ease se the the pump pump speed speed sowy sowy and adus adustt the the fu load stopper bot so that the rack s positioned at "Rt when the pump speed eaches "Nt

Set the contro lever at the full oad positon and set the speed contro eve at the maimum speed position ncrease the pump speed slowy and adust the speed contro lever stopper bot so that the ack stats to move fom Ra towad fue deceasing directon when the pump speed eaches "Na"

13-75

m c-

FUEL AND ENGINE CONTROL SERVICE PRCEDRES

  



Ra

E E 0

·.

b

0

Na Nb Pump speed (rpm)

04434B

2) Ch Chec eckk of of spe speed ed re regu gula lati tion on Increase t_he he pmp speed sowy nt the contol ack s pulled back to "Rb" poston. Upon eachng "Rb" poston, check that the pmp speed s "Nb" Frthe incease the pmp speed and check that the ack pull bak amont "L" s as specied NOTE:

1. If the spee speed d regulati regulation on check check poit poit (point b) is where the amper spring acts, check the speed reglati aUr idling and damper spring adjusment 2. If the the valu value e is out f specif specifica icatio tion n replace the govern spring

(e) Adjustment Adjustment of idlng sprng (govenor (govenor with with idng idng spng ony)

D4506A

1) Set the pm pmp p spe speed ed at "N "N" " (Nd + 100 pm) and adjst the stopper stopper bot so that the ack s positioned at "Re.

13-76

2) owe the pump speed to "Ne" and adjust the iding spng using the specia too, Wech so that the ack s postoned at "Re" ) Whe When n the pm pmp p is stop stoppe ped d the ack ack shod shod be at "Rf" o highe positon Aso check that the ack is positioned at "R" whe the pump speed is nceased to "Nd"


(f) Adj Adjust ustmen mentt of Ungleic Ungleichh sprng sprng Vehcles wth Unglech sprng only) E 

Ra

+

(



0

0

a

0

Nf NgN N � ump speed rpm) 845A

Pump speed (rpm) 8450A

B452A

Special Wench 15796-2620 84317A

1 Set the pum pumpp speed at at "Nf" "Nf" and and place place the load contol lever n the full load poston. 2 Us Usng ng the spec speca a too, Specal Specal Wenc Wench h adjust adjust the Unglech spng capsule poston so that the Unglech stoke n the state o Step  wll have the speced va�ue Ate the adjustment rmly tghten t wth the lock nut

3 Slow Slowly ly ncr ncreas easee the pum pumpp spee speedd rom "N "N to Ng and adjust the screw poston so that the Unglech sprng wl stat wokng. 4 In Inc ceas easee the pump pump spe speed ed to che check ck that that the the Ungle Ung lech ch sprng stops workng at Nh" 5 Change the pump speed between "N" nd "Na" to check that the Unglech stroke has the speced values. NOTE: 1. If the the Ungleic Ungleich h stroke stroke is out out of spec speci• i• fication, readjust the Ungleich spring capsule position 2 If the the speed speed at which which the Ungle Ungleich ich spring stops working s out of specification, replace the Ungleich spring cap sule

13-77

D

FUEL AND ENGINE CONTRO SERVICE PRCEDURES

(g) Measu Measuremen remen of load load corol corol eve agle Check tha whe the load cotol lever is held at he idlig poso· ad the ul load l oad posiio, he lever agle at the especive especive posiios is up o specicao. I the eve agle s ot of specificaio replace the sh staled betwee the shter ad sleeve NOTE: If the shim was replaced, repeat adjustment of the governor from the beginning.

(h) Adju Adjust stet et o dap daper er spig spig 3495A

E

2 Ad Adus us the the daper daper spig spig gh ghei eig g aout aout so so that the the ack is postoed postoed at "Rg  0   

Damper sping t pont

Rg _ R-0.1 g R02 ·; ·; Ri

+

1

- .

I \

u

" a

' \

0

Ne

Nh

Pup peed (rp) -

B406A

1) Hod Hodg g the the oad oad co cool ol lee leerr at the de posit posito o (po e ad slowly icease the pup speed ro "Ne uil uil he he ack is positioed a "Rg - 02   Hold the pup speed "Nh whe the ack s so postoed

13-78

·

3) Ate Ate adjus adjuste tet t stop the the pup pup ad ad oose oose a adust he soppe bolt so that the ack s psioed a "R.


(i) Adjust Adjustmen mentt of rac rackk l ltt 1) Cap type

�t ( Guide Screw/ 15796-300 \ 

D

Afte adustmet nstal the cap nut secuey. 2) Scew type

B3767A

a) Rem Remov ove· e· th thee gude scew scew fom fom the bac of the the pump housng and nsta the specal tool, Gude Scew.

B4583A

a) Pla Place ce the the load load contr control ol leve leve n n the fl fl o oad ad poston and eep the ump speed at "Nv b) Adju Adjust st the scre screw w of the the ac ac lmte lmte so that that the od poston and fuel njecton (pont E) wll e up to specfcaton, and secue t wth the loc nt. () Adu Adustme stment nt of stat stat ooste ooste (smo (smoee set assem assembly bly))

B38A

b) Usng a depth gauge measure the rac cap depth 0349A

B369A

c) Adj Adjust ust the the adust adustng ng nut nut mounte mountedd to the tp tp of the ac fo the same depth as the ac cap depth measued above. Fx the nut n poston wth the oc nut

13-79

D


) With the oad contro leve set at the fu oad poston, set the smoke set assemby adjustng nut at O to 4 mm om the stoppe tp. 2) Adust to make sue that when the pump speed s changed to "Nd" the rack positon w change fom "Ra" to "Ra'

I Lockng wth we

To be locked with wre

·,"'

To be ap loed

B4320C

After adjustments ock the governo

03497A

3) Set and x the nut so that the rack s positoned at "Ru" when the pump speed s "Nu" (k) Adustment o adaptaton to engne Ater the governor has been adusted measue overa nection amount at the same eve angle as in the high speed contol and in ccordance with the adjustment standard and eadust as necessary

13-80

TE: Lock parts marked with * after adjustment of no load maximum speed. 52.4

Inspection and Adjustment of Noand Maximum load Minimum Speeds

[Refe to 58

FUEL AND ENGINE CONTROL SERVICE PRCEDRES

5.3 531

FEED PUMP Disassembly, Inspection and Reassembly

Eye bot (sucton sde: wth gauze flter) 2 ye bol (devery sde) 3 Pmng pump 4 Check valve plug 5 Check vave sprng 6 Cec valve

Pug 8 Pston spng 9 Pston 10 Snap ring 11 Tappet 2 Feed pump housing 7

For reassembly, evere the order of isassemby. NOTE:

Before disassembly, know the troube spots throughy y makng tests. 89175A

3-8

D 5.32


Test and Adjustment

The feed pump t ests are as ollows.

Delivery Condion Fue passed hrough 1.54-da nozze for 5 seconds when · pump s opeated a  000 rpm NV Refer o 3 Servce Sandard Tabe

Lfn cacy Condon No o sokes requred befoe fng when operaed a 60 to 00 strokes pe mnte NV 25 sokes o ess

Ar ghness es Air presse 95 ka (2 kg/cm'

No eas from psh rod sidng aea

-t

Feed pmp

Tes codtons Fue pipe  8 Lengh 2 000 Cam if 6 (eccenc cam) [KE ype] 4 (dobe cam) [K ype Hegh om o eve  000 Tes bench FP Tes o SAE Sandard Tes O SAE J967c) NV  Noa Vaue 

13-82


5.4

AUTOMATIC TIMER

541

SA Type Automatic Timer

() Disassembly and nspection For disassembly and reassembly of the automatc tmer, se SA Type Aomatc me Specal ool (105790-500). Wear of pin secton Daage o cuved srfae

10

C Ron n

2 me plg 0 imer case 4 O seal 5 Flange 6 O seal 7 Sprng 8 Sm 9 Fywegh 0 Hoe

pin seion 1

4

Wear, damage

3

For disassebly o pas wih a eiled nme see olowing iems.

03152A

(a) Remove e coping om the aomac ime

383

D

FUEL AND ENGINE CONTROL SEVICE PRCEDURES

Special Sanner /15796-5320

y/

8979A

89176A

(b) Mount Special Spanne (special tool) in the coupling mountng theaded hole to pevent tunng, and emove th'e ound nut.

@

(e) Remove the tme pug and place the automatic time on Base (special too). NOTE: Line up the hole in the timer pug wth the pin of the base.

Had Spa 5920

' -

Extao 9220

-

6�

_ , �'

8977A

(c) While hoding the automatic timer with Specal Spanne (specal tool) to pevent it fom tuning emove the automatc time with Extacto (specal tool).

Gud Bolt 9240200 as 92400

897A

(d) Mount Base and Guide Bolt (specia toos) in th vce 13-84

890A

(f) Using Hand Spanne (special tool) emove the tme case y tuning cockise


(2) Reassembly

9

3

2

After rassmbly, pack AUTOMAIC TMER GRAS (Dis Kik pduct) o qivan 150 g.

10

ring

8

5

10

-·

9

03153A

Thrst Bshing 57924500 Bs 579400

Gid Bot 57924-0200

Gid Buhig 794200 il sa Flng Block 57940800

B982A

7A

(a) Mount Base and Guide Bolt (specal toos) in a vice.

(b) Install the oil seal in the flange 1) Mount Bock (specal tool) to the base 2) Put the lange so that ts pins will ft n the holes n the block 3) Apply NEJ LOCK to the ol seal installing hole in the ange 4) Put the ol sea in the hole n the lange nstall the oil sea by turning down Thrust Bushing (special tool) with Guide Bushing (speca tool) in between

13-85


e) Afte plang Support speal ool) on he flyweght, sal the shi and spng. hed ude speal tool) onto he gude bol

Trust Busig 5794-500 Bushing Guie 157924-300 mer cse. Gde 57940900 Blok 57940800

.

NOTE: Select the proper shim thickness suitable for the advance angle of the automatic timer.

�  _  Oi ea B9183A

Spea Spe 5796530

T Big 57940500

) Install he ol seal n he imer case. 1) Moun� Blok and Guide (speial oos) o he base 2) Pu he ime ase on he gude 3) Apply NEJI LOCK o he oil seal insalling hoe n the ime ase 4) Put he ol seal n he hole in he me ase Insall the oil seal by tuning down Thust Bushing speal ·ool) wh ude Bushing speial tool) n beween

B9186A

f) Put the lange so hat the pn o he flange wll ouh one end of the sping. Moun Speal Spanne Speal tool) to the oupling mounng hole of the lange Furhemoe mount hust Bushng speal ool) wh a bolt.

O Se Gie 57940600 B984A

(d) Plae he holder on Base speial oo).

B9187A

g) Aer plang Ol Seal uide speial ool) on he lange inser he imer ase

B9185A

13-86


m

(i) Injet appox. 150 g of automatc time gease from the timer pug hoe Ater grease has been injected, tighten the tme pug.

Special Spanr 157916-5320

8910A

(h) After the oil sea guide has been emoved, tun down the time case onto the hode with Hand Spanne specia too) and punch it NOTE: Turn down the timer case until the injection stat timing lines inscribed on the timer case and flange are in alignment.

99A

() Ate the automatic time has been nstaed on the camshaft fit Specia Spanne speca too) into the couping mounting hoe Whe hoding t to peent trnng tighten the round nut to the specfed toque

B99A

13-87

D 5.42


SP Type Automatic Timer

( 1) Disassembly and Inspection

For disassembly and reassemby of the automatic timer, use the special too SP Type Automatic ier Speca Too (105790-5050).

Wear

1

3 Defomation Damage o

Deioraon,

curved sfa w

11

0 3

4

®  (

9

8

1

9

14

10 1 12 13 4

Cp screw Roud t ove Ol seal Wshe Roe Bsng Flge Retne Tme spng Spng seat Shm Fweght me housg

Fo dsasembly o pat wth  ecl num. e oow em D31A

(a) Remove the couplng from the tmer.

Extraco 157926-220

�

", Bx Spane '"595-2320 Bx Weh 5962800

05 34A

b) eove the cap screw of the ter Whe using Box Spanner special too) reove the round nut with Box Wrench (speca too)

13-88

(c) Mount Specia Spanner specal tool) by takng advantge of the coupng ounting thread. Whe hoding it to prevent turnng reove the er fro the njecton pup usng Extractor (specia too)


Base 157924-0

L 8 � 

D3106A

(d) Mount Base (special ool) in a vice.

(f) Moun Specia Spanne (specia oo) to the fange Wh he imer sprng compressed, remove he washer ole and bushing.

(e) Fix the imer to Base (specia oo)

13-89

D


(2) Reassembly ,- 

  







 

  

9

�

Ae eassembly, ill 20 to 20 cc engie oil

22 o 24 Nm (22 o 24 kgfm)

Apply engine oil to rip.

4 1

29 o 39 Nm 3 o 4 gm)

Gase

14 13 1 2 11 _10 8 7 6 543-� 21

rin

8

14

D31128

Base 57924-20

_;

B�G

(a) Mount Base (special too) n a vice and secure the ime housing to the base.

13-90

(b Mount Spea panne (spea tool to he flange Wth the tie spring ompessed, instal the bushing rolle and washe


m

Cover sid

Role se

0313A

NOTE:

When the washer is nstalled, drect it as shown.

d) Remove the plug at the ea end o the time and supp 250 to 270 cc of engne oil

4A

(c) Install the key to the injection pump cashaft and nsta the atoatic tier. While using Specal Spnne specal too) to pevent tuning, tighten the round nut to the speced toque

13-91

13-92

D


5.5

PUMP DRIVE CASE

551

For emoval and instaatio of he pump de case, ee to 5.11 in Gop 61 Specia Eqipment

Removal and Instaation

Pun1p dive case

J "' 552

Disassemby and Inspection

5 Wor

Crk

4

10

4

Senso pae Injecton pm gea Coa Beang hode

5

Oi sea

2 3

6 ha 7 Beang 8 Beang 9 Coe 10 Cankcase

L

2 C or wor 84196A

13-93

D 5.53


Reassembly

215 Nm (22 kgfm)

5

0 • 8 � 6  3 

4�7-5J

10 2

For assembly of prts markd o, refer to he olowing seion.

Installation of Injection Pump Gear

Alg mks "O nd "U" we sled

D928

Insta the injecton pump gear, senso plate and nt as shown. 13-94

B4197A

FUEL AND ENGINE CONTROL SEVICE POCEDUES

5.6

INJECTION NOZZLE

561

562

Dsassembly

Removal and Installation

(1-spring nozzle)

[- 1

Wear 4

�  Setling f �5

9 � S � 7 Wer

Carbonted 8 depos

©w- 6 @

Disassemby sequence

NOTE: , h w zz ch h  y   y .

 2 3 4

Cap nut Adjustng screw Sprng Push rod

I

5 78 

Connector 6 Retainng nut Neede vave Nozzle Nozzle ode

0727A

C5778

2spg nozzle

Gke,-

3 2 Ck d"' : I

Wear 6 Si(formpreif)  _   Si(formvve openinJg pure  Crk 8- deterioraton

9

- /j

Dsassemby sequence 2 3 4 5 6 7 8 9 0  2 3 4

Cap nut Adjusting scew Lock nut No. 2 spring Set scew No 2 pus od Space No.  sprng No  pus rod Retaining nut Nozze Neede vave Nozze oder Connector 0715A

395

•


5.6.3 Cleaning and Inspection

(1) Cleaning

Nozzle Cleaning To 105789-0010

4A

0712A

After washng the nozze n gas oil, emove deposted cabon usng the Nozze Ceaning Too (speca too) by the oowing pocedues.

(b) Insert whe turning a ceaning neede nto the njecton ofce o the nozze to remove carbon Use the neede of proper sze for njecton orfce

NOTE:

Never change the combination of the noz• zle and needle valve.

9A

(c) Cean the nozzle seat usng the ceanng needle (d) o emove bunt and hardened cabon use FSO Cabon emover o equvaent (2) Inspecton D/3A

(a) Remove the neede vave from the nozze and cean the neede vave wth the neede vave ceanng wood pece

D58

Cean and mmerse the nozze n gas o sde the neede vave and check that t moves smoothy 13-96

FUEL AND ENGINE CONTROL SEVCE POCEDUES

Next, pll p te needle valve vetcally about 1/3 of ts ente stoke and check tat it falls nde ts own weght If t does ot all eplace te ozle.

5.64

Reassembly and spring nozzle)

Adjustment

( 1) Injecton Pressure

Iatj (vr � 60 to pressr 00 soes Test 26 prssr MP (20 

( 1-

39 to 49 Nm /1 (4 to 5 kgfm) 69( oto 878kgm) Nm

- 2

5 - 9 3

7A

  _ . Locating pn Nm  - :;  59(6 too 88kgfm)

(a) Remove the cap nt and nstall to te nole teste () Loosen te adjstng screw and opeate te nole teste two o tee tmes o leedng (c) Opeate te noe teste at seced speed adstng the adjstng scew o speced necton pesse

Assembly sequence 9+5+2 68J

NOTE:

NOTE: 1. Never touch the slding surface of the needle valve by hand 2 Install the cap nut after njecton pressure adjustment

Never let yourself exosed drecty t the atomzed fuel njected from the nozzle

0728A

8A

(d) Ate adstment tgten te cap nt to seced toqe F te adjstng scew wt a scewdve nseted tog te cap nt ole to pevent tnng o te adjstng scew (e) Ate tgtenng te cap nt ceck agan te njecton pesse

13-97

D


(2) Spray Condition

2 Goo

Good

5.65

4

5

i

�

Poo

i

I

3

Poo

Poor

I



)

(' I'

Good

\

6 Poo

i

l

Poo

Reassembly and spring nozzle)

Adjustment (2·

Adjust whe assembn the pats by the foowng pocedues. As the peift is adjusted n 1/100 mm ncements use cean detergent to thooughly emove dust and dt before adustment. For adjustment the foowng speca toos ae e qured. Special too

Diese Kki a No.

Nozzle tester (500 kgm 2)

105785-00

Adjusing devc

05890500

Evenly spyed om fou (five with 6D-TC) injecto ofices 

Een and symmeical

3

Asymmeic

4

Banced

5

T

6

Iegl

2

D7009A

When adjusting the pressue wth a nozze teste, check also for cogged injecton oifces, spay condi tion and fue leas fom the ofces. Repace the

'

noe f defectve.

(3) Fuel Tightness Test



es pee 19.6 MPa 00 k/cm'

7

6

8

B3942A

D7010A

Instal a noe that has been adusted to specfed njection stat pessure to the nozze teste. Slowy increase the pessue to the test pessue and keepng ths conditon check fo fuel eaks fom the bottom of the noe. The nozze is functionng normay if there is no eak. 13-98

==



Adjstng deie assembly

1578920220

2

Dal gage

579543800

3

Pn,

f



i

(

5

Coneto assemb

1578921320

6

Base

57892-800

7

Gaset fo etaing nt)

57892500

8

Retaing ut fo adjsmet

5789220

9

Gaset fo olt of etaing nt

02650840

50 mm

57892-200

605 mm

5789200


!  2309olo249NNmm (42oo 5.kgkfm )  4 9    9 N m     6 k g  m   , �'< iJ1 7 I, •\I,·1-T_ -   o 8 kgfm;\t�J J  Locg p I� \   '�·  As4 e9m2 bBy s eq  en6e-4 W' i  hdh  d   h  d DC ·1

 II i ,iIH\: [ ' ·!._1 ._:1 :

1,

I

2

4.

il 11 i!·t rI . _ s ·, f 3 1 ,\ _I

· Shim (for valve opening pessue)

L -� 69 to 78Nmj,i[� 1 : 1

I

I \ , " ' l P

J

12

II i

59 to 78 Nm



(6 to 8 kgfm)

(1) Adjustment of Nozzle Valve Openig Pressure

fm)

3

I

R-1

D

11-12

NOTE:

Adjusting steps

D Adjustment of nozzle opening pressure  Selection o pret adjustng shims (�) Adustment of 2-sprng adustng pressure < Ceck o neede valve u it _   Instaaton of prelft shims  Checking o prei *D Ceckng of sprng adusting pressure ® nspection Inspection make operatons marked wt  as neces sary o inspection or conimation.

Noze oe Ne e   e v a  v e R e     i  g N u   o r  j  s  m e n       8 9 2   4 2 0  8 N  6  8 kgm " Gas8k9e20



a Using te Retaining Nut or Adjustment specia tool nsta the noe and needle vave to te nozze oder NOTE: . Make sure tha the kock pi has seated competey i the ozze before tighteing the retaiig nut for adjust met Tighte the retaiig ut figer tight and then tighten to specified tor· que usig a torque wrech 2 Remove the olt from the tip of the retaining nut

139


OE 1. When using a shim, be sure to check its thickness by a micrometer 2. Use same shim for prelift adjustment 3. Use of a 002 mm thick shim changes the valve opening pressure by about 235 kPa (24 kgf/cm )

Set screw 49 o 59 Nm (5 o 6 kgfm)

2

Spacer

(2) Selection of Prelift Adusting Shim

(a) 0 point adusmen of adusting device

Shim (or valve .openg pessure 1s sprng s push rod

Dial Gage 5954-3800

Adusig Devie 58920220

/

  = 05 589-00 d push rod

D7018A

Base 5892800

(b) Insert 1st push rod 1st sprng, vave openng pressure adjusng shm (f!s use abou 1 mm thck one) and space to he nozzle holder Then tighten the setscrew o specified toque.

Opere ever  0 o 00 srokes/mue 7030A

Ijecon pressre NV 17 MP 80 kg/m')

Keep bol emove D709

(c) Insta the nozze hoder to the Noze ester (speca too) and adjust the shim thckness for nomna necon pessure Shim types: 0.50 o 54 mm (by 0.02 mm)

13-100

nsall he Dal Gauge (special tool) o the Adustn evce (specal tool) nsta the 2n push rod o te Base (speca too) an nstall he assemby o a vice. Set the pin and adusng evice as ndcaed in he above illustraon an adust  point of the da auge Use a 605 mm ong pin (b) Insall the 2nd push rod o the nozze holde OE Do not install the 2nd spring and prelift adusting shim


 Remo he ajig evic fm e nozle hler

(3) Adjustmnt of 2-spring Adjusting Prss· ur Dial Gauge hoder (od ts hode o soke up and down) Inemedae scew of Adjsg Deve

Se scew

20 o 25 Nm 2 o 2.5 kgfm Adusng scew

� \

-1 2nd sprng -

Se srew

Nozze hode

2nd pus od

032A

Inall  2nd sg du cew d lok u o he ozle oler D7031A

NOTE Do not nstall th prlift adjusng shim.

) Install he adjuig device o he t screw ing t ermeie cew. Af naatio, hding he l ge  t oler mv  up ad down t ceck t he  oees smoly Pu own te ge holding  oe d ead t if .

Opeae ever at 60 o 100 sokes/ne neo pessue NV 248 o 25 MPa 253 o 59 g') Noe Tese 105785-1010

NOTE: Read to 1/100 mm. ( Sele of pelft aji m  =  +  We :

T

019

Sm ickes meed



Pelift (010  002 m

h

Dmeio elee n 

 ± 0.015 mm T

Keep bo emoed

ckness  hm o be used

Ad  -in aug es ope pe e o he ma val usig e dusng screw nd ozle eer. A djtme gten te oc u  pi oque

ype o shms .75 o 0 m (y 00 mm

3-10

m


(4) Checking Full Lift of Needle Valve

1

(

'.

,

\ "0 \' '

;

'; · �

39 to 49 Nm (4 o 5 kgfm)-v 0

Gesk< [

265814 

1 -

(b) nsta the pre shim seleced in (2) between the spacer and 2nd push rod (c) nsal he 2nd push rod and 2nd spring and ighten the sescrew, lock nut and adjusing screw as an assemby to specified orque (d) Check again tha the needle valve ful if dimen sion S with he dial gauge by he procedures_ described in (4).

Dial Gauge 179438 Connector 5789232 Pi / = 5 mm 578922 Retaining Nut for Adustmet 5789242 Bot

(6) Checking Prelift D7033A

(a) Install the specia oos indicated in above iusra ion an se O poin of he Dial Gauge. (b) nsal he nozze to he nozzle ester and operate he eser ever o bleed he inside of he reaining nu Also check for fuel eaks (c) · perae he tester lever to increase he pressure o about 345 to 44 MPa (350 to 450 kgf/cm') so hat he needle vave of the nozzle is fuly ifted. Read this lift dimension "L off the dial gauge (d) Remove the Dial Gauge, Connecto and Pin (special ool) (5) Instllation of Prelif Shim

Adjusting scew Lo ut Se sre 49 to 59 Nm 5 o 6 gfm)

704A

(a) Remove he setscrew, lock nut and adusting screw as an assembly from the nozzle holder.

3-02

NOTE: Neer loosen the lock nut as loosening it changes the 2-spring adjusting pressure.

Check he preif based o dimension L measured in (4) and dimension "S measured in (5)   S = 6 where   002 < 6  <  + 002 mm   Prelif (measued) : Preift (0 mm) L Neede valve ful lif dimension (mea sured) S Neede vave li dimension (measured) wih preift subracted f 6  is outside of specified dimension  ± 0.02 mm repace the preli adusting shim as de scribed in (5) and repea steps (4) and (5) so tha   wil fa within  ± 002 mm. Select hickness t of shim o be used as follows. t t + ({  !{) T t  005 mm where t Thickness of existing shim t Shim thickness  hickness of shim o actualy replace exising shim  Prelif (0. mm)


(7) Checking Adjusting Allowance of 2spring

2-spring adjutg pee (lt 0.05 m) NV 23 to 23 MPa 2 to 240 kgf/cm')

() Spray condton

5

,;

Poo

Po

3

I

Good

Good

Poo

Poo



.,  l )

!

Nozle Tee 1078100

(a) Ater checking the prelit in Item (6), ncrease the pressure again to about 345 to 44 MPa (350 to 450 kgf/cm') so that the needle valve o the nozle is ully lted.

NOTE: The Retaining Nut for Adjustment (special tool) must have a bolt fitted at its tip.

I

'

)

�

D7035A

I

-�

;J '!

Poor

Good Evenly spayed from for (ve wth 622TC) necton orces 2 ven and symmetcal

3 4 5 6

Asymmetrcal Branched Thin Irregular 79A

(b) When the nole tester lever operation is stopped with the nozle needle valve fully lted the pressre wll start to drop and the needle valve will go down (c) At the moment the nole t has dropped to 005 mm, read the pressre gauge indication (d)  the 2-spng adjstng pressue !cover pessure) is ot o specicaton adjst the 2sprng adjstng pressure as descbed n (3).

NOTE Adjust without installing prelift shim (e) Remove specal tools.

When adstng he pressure wh a nole tese check aso for clogged njecton oces spray cond ton and fue eaks om the orfces Replace he noe  deectve (c) Fel tghtness test

Te ee   6 g

(8) Inspection (a) Tghten the etaning nt and cap nut to specifed toqe

NOTE 1 Make sure that the knock pin has sea ted completely before tightening the retaining nut 2 Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench

71A

nstal a noe that has been adjsted to speced necton star pesse o the noe teste. owly ncrease the pressure to the est pesse and keepng ths condton check fo fel eaks fom he bottom of the nole The nole s fnctonng normaly f thee s no eak 13103

m 5.7


FUEL FILTER

Fuel fie head Cracks, damaged hread

Opton raks, theadeddamaged oron Fue e head 25 Nm

instaaton, apy  6 �  0 '  aBefore thi coa of engine 1 to gaket.

.- _if"  ) \

" Fue ite eeen

Fe fer eeme '·"-./

I    _ 

D309

D7301E

NOTE: 1 When removing the element, check for the gasket left behind on the hea side. 2 To mount, apply a thin coat of engine oil to the gasket, and then secue the element by tightening 3 /4 to 1 turn aHe the gasket comes in contact with the fuel filter head 3 After installation, bleed the fue system 4 After bleeding the air, start he engine and check for fuel leaks

Fte Wench MH72

B181C

To remove the elemen, use Filer Wenc (speca oo).

34

FUEL AND ENGINE CONTROL SEVICE POCEDUES

5.8

WATER SEPARATOR

1 2

3 4 5 6 7 8

Drain plug Rng nut Case Baffle plate Isoation pate Screen assemby Water evel ring Cover

4-

7-

:� 0745C

f the red wate leve rng in the tanslcent case ises to the eve of the ed lne maked on the oter ccmference of the case, mmedatey oosen the dain pg to dschage wate. t s not necessay to competey emove the dran pug, as water is dschaged gadaly thogh the groove of the oosened pg NOTE: Drain plug

After draining, tighten fimly the drain plug before bleeding the fuel system. 744A

13-105

FUEL AND ENGINE CONTRO - TROUBESHOOTING

6. TROUBLESHOOTING Pobable cause

Symptom Engine s had to stat

Remedy

Re. goup

Deectve eed pmp • Cogged gaue fe

Cean

• Check vave nopeatve

Repace

• Bndng or won pisto

Repace

•

Bdng psh od

• Wo tappe

Repace Repace

eectve jecto pump • Bndng or won ·pnge

Repace

• Bndng coo ac o coto od

Repace

•

Bdg devey vave

Repace

• Wo tappet

Repace

• Wo camshat

Repace

eectve necto oze •

Bdg eede vave

• Vave openg pesse too ow

Adjst

• Cogged jeton ce

Cea

• Noze ot a-tght Fe ak empty Cogged ue ppe o e ea om coectons A o wate tapped  ue system

Ege stops mmedatey ate statg

Ege ocs

Repace

Coect o epace Suppy ue Coect o epace Beed o epace

Cogged e te o seconday te

Repace

Cogged ue te o secoday te

Repace

A o wate tapped  ue system

Beed o epace

eectve eed pmp

Chec

Ijecto tmg too eay

Adust

eectve jeco oe • Vave opeg pessue too hgh

Adjst

• Cogged necto oce

Cea

• Noe ot aght oo qaty e  use Smoy exast gas ad egne ockng

13-106

Coect o epace Repace

eectve jecto pump •

Incoect jecon tmng

Adjst

• Wo pge

Repace

• eectve vave seat o devey vave

Repace

Goup 1

oup 

D

FUEL AND ENGINE CONTROL - TROUBLESHOOTING

Sypom Soky exhaust gas and egi

kockig

Probable cuse

Dev njcto nozle

. •

Ustabe

Ve og

too ow

p

Adus Repace

Boken ng

Cogged jection

Cea

ofc

tv nton mp

. •

Isffie pger sdig stroke

Rpace

Broke pluge spg

Repace

• Coto ck o ono

rod ot sdg soothl

• Wor o stcky tappet

. •

Broke devery

valve

sprg

Repace

Loss of ar-ightess du o oose deiery ae ho

Deecie ieco oze • Nede a o slidg soohy

Rpac

Repace p

Deece feed pup • Ceck a ot

oo ow

Adus

fuctoig ormaly

Repac Repac

• Won pso

Ai or watr tappd  fue syse

eed o pace

Cogged e fe· or secodary flter

Repace

Icoec jco m

Adus

Coo lee o i cotact wt fu spd se o

Adus

Defcie iecio o Noz o a-ight

Corct o pac

Boke spig

Rpac

•

•

• Coggd co

•

(roke) Daaged deliy ae spig

Rpac Rplace

oss o atghess due o oose dliery a hode

Coect

Dfece goeo • Too ary oato coto du to wak goeo spig

Adust

•

Ads

Fauty fu oad sopper postio

• Adusig e o load cotro  poory adused Pooy adusted

neco

tg

coec tg

advance

of autoatc

oo quay ue  use

11

Repac

• Dcie deliy ae seat •

Gop

Cea

ofice

Defect ecto pup • Wo pge

Loss of eg ouput

Corct

Repac

• Bok spg • ae opg

Co

Repace

• Dey ae ot fuciog oray

oss of egie oupu

Ref. group

Replac

 qty fl in 

•

enn otpt

Reedy

Adus Adust



Adust Rplac

13-107

•

FUEL AND ENGINE CONTROL - TROUBLESHOOTING

Poable cause

Sympto Engin cannot devop maximum sped

Defecive oveor Goveor spring too weak control

eve! poory adused

Cean

Noe ot ai-tight

Coect o epac

•

• Vave opening pessue too ow Engine maxmum

sped to high

Coct

Defectve goveno Goveno sping too weak

Adust

•

Fyweight ot uncoing efectivey

Dfective ncton pump Bidng, sticky o won pung •

Coect

•

unge sping not seatng cocty

Repace

•

Deivey vave hode too tght

Coect

•

Uneven fu iection ate aog cyindes

Adust

•

Bok punge spg

Rpace

•

Adust

Bent ikage

Coct

•

ag fiction o pay n kage

Repace

•

oose oud ut

Corect

•

oory adjusted dig set ot

Adust

Defctive feed pup Defective check vave •

Repace

• Wo pston

Repace

Cogged gauz fte

Cogged fu fte o sconday fitr

Ca Rpace

ooy adstd iecto tig

Adst

Defctive autoatc tme

Coct

Defective nectio o Cogged iecton oifice •

 Wak spg •

13-08

Bed o pac

•

•

oo suppy of ue

Repace

Loose conto po

Defctive goveo ding sping too weak

gne wi not stop

Coct

•

 Ai o wat tappd in fue syste

dg is ot smooth

Adust

Icton pup conto ack o coto od not sdng soothy

•

dig s not sooth

Adust

Defctiv inectio nozze Cogged ineo orifice •

Ref. goup

Adjust

•

• Adustig eve (o oa

Redy

ozze not aitght

Cea Rpac Coct o epace

Bokn o eogated gne stop cae

Rpac

ngie stop cae pooy adustd

Adust

Damagd govo stop mechasm

Rpace

Cacked fu hose o pipe

Rpace

Fue tank ot ai-tight

Repace

Goup 1

I

COOLING CONTENTS

1 GENERAL ••••••. 2 SPECIFICATIONS  3 SERVICE STANDARDS  31 SERVICE STANDARD TABLE  32 TIGHTENING TORQUE TABLE  4 SPECIAL TOOL  5. SERVICE PROCEDURES  51

2 3 4 4 4 4 5


 52 WATER PUMP  521 Removal and Instalation  522 Disassembly and nspec· tion •• 523 Reassembly • 53 THERMOSTAT  531 Removal and Installation  532 Inspection • OF COOLING FAN

54 FAN DRIVE  541 Disassembly and nspec tion 542 Reassembly • 55 TENSION PULLEY  551 Disassembly and nspec tion

.

9

9 9 9 9

5

552 Reassembly ••••••• 1 56 RADIATOR  1 0 561 Inspection  1 0

5

5 7

5

INSPECTION AND ADJUSTMENT OF V-BELT TENSON

5 7 8 8 8

58



11

CLEANING OF OOLING

 1 5 GAS LEAK TEST  14 510 BLEEDING THE COOLIN SYSTEM  4 6 TROUBLESHOOTIN  15 SYSTEM

14-

I

COOLING - GENERAL

(2) Thermostat

1. GENERAL

The engine is cooled by foced circuaion of coolan by the wae pump. The lustaon beow shows he cooan ow

Raditor cap

,

When coa emear s gh (boom yass va s clo I

-



 r -   l Ol cooler

o � �

·, Wa um

L

/{i

/ :•,

I

I

.

Drain cock ) :

\

/�

i'

Dra cock "_

B9017A

To wae m

( 1) Water Pump

Whe coola emeae s lo oom yass alve s oe)

B74A

t From adito B746C

he wate pump s a centugal pump Mounted on the et sde o the cankcase, he pump s dven by the cankshat pule va a V-belt An mpelle havng a bade s mouned at one end o the wate pump sha and coolant is sealed of b a un sea Fo ubcaion o he wate pump, ee to "Goup 12 Lubcaton

The hemostat is a botom bypass tpe wth a speca wax enclosed n a pellet When the wa s heated, t changes fom sold to qud and its volume aso changes This change n volume changes the openng o the vave and changes the uantt o coolant owng ino the adao and wate pup (bpass sde) heeb contoing the coolant tempeatue (3) Radiator

Press ca

[email protected] Parts phone: 269 673 1638 B9018

The adato coong capacity vaes dependng on appicaions nsaaton n an encosed geneato oom o a bdng opeaton n statona state, etc) 42

COOLING - GENERAL, SPECIFICATIONS Considerations are, heefore pad o he fan diameer radiato capaciy and oher facos. Some units for consucion plans are equpped wh an oi cooer o coo hydrauic oi

(4) Pressure Cap

Pessue eease eve ,. -1 Pessue sping · , : i

-

�6

f-1·

fl-

;�j

T Jj"--, o ovefow ppe : � � Pesse' Vent  vave  " opeaion Ven vave vave . spng  condion �l , -

:·

T

81716

Withou pesse eease eve ne negaive Une posive pesse pessue Fom eseve ank

m

The pressure cap reguaes he pessue in he cooing sysem When he pressure buids up n he sysem that exceeds a predeermined eve he pressure vave copresses he pessue sping e easing he excessive pressue hough he ovefow pipe no he amosphee If equipped wh a eseve ank he cooan ha has overfowed s channeed no  When he cooan empeaue drops and negaive pessue buids up in he sysem he ven vave opens to ake n ar o preven he adao fom becoming defomed If equipped with a reserve ank cooan is aken fo he reseve ank o pevent he adao fom ecom ing defomed and o keep he quany of cooan n he sysem consan  f equipped wih a pessue reease eve on he cap asing he eve upight opens he pressue vave and eeases he pressue in he coong sysem

80295A

2. SPECIFICATIONS Item

Watecooed, frced ccuatn

Clng methd

6022. 6022: 22 t 6022C 24 t

Coong water uantty !Egne pper Water pump V-be

Specifcaton

Type

Centruga type

Dve

V-bet dve

ype x quantty

Wth fa Lw edge cgged 8 type x 1 f water pump) Low dge cogged C type x 2  fan drve Wthut a Low edge cgged C type x 1 fr wate pump)

estat

ype Vave penng temperatue x 'ty

Wax peet bottm bypass 6.5"C x 2

Fan

ype

Puser type or sucn type

Radatr

ype

ue ad crrugated f type r tue ad pate n type

14-3

•

COOLING - SERVICE STANDARDS, SPECIAL TOOL


SERVICE STANDARD TABLE Unit:mm Desciption Vave openig start tempeate

Thermostat

-

Repace



Ressembg p to two times

2 00 to 008

teee_ce between pmp st and mpeer

11.8 003 o 006 39 to 9 kPa (04 o 0 g/cm')

Coectio and remks

-

Repace pesse cp

98  (10 kg/cm



oect o epce

w/a dive

10 to 1



Adjst

w/o an dive

1 to 22



Rdiato chec pesse

32

74.5 to 8"C

Inteeece beween pmp sh d fnge

Radto pesse vve opeig pesse

Tesio o V-be (defectio of Vbet when pessed down at midde nde approx 98 N (10 g pesse

Lmit

10 o moe/90C

Vave ft/tempete We pump

omnal vue !Basic diamee

TIGHTENNG TORQUE TABLE Thead size  X pch m

Tightenig toqe m (kgm

F dive age t

M20  15

 (1

Tesio pey st 

M 

98 (10

Desciptio

1.5

Rems

· 4. SPECIAL TOOL Uitm Tool nme Wate mp mpee e

a No

Remova of· pmp impee

H011

8

[email protected]

14-4

se

Sape

21A


m

COOLING - SERVICE PROCEDURES


52

5.1

52.1

REMOVAL AND INSTALLATION OF COOLING FAN

WATER PUMP Removal and Installation

B901B

522

Disassembly and Inspection

ighteing margi B 18 NV 003 to 006

1

Reassembly up to

Tighteng margi BO 25 NV 0.05 to 008 Reassemby up to two times allowed

1 Wate pump plley @ Fange 3 Ol seal 4 Snap ng 5 Snap ring 6 Waer pmp cover 0 Impeler

® 9 10  12 3 4

Wate pump shaf Bearng Space Bearng Oi sea Uni sea Water pump case

For part wit a ecircled mber, refer to Disassembly a Ispectio Procedres tat folow.

004C

14-5

I

COOLING - SERVICE

PROCEDURES

Disassembly and Inspection Procedures mpeller Water pump Impelle Pule MH06147

Wae pump saft 31C 0138

(3) Impeller to Water Pump Shaft Tighten• ing Margin

(1) RemQval of Impeller Using two theaded holes (MB x 1.25) n the mpeler and the Wate Pump Impele Pue (specia tool) pu off the impee Wae pmp flnge

Wae pump shaf

038

(2) Flange to Water Pump Shaft Tightening Margin f the tightening magn exceeds specification, eplace the fange o water pup shaft

NOTE: Do not reassemble more than hree times even when the specification is met.

14-6

f the tightenng magn exceeds specifcaton eplace the mpee o wate pmp shaft

NOTE Do not reassemble more than three times even when the specification is met

I


5.2.3

Reassembly

Apply engie oi to lps. 12

Appy ege oi to exteal cyder 13

Itallatio load 392 kN (4000 gO

Impele ut be fluh wit wate pump ha whe talle 6

5

Apply ege ol to lp

12

8 1 0 94 7 -

@J

NOTE: 1. After reassembly, turn the water pump puley by hand to make sure that the impeller s not n contact wth the case and cover 2 When press-fttng the impel ler and fange, make su re that they cannot be nstaled wth a load of 49 kN (500 kgf)

Installation of Unit Seal

0470

To install the unt seal, use the press-t jg as shown and essfit the unt sea untl the nstaled dmen sons shown ae obtaned.

Uit eal

Iallato loa 3 to 44 N (3 to 45 g) talatio pee 4 o 8 /e 84153A

14-7

I 5.3


THERMOSTAT

531

Removal and Installaton

Agitate water in the container wt te stirrer to obtan uniform temperatre. For the nspection, se te foowng procedres (1) Slowy eat water to te termostat vave openng temperatre Te vave openng temperatre s stamped on te termostat Its nomna vae s te stamped temperatre ± 2  Keep ts condton for abot fve mntes and make sre tat te vave s open. (2) Raise te temperatre frter to eat te water to· te vave ft measrng temperatre correspondng to te valve openng temperatre. (See te table above) Keep ts state or fve mntes and measre te bypass vave ft (3) Lower temperatre down to 65 C or beow and ensre tat te vave s fy cosed If te termostat s fond defectve  any of te above tems repace t wt a new one. °

690216

532

Inspection



Themostat stamping

76.5

Valve opig tmprature ( C)

NOTE: Support the thermostat so that the heat will not directly transfer to it

74 to 785

°

Valv lif/ tmpature mm!C)

More than 10/90

Bypass valve lft Stiig od

Vave opeig tempeatue stamped positio

emosat

� Heat souc

- 0316

14-8

m


5.4

FAN DRIVE

541 �

Disassembly and Inspection

-











  





8



1

542

55

Reasembly

Disassembly sequence> Fan puey 2 Flange 3 Snap ring 4 Fan dve sha 5 Ba beang 6 Spacer 7 Ba beaing  Beang case

89023

TENSON PULLEY

551

Disassembly and nspeion

  to  f otw. To  k wt  (to ) 145 N (15 k)

o   wt ox 8  of  (to )
[email protected]


 Rott oto Dsassemby sequence djsng bl 2 ensn pey bace 3 Snap ring  ensin pey sha 5 ensin puey 6 Ba beaing

890E

14-9

I 5.5.2

COOLNG - SERVICE PROCEDURES

Reassembly

Inspectio preue  kPa (10 kgf/cm')

Sealing sde to be faced ouward. To be packed wh grease (mprpose grease)

3

98 Nm (10 kgm 0098

4

2) Connect a hose to one of the radiator pors cap he other por and mmerse he radiaor no waer Using a radator cap eser force he compressed ar under he specifed nspecon pressure from he hose end o check for leaks If here is a lea resolder the poin of leakage or repace the radaor.

o be pace wh approx 6 g of grease (mlprpose gease

5 _ 6i 4-3.21 89024E

5.6 5.6.1

RADIATOR

Rdo ca e

Inspection

eco presure

39 o 59 Pa 0.4 o 06 g 2 

adao cap

040A

) Inspecon of radaor cap

040A

(1) Using a copper wire or similar device, remove drt mud and bugs from the fron of radiaor core wth care o prevent damage o urbngs.

-10

Check the sprng enson and sealng condton of he pressure vave and ven valve f defecve, replace Check he pressure vave openng pressure using a radiaor cap teser


5 7

INSPECTION AND ADJUSTMENT OF V-BELT TENSON

(1) Inspection

m

(a) Altenator secto Slghtly loosen the alternator mounting bot and adustng bolt, then move the alteato to ight or eft by nsertng a tool such as wech handle

< With (an drive:

NOTE When movng the alternator, try not to damage the stator coil secton between the front and rear brackets The same apples to the bolts Autig olt

, Without fan �rve>

166

(b Tenson puey section 0164

Adjust the belt tension to obtan the specfed bet deflecton when the center of each bet s pressed wth a foce of appoxmately 98 N (10 kg.

Loosen the dler puley mountng nut, then adjust mong the der pulley by means of the adustng bolt 58

CLEANING OF COOLING SYSTEM

NOTE: 1.  slack belt can be a cause of overheat ing and undercharge 2 n excessively tght belt may result in damaged bearngs and belts (2) djustment Adjsg bolt

80429A

E65

If the adiato is used fo a ong time, ust, scale mud, etc ae deposited nsde esultng n oeheat Clean the coong system with city wate by usng the foowing pocedures The city water to be sed shoud hae the foowing properties Requed propetes of cty wate 14-11

I

COOLNG - SERVICE PROCEDURES

Total hardness

300 p o lss

Sufate SO-,

100 ppm or lss

Clorid Cl

00 pm or ess

Toal dissolvd solids

500 pp o lss

(a) Discharge coolant rom the radator, and crank case. (b) Aer draning the system, f t wth tap water (preferaby hot water) and with the water tempea ture kept at around 90 C run the engne at de or about 10 mnutes Then discharge water Contnue fushng unt the draned water runs cear °

6 to 8

PH

NOTE: 1. Use a cleaning solution if the radiator is seriously obstructed or coolant is seriously contaminated 2. When the cooling system is cleaned or washed with water, make sure that the coolant temperature is maintained at 90 C; the coolant temperature below te valve opening tempeature closes the thermostat resulting in poor coolant circulation 3. For quicker rise of ater temperature you may cover the radiaor front with cardboard, etc 4. If much rust is found, water may lak from the radiator afe cleaning Check carefully each section o he adiato after cleaning

(2) Washing with Cleaning Soution (When radiator clogging or coolant contamination are serious)

°

Coolant i us

lg rv Evy 2 yeas

FUSO Diesl Lo i Coolant Ati-st atifeez

8027A

a) Dscharge cooant from the radator, cankcase and reserve tank (b Ready a mxture o Fuso Radator Ceane (Radpet7 o equvaent: 5 to 0%) and coong wate Pour the speced amount o mxture nto the radiato

At tim of coolant eplacnt of very 6 nts o bfor and at se of antreze

(1) Washing with Water

80A

(c Run the engne to rase the souton temperatue to around 90 C Let the engne run at dle or anoter 30 mnutes, then remove the souton 

80426A

14-12


m

Relace e coolat once every two years to etan ts ant-freeze and anti-rust effects For usage of ong fe Cooant, refer to ts nstructon manual NOTE: 1 Be sure to use FUSO Diesel Long Life Coolant 2 Never mix it with DIAQUEEN Long Life Coolant or other commercial long life coolants, anti-freezes or antirusts B0426A �



-



(d) After dschargng the soluton, fll the system with tap water (preferably hot water and wth the water tempeature. kept at around 90"C, run the engne at dle for about 10 mnutes Then, dran water Contnue flushng untl draned water runs clear NOTE: 1. If the inside is heavily stained, washing with tap water before charging radiator detergent will be effective 2 Running the engine at idle for longer than an hour with detergent left in engine could cause damage to the cool ing system Be sure to observe speci fied cleaning time 3 After cleaning with detergent, fill with coolant as soon as possible

1\

(b) When used:

Antirust

and Antifreeze

are

1 Afte cleanng, add uso Radator Ant-rust (Radpet98 or equvalent at a ato of 5% to te cooant quantty to pevent corroson n summer

(3) Cooling Water

12

D1328

(a) When Long Life Coolant is used:

In order to prevent freezng of coolng water and corroson of the coong system, add FUSO Desel Long fe Coolant at a ato of 30 to 60% of quantty of wate

2) n wnter add the uso Antfreeze o equvalent at a rato of 30 to 60% to pevent freezng or usage of antrust and antfreeze see respectve nstucton manuas NOTE: When the antirust or antifreeze is used never use with other long life coolants

43

I 5.9


GAS LEAK TEST

Air or exhaust gas leaked into the cooant promotes coroson and ust omaton. Peform the folowng check and if defects ae found, take emedial action.

(1 ) Inspection Remove the pressue ca from the radato and run the engne to ase the cooant temperature p to aound 90 C If bubbles contnue foming n the cooant under the condton t ndcates that a or exhaust gas has eaked nto the coolant °

(2)Causes (a) f a is trapped n oolant check cylnde head bots wate pump mountng bots and hose and ts connections for looseness. Check also hoses for damage · (b) If the exhaust gas has eaked into cooant check the cynde head gasket o nozze tube end stake for damage Check aso cyinder head fo cracks

14-14

510 BLEEDING THE COLING SYSTEM ( 1 With the pressure cap removed from the radato et the engine un at dle wth cooant temperatue of about 90 C to beed the system completey (2) Afte the system has been bed of a add cooant to adato and eseve tank as equied. 

m

COOLING - TROUBLESHOOTING

6. TROUBLESHOOTING

Symptom Ovhating

Probable caus

Dctv V-b .

I

Incoret tensio

Brok b Coggd coolg Dfcv thrmosat Dcv wa pump Loos shaf to fag gagm shaft o mplr gagmt .

sytem

.

•

Lo

.

Ict mplle t a ce

Damagd mpllr Cloggd rado s Damagd coog a ow coola lv Dcv hmosat I Dfcv radato hos

Rmdy

Rf gop

Adjst Rpac Cla Rplac Rpac

.

Ovrcoog loss oQckcoolat

• Po ho oeo

• ackd or damagd hos Dcv radao ght Radator popr Dctv prssur cap Dfv wat pump Dctv u sal Dcv o sa Poor pmp staao (dfctv gaskt! Dfcv ol coor oo hrmostat saao dctv gask dctv gask) oor hrmosat oo bypass hos stalao Dctv ha hos oor hos coco • rackd o damagd hos Dctv cdr had gask no 

•

I•

•

a Rpac Rpsh Rplac oc Rplac Rpac Rpac

•

•

ca

R.p ac Rpac

Gop 12

cover instalato

•

orct Rplac Rpac

Gop 

14-15

INTAKE AND EXHAUST CONTENTS

1. GENERAL ••••••••.•••••••.••••.••••..•••• 2. SPECIFICTIONS •••.•••••••••••••••• 3. SERVICE STNDRDS ••••.••••••• 3.1 SERVICE STNDRD TBLE •••• 3.2 TIGHTENING TORQUE TABLE ........................................ 4. SPECIAL TOOL .............................. 5. SERVICE PROCEDURES ••••••••••.•••• 5.1 REMOVAL AND INSTALLATION OF INTAKE SYSTEM .................. 5.2 REMOVAL AND INSTALLATION OF EXHAUST SYSTEM ...............

2 5 6 6 7

7 8 8 11

5.3 AIR CLEANER ............................ 5.3.1 Disassembly and Reassemby ••••••.••••.••••••.•••• 5.3.2 Inspection and Cleaning ••.•••• 5.4 TURBOCHARGER ...................... 5.4.1 TD08 Type Turbocharger •••••. 5.42 4LF Type Turbocharger ••••.••• 5.4.3 3LM Type Turbocharger .•••.••. 5.5 AFTER COOLER ......................... 5.5.1 Disassembly, Inspection and Reassemby •••••••••••.•• 5.5.2 irpressure Test ••••••••••••• 6. TROUBLESHOOTING ....................

13 13 14 15 15 25 30 35 35 35 36

15-1

m

INTAKE AND HAUST - GENERAL

1. GENERAL 

(  ) ir Cleane

Air

  Vc   

8061A

r

To egi t-1vacuor

vave Guide v

89004A

Db   I 

0620A

The ar cleane uses a flter paper type eement. Because of pastc coatng and eat teatment, te eement s igy esstant to wate and o Even f  t s contamnated ts functons can be eganed b ceanng e ntake a s gven a spn by te eement vanes fo centrfugal sepaaton of lage patcles of dust and dt Sma patces of dust and dt ae fteed out b the fe pape eement so that a cean a s drawn nto te engne e standad a ceane s a snge eement type and te double eement tpe can be effectve o operaton safey under unusual condtons wt a ot of dust and dt

(2) Pecleane

B060C

Osi i   l

8060A

e peceane couped wt te a ceane coects eatvely age patces of dust contaned n te ar dawn n by engne. e a enteng te peceane s made to spn b te gude vanes of the precleaner to centrfugally sepa ate lage partcles of dust befoe te a s dawn nto te a ceane 15-2

m

INTAKE AND HAUST - GENERAL

(3) Vacuator Valve

Ate  me as be leaed o replaed depe he eset tto  he top, ad he s a w e  ts oga sti.

Wag lamp Elcrcal du indco

ae wh

� l

Baey

80624A

The cntrifugally sepaed patces o us a dit ae coect a th bottm of h a eae. he coected paticles o ds ad dit ae ischagd sde by sations o  vaato vlve md  e a eae. In te ege speed case (to 800 pm o moe ), the vacao vve wil e cosed by  high gave pessre n e i cleae   oid a w b dwn i.

812A

n he eectc ds a ts eec coact poits cls a a egave pss of 6.23 Pa (63  2 ) o 7 kPa (6  2  o u o he wang lamp ci  the dve t tme o ea  c he lent (5) Turbochrgr

(4) Dust Indicator Reset buton

Idicao ody

Copeo weel

Sgl Exa et Tapare section

le mafld 806058

he s ndca s decty td ea he olet  e a eae he dst ca pates on  egave pesse o the a awn o he ngin peomng e non of icati   m  lea o ace he elemet. f s is coece  he eme h scn sae ineses We e negti pesse eahes 74 kP (62 mmH 2   .3 kPa 635 mmH 2  e sgnal is pled w agais th pg ese, ad the taspat po of the bdy hags o , ndag e e  o clea o epace he emet.

8125A

he ubc e lzs th negy f he ge exhst ga o fe oe a io he e e heby oei advs s as bsed  ie owe outpt hi fel onmio a cd egn nse 1-3

INTAKE INT AKE AND HAU HAUST ST - GENE GENERAL RAL

4F Type

TDOB Type

Bearing housg

Tubne wheel

cover

,\� ck plte

Turbine wheel

B123A

3LM Type

Cmpess co

Compreo wheel

 pae

I

ure wheel

ure houg

B9026A

202A

The exhaus gases discharged from the engine cylin ders are deivered hrough he ehaus manfod o he urbocharger, acceeraed n he urbine housn, and blown agains he urbine wheel As a resu, he urbne whee urns a a speed of severa ens of housands of revoluions per mnue whch spns he compressor whee As he compressor whee spins, he amoun of ar far larer han ha supplid when no urbocharger is insalled is forced no he engine cyinders, allown more fue o be burn in he cyinders. hs increases he effecive pressure durn combuson (he pressure forcing psons down), hus boosing he power ouput he turbocharger is dvided ino wo basic secions: he urbne wheel ha is driven by he ehaus ases and he compressor wheel which s suppored by he bearin and forces nake air ino cynders A thrus bearng s mouned on he compressor end he ubricaing o is suppied from he oil main galery a he fron end of the engne and roued hrough oi holes in he bearing housng o ubricate he bearings he o is hen reurned o he enine oil pan hrouh he drain por a he boom of he bearing housng [Refer o Group 2 Lubricaion]

15-4

INTAKE INTAK E AND AND EXHAUST EXHAUST - GENE GENERAL, RAL, SPECIFICAT SPECIFICATIONS IONS (6) Afte After r Coole Coole

•

The ntake ar coole system, incopoatng a plate and-cougatedfin and-cougatedf in type heat exchange wth a bu lin nlet manfold transfes heat om the ntake a to the engne coolant he system cools o he ntake a whose tempea tue has gone high due to compession by he turbocharger though heat exchangng wth he engine cooant. his allows he density o ntake a to be increased admttng moe a nto he engne which n tun nceases he uel injecton rae and

e Turbochage Turbochag

Afte le

mpoves the combustion ecency. hus the fuel

.,

economy and output are impoved and he ehaus gases are euced to a minmum

Jf



Wate pmp

80627A

2. SPECIFCA SPECIFCATIONS TIONS Speifitin

Item

(Nippn Dnasn Lt. p

A ene Eemen

Cyne type ppe element

ype

The Mde Afte e

[-CJ

[T

Type

(Sanad 

(Optn)

Mitsish TD

Mtsishi Sitze 3LM  4LF

Mtss D nne-lnte, with it-in net nf nf 

15-5

m

INTAKE AND EXHA EXHAUST UST - SERVI SERVICE CE STANDAR STANDARDS DS

3. SE SERV RVICE ICE STAN STANDA DARD RDS S 3.1

  BL Uit:m Descriptio

Tbochage 3LM)

Nomal value (Basc diaete!

Li

-

1906

Replace

Beag joal 



8

Replace

Shat coceticty



005

Replace

Pisto ig ope ed leaace

005 to 08

-

Repace se

Sha ad tube wheel to tube hoig cleaace

053 to 04

-

Repace

Shat ad tubie whee ed play

005 to 03



Replace

074 to 55



Replace



20506

Replace

Beaig joa 

-

996

Replace

Shat cocetcty



005

Replace



20382

Replace

ID.

2042

. of beag netg poto of beaig housig Shat ad tbie whee

Coectio ad eaks

in axal drecton

Shat ad tbie wheel to tbie bac plae ceaace Tubohage T-O)

 of beag ieig poto of beag hosg Sha ad tue wheel

Beig

Legth Ceaace betwee copeo whee

94 008 to 028

-

Replace

005 to 025

-

Repace

Sha ad tbie wheel to tbe hosg cleaace

039 o 0

-

Repace

Shat ad tbie wheel ed pay i axa diectio

005 to 055

-

Replace

Shaf ad tubie whee to ube bac pate cleaace

048 to 02

-

Repace

Beag setig aea .



22268

Replace

Pisto ig isetig aea 



225

Pisto ig gooe width



68

Beaig joa 



4254

Sha coceticty



OQ5

ad ompresso ove

Pisto g ed gap i

Tbochage 4LF)

Beaig houig

Shat ad tbe weel

15-6

insert

Replace

•

INTAKE AND AND E EXHAU XHAUST ST - SERV SERVICE ICE STANDAR STANDARDS, DS, SPECIAL TOOL

Unit:mm Oescipt1o

Nominal value !Basc mete

imit

-

3.3

Pso ring groo wdth of lg ev

Tbocarg 4LFI

Sa a trbine wee o urbe

084 to 175

-

008 to 0 152



housg clece

Saf an tube wee en pay

Correction an remarks Repace Repace Replace

n xa deco

Sat an trbine wee o bne back plate clearance



03 to 05

Cence eween comesso cove n coesso wee n ec econ

05

Clearance betwee saft an tbe wee an tbine hos

015

 

 ec eco

Piston g e gap n se Aer cooler ceck esse

6D-C

Dust nicator operatg essnce

Stana



95 kPa ( kg/cm' 7.4 .47 7

(6

.



± 05 kPa 58 mmH,O

63  05 kPa (635  58 mmHO

Option

3.2



003 to 08



Repace Repace Repace

Replace Repace Replace Replace

TIGHTENNG TORQUE TABLE Description

rea size  x Pitc m

igtenng toque N kgm

nlet manol bot

M x 1.5

35 36)

xaust maniol

M0 x 5

 (

Attacing nut

M X 5

6 ()

ock nut

M x 5

35 (36

Sa a trbine weel attacng nut



 to 0 (3 to 0

Compresso cover attacg c scew



6 0

rbocarger attacig nt ubocage (3M

nut

bne osig attacing



cap screw

 (

rbocager (D

Copig assembl



59 (Q6)

Sa an tbine weel lock ut



0 (

ocarge ()

V camp attacing nt



 ( )



Sa an trbine weel lock nt

Remaks

 (8)

Appl MO YKO gease or eivalent o treas Appl MOYKO MOYKO grease or eivalent to treas

4. SP SPEC ECIA IAL L TO TOOL OL ool name Socket

Part No MH0642

Sape

se

'

Remova an installation o east maiol montng n

�

Width across flas 14

[email protected]


53A 15-7

•

INTAKE INTA KE AND HAUS HAUST T - SERVIC SERVICE E PROCEDRE PROCEDRES S

5. SER SERVIC VICE E PRO PROCED CEDURE URES S 5.1

REMOVAL AND INSTALLATI INSTALLATION ON OF INTAKE SYSTEM

<6022>

Install the air heater wth te embossed aow drected to the let afold sde.

35 Nm (3.6 kgfm)

3

2

Earth plae 2 Inle pipe 3 Air eae 4 ne manifd

NOTE:

1. 2 3

Remove al harnesses beore disassembly Pay attention to the air heater mounting drection For inspecton of air heater, see "Group 6 84556A

15-8

INTAKE INTA KE AND HAUS HAUST T - SERVI SERVICE CE PROCEDURE PROCEDURES S

<6D22-T>

4 5

� 

5

.

��nstall  the air heate wth the

35 N (36 kgf

embossed aow dected to dowwad.

Earth plae 2 Ine pipe 3 Rubbe hose 4 Ai eate 1

5 nlet manifold

NOTE:

1. 2 3.

Remove all harne harnesses sses before disassemb disassembly ly Pay attention to air heater mounting direction For inspection of air heater, see "Groupe 16 84557A

15-9

INTAKE INTA KE AND HAU HAUST ST - SERV SERVCE CE PROCEDUR PROCEDURES ES

<6022-TC>

Install the air eater wth the embossed arow directed to the cyider ead sde.

Inlet pipe 2 Air escape ppe 3 Wae ine pipe 4 Wae retun pipe 1

Afte ooer assembly 6 Eah plae 7 A heae 8 Rubbe hose

5

NOTE:

1. 2 3

Remove all harnesses harnesses beore disassembly Pay attention to air heater mounting direction For inspection of air heater, see "Groupe 16 8455A

15-0

INTAKE INTA KE AND EXHAU EXHAUST ST - SERV SERVICE ICE PROCEDR PROCEDRES ES 5.2

B

REMOVAL AND INSTALLATON OF EXHAUST SYSTEM

<6D22>

2

2

Stamped mak "TOP To be istaled with stampe mark towad maifo.

Sea ing

t Eds

•

Ista he sea ig so that the es of each ig ae posioe 180 apa om those of he othe nsta he expasio g so that ay oe of ts ests is ot positioed at the sea ig eds °

•

Heat insulator 2 Exhaust manold 3 Sea ing 4 Expanson ing 5 Center exhaust maniold 1

B4560A

The exhaust maniod mounting nuts should be tightened o the specfied orque though use o Socket (speca too: M061242). 15-11

INTAKE AND HAUST - SERVICE PROCEDURES

<6D22-T, C>

4 35(3.6Nmkgfml 2621Nmkgm � L. 5 8

�i d'o_.

2Nm kgml _

(�1 [0� ' - -

  r -----   � -" \ 1 � stamped mark towad manifold.  : ( J\

Stamped mark "TOP

J�

Expansion ring

\V

0

To be installed wth

t}

Sea rng

!ds • Istal the seal ring so that the ends of each ing are positioned 8 apa om thoser g o the otheany oe o ts crests s not  Insta th expanson so that positioned at he sea ring ends

\

°

2 3

4 5

6 7 8

Heat insulator O ppe Oil return ppe Tubocharge Exhaust manifold Seal ing xpanson ing Center exhaust manifold

84561A

The exhaust manifold mounting nuts shoud be tightened to the specifed toque though use o Socket (specia too: MH061242. -2

INTAKE AND EXHAUST - SERVICE PROCEDURES

5.3 531

m

AIR CLEANR Disassembly and Reassembly

Assemblin deo ark Clap Dust ndcao

Bafe nu A leane body

Gaske

l

Eleme

Wg u Cove

A eae bd

Double eeme ye

Dust

A leae bod

Dust u Oue

ae

u

Wn nut

Vaua valve

p

Assembl deto ak

nu

Do o remove he ie eeme whe cea he oe eeme.

E0158

15-13

• 53.2


Inspection and Cleaning

(3) Inspection of Element

(1) When there is Dry Dust on the Element

209A C207A

If there is dry dust on the element, clean the dust by blowng 685 kPa (7 kgf/cm ) or lower compressed air against the eement. Blow the compressed a from nsde the eement up and down aong the rils o the flter pape and cean the whole element evenly 2

NOTE:

1 Do not strike the elemnt or srike it against a hard object to loosen the dust 2, Do not clean the iner element

Afte the element has een ceaned put an electric lamp insde the element to check for damage and pin holes If there are thin portions in the filter pape repace the eement. If the packing on the top surface of the element is broen repace the pacng.

(4) Cleaning of Air Cleaner Body Clean the insde o the air cleaner body and dscharge the deposited dust.

(5) Inspection of Dust Indicator

Ree buon

(2) When there is Moist Dust on the Ee· ment If the element is contaminated with moist soot 'replace t regardess o the specied repaceent frequency

Operating ressace

Wdw (red sga!

NV .4 ± 05 kPa 62  58 mmH,O) 623 : 05 a 165   mHO

NV Nmal vae 0

Start the engine nd close the inlet port of ar ceaner gradually to increase negative pressure. f the red signal is dsplayed at the dust indcator o warning lamp lights for the electric type the dust indicator is norma NOTE:

Perform this inspection after cleaning or replacement of the air cleaner element if the element is heavily clogged

15-14

INTAKE AND HAUST - SERVCE PROCEDURES

5.4 541

TURBOCHARGER TD08 Type Turbocharger

(1) Disassembly

'. 15

17

Interfec with tubie whl, raks de to ov, pitchig, dformtion 13

Blad bed d dmage orosio ms o neere on back s

Irrec wi trbe wl dmag 8

Berg hol sra oghss dmge, gas oosio bie sd lge deomaio

Disassembly sequence 1 Coupng assemby 0 Tubne housng 3 Snap rng assembly © Compress cover 5 Compessor hee 6 Snap ng ( Insert 8 Piston ng 9 Ol defecto

10 11 12 13 14 15 6 17 18

Thrst sleve Thust bearng ust ng Shaft and tubne whee Psto ng Tubne back pae Beang Snap ng Beang housng

For pts wih  ecird mber, ee o Disassembly Poedr th olows. C8965B

15-15

•


(c) Removal of compressor cover

Disassembly Procedure Alinment mark

Tub hos 

Cpssr cv Baig hui

82190

(a) Befo�e disassemblig the turbocharger, make aigment maks on the compressor cover bearg housig and turbie housing so that they ca be propery reassembled.

(b) Removal of turbine housig

C92C

Remove the compresso cove by tappng it with a pastc hammer wth the snap rig loosened NOTE:

Use care ot to damage the compressor wheel durig the removal procedure. (d) Removal of compressor wheel

Cpin asmby

�

Br us

b hsi rb hsin

839468 22

To remove the turbe housng remove the coupg assemby and tap the housg wth a pastic hamme or smiar tool to prevent damage to it NOTE:

The turbie wheel blades are easy to bed. Use care ot to damage them.

15-16

1) Ft the bearg housng ito the tube housng which is clamped i a vise


(e) Remove the insert.

C8983C 8978

2) While holding the sha and tubie wheel boss, remove the ock nt that secres the compresso wheel.

1) Remove the snap ig. NOTE: Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring piers

C8984A

3) Remove the compesso whee. C8985B

2) Fit the tip of a scewdver into the poton o the nset shown and caeflly emove it fom the eaing hosig.

5-7

•


(2) Cleaning and Inspection

Piston rng end gap NV 0.05 to 025

Clean

Clean  L 20.382  L

Clean

Beaing jouna  L 11996 Shaf concentcty  00 (toa gauge eading)

Cean Beang netng potion   20506 NV L

omna Vaue L C89B

15-8


(a) Cleaning Turbocharger manufacturers use a basting equip ment for cleaning parts at their workshops. As an aternative effective method fo overhaul at the deale's workshop, use the following procedues When a commecially available neutra detergent is used for ceaning make sue that it does not contain corosive component ) Befoe ceaning vsually check the condition of the parts Check fo buns wea etc whic coud not be identified after washing

891A

4) Cean deposits usng a pastic scaper o briste rush

NOTE: Use care to prevent damage to part.

C8989A

2) Immese al the pats in a non-infammabe so vent (Daido kagaku Kogyos ai Ceaner 30 or euvaent) to cean oy contamination C899A

5) Blow cean compressed air again against the entie internal and externa sufaces

NOTE The bearng houing and turbne wheel shaft should be re-mmersed n a non nflammable detergent fter Step 4) After deposts have been removed, blo com pressed air C8990A

3) Bow cean compessed air against the ente interna and external surfaces

19

INTAKE INTAK E AND HAUST HAUST - SER SERVCE VCE PROCE PROCEDURE DURES S

2 Mea Measu sue e ID. OD OD and en ength gth of the the bea beang ng f the measured vaues exceed the service mit, replace the beaig

B9036A

6) To preve prevent nt rust, rust, apply apply engin engine e oil to to the enti entie e interna and external surfaces of the beaing housing turbin housng and turbine backing plate and the shaft portion of the shaft and turbine wheel

(b)) Insp (b Inspect ection ion

8913A

3) Mea Measu sue e the shaft shaft and and turbi turbine ne wheel wheel jour joural al dameter If the measured dameter is less than the limit, replace the shaft and turbine whee.

C904A 895A

1) If the the beang beang hole diamet diameter er and and pston pston rng rng hoe hoe dameter are beyod the mt, replace the bearing housing.

Measuring diectio

Measrng posio

4) Set a dial dial indicator indicator beside beside the threaded porti portion on of of the shaft to measure the concentrcity If the deflection of the dia indicator is beyond the lmt, replace the turbine wheel shaft. NOTE:

Do nt correct but replace a bent shaft.

C897A

15-20

INTAKE INTA KE AND AND EXHAUS EXHAUST T - SERV SERVCE CE PROCEDU PROCEDURES RES

m

5) Inser

Isert

Ends

nser a new piston ing secuely n he bore n the nser ad mease the end gap o the piston rng. f he end gap is o of specicaion, repace the inser

ing

B0467A

(3) Reassembl Reassembly y

11

I Apply eie oi 5.910.6 Nmkfm)

App easeioockequiuvae o hey MOL sea YKOT ad heads 2

15

20(2 km Nm App O ease o equiy OKO vaeKO o heads. Appy eie oi   Compesso cove whee o compesso ceVaace 008 o 028 NV   Nomia Vaue Assemby sequece 876} 2  43 _ � FoPocee pas wihah aooeciwsced mbe, ee o Reassemby

J Appy ee oi Shaf abackubipaee whee o b  e c e aace NV 048 o 092

4

9 10(ar 7

)1 2 )1 6  @ � 3 - ( 2

-  ubi Shaeadhousiubiecewhee o aace NV 039 o 0 13

e whee axiShaf aNV 0pad a075y ubi o 055 C8974B

15-21

•

INKE INK E AND AND HAUST HAUST - SERV SERVCE CE PROCEDUR PROCEDURES ES

(b Instal Instalation ation of of sap ring

Reassembly Procedure (a) Insta Instaati ation on of piston ring

Thrust sleev

Oi defleco

Pson rg

C897

B0472C

Set the thrust sleeve into the oil deflector, and install the pston ring. NOTE:

1. When mounting piston ring to the thrust seeve, ensure that the ring is not ex• panded and ring ends are not twisted. 2. If the the piston piston ring ring is to be repa repaced ced wit with ha new one, be sure to repace aso the thrust seeve and shaft and turbine whee with new ones.

Install the snap ring to the bearing housing with its taper up After installaton using a screwdrver drve the snap rng nto the groove n the beaing housng y hummering NOTE:

1. Reain the snap snap ring ring by hand to prev prevent ent it from springing out when slippig of the snap ring piers. 2. Spe Specia cia care care must must be exercis exercised ed when when tapping the snap ring into position, to prevent damage to the bearing housing by the screwdriver.

15-22

INTAKE AND EXHAU EXHAUST ST - SERVI SERVICE CE PROCEDU PROCEDURES RES

(c) Measur Measurement ement of clearance between between shaft and turbine wheel and turbine housing

m

2 Coa Coatt theads theads n the the shat shat and and ubi ubine ne whee whee with with moybdenum disuide base grease (NLG No2) i soap and mount the compressor whee ono the shat. 3 od oding ing the boss boss on he he tubi tubine ne whee whee side side tighten the compesso whee ock nut t o the speciied toque NOTE:

t

Set the bearng housng carefully to pre• vent amage on the turbne wheel blades.

Turbine wheel �saft

Saft and tbe eel C901B

Set he dial gauge on the shat and urbne wheel end. Move he shaft and turbine whee in the axia direcion and measure he clearance between he ubine whee and tubine housing If the cearance s out o speciicaton, disassembe and soate the cause

(d Install Installaton aton of compressor wheel

t C903B

(e) Set a dia gauge gauge on the shaft shaft and and tubine tubine whee whee end Wih compesso whee moved in the axia diection measue the end pay  the play is out o speciica tion disassembe and check o ocate the cause

Beang oug Tbine oing

B28C

Lock nt ' C904B

() Wih the turbine housing emoved om he bearing housing and compressor cove instaed measure he oowing C902C

1) Hod Hoding ing he tub tubine ine housi housing ng in a vice vice se the the urbine whee side o the bearing housing into the ubine housing 15-

m

INTAKE INTAK E AND AND HAUST HAUST - SER SERVICE VICE PROCE PROCEDURE DURES S

Using two thickness gauges, measure the clearance between the tubine back plate and tubine wheel back surface. If the clearance is out of specification disassemble and check to locate the cause

(h) Instal Installation lation of turbine housing housing and comcompressor cover

NOTE:

Be sure to use two thickness gauges and take measurement at the tip of the blades.

Alignmet mark

(g) Shaf Shaftt and turbine wheel to compressor compressor cover clearance

Compess cover Sa g Culg assembly 2819E

Make sue that the algnment marks ae aligned and secure the pats with the coupling assembly and snap ring. Insta the coupng assemby by the folowing proce dues B468A

Check by the folowing procedures. 1) Mov Movee up and down down the compr compressor essor whee wheell to to measue runout (R) NOTE

Do not measure runout by turning the compressor wheel

2) Mea Measu suee compress compresso o cover cover insd insdee damet dameter er (D) (D) 'and compresso wheel outsde damete (d) at paces indicated in the ilustation 3) Ca Cacua cuate te the the cearan cearance ce by the equa equation tion giv given en beow. If it s out of specfication disassemble and check again Cearance

54

/(0 - d  )

) Tig Tighte hten n the coup coupng ng assembly assembly to speci specifie fied d tor tor ue 2) Hamm Hammer er the the coup coupling ling ass assembl emblyy all arou around. nd. 3) ghten agan the coupling assembly to specified torue ) Aft Afte e reasse reassembly mbly tun the the turbine turbine wh whee eell and compresso whee by hand and check for smooth otation. If the wheels turn heavy o bind dsassemble and locate the cause of toube

m

INTAKE INTAK E ND HAUST - SERVI SERVICE CE PROCEDURES PROCEDURES

5.42

4LF Type Turbocharger

See pages describing the TD08 tubocharger fo disassembly, ispectio cleanng ad eassemly pocedures.

(1) Dis Disass assemb embly ly covering layer,

Interference wih turbine whee damage 24 \

20

22

7

eerence wth turbne wheel cracks due to overea, pitching, deomaton 6 Bade bed and damage, corosion, maks o ineerence on back surface

Won beond coveng laer, dee scrach earing hole suace roghness, breakage gas 25 corroson, turbine-ed lange deormatio

1 2 3 4 5 6 7 8 9

V-clamp Trbine housng Vcamp Compesso ove Compresso wheel Shaft and and be whee Pison ng Sap ig Inset

iston ing  Finge seeve 12 Oil deecto 3 hust ng 4 Ths beaing 5 Sleeve 6 hust ing @ Snap ig 0

8

Beaig Sap ing  ® Snap ng 2 Ol cool sleeve 22 Beang  Snap ng 2 Tubine back pate 2 Beaig hosig

For ars wh an encircled number reer to Dsassembl Procedure that ollows. NOTE: 1.

Make aignment marks to cariy the postonal reationships among the compressor cover, bearing hous• ing and turbne housng beore disassemby

2

3.

The compressor whee and turbne whee bades are easiy bent Use cae not to aow them to fa and not to strke them. Do not emove the two pns o the beaing housing 84265A

[email protected]


15-25

B

INTAKE INTAK E AND HAUST HAUST - SERV SERVICE ICE PROCE PROCEDURE DURES S


When te sap rig oldig e bearig  posiio is o be removed, use piers (ip daeer 1 )   preve daage o e sid sid..e of e bearig bearig osig osig

Pliers B4266A

(2) Clenin Clening g and Inspecton Inspecton

Cea (Nsewtoprstgoedrggapto be used for measuremet!

Cean

j O � o O ,l� t \ · �,£: t

!'

NV

. 

L

Bear n22g 268seg porto .

3.3

ea ng joa poton 0. �CBear L 1425 Pston ewng pgroove wgdtsh ot clearace whe s t o  r  ed)  68 (Shaf totat rot d5cato readng)

NOTE: -Before cleaning, visuay check the parts for b urnt r t-  ark ks which would be hard t fn fnd d out after sto rig rig n 10.. rubbed mar Psto P potio 10 setig potio nsetig L

5-26

22..5 22

cleanin clea ning. g.

67A

INTAKE INTAK E AND HAUS HAUS - SERVICE PROCE PROCEDURE DURES S

(a) Measureme Measurement nt of piston ring groove groove width

m

(b) Measuremen Measurementt o linger sleee grooe grooe width

New piston rig

C8914A

Instal a new' new'piston ng in the piston ring goove and measre the earance. f the eading is more than the imit, replace the shat and turbne wheel

C896A

Mease the pson ing groove wdth o the flige sleeve. If the eading is moe than the mt epae the flinger sleeve.

15-27

•


(3) Reassembly

Cliandnediarcompr aamencerbeecaorwdeenrcover compr e or wee NV 015 ecio ngine o o e appied o hs ie Fareciedde oowared di � 8

11(11Nmgfm) seaMoo eynotgappesurgrifeaedceao cror eequw advaen 3

1

wngeen anda andCNVrearina0.encer4oi neeo wee 1.75 2 Gro efaeangeorefaappce ied ngio beneappoied pSaVa 0nand0axi ao r0dbrneecwee on ween anda andebiarnaencerbbacneewee V 04 o 1p0ae 7

7Nmkgm oroo eeoappveageerneda:e  oT--+; creaewngandrface Engio eneappoi ied 10

13

Greae o fangeoaeeappied

faced

4

NOTE: 1.

2

3

The piston ring shoud aways be eplaced with a new one. Snce it is easily broken, do not open it more than necessary Appy engine oi to al sliding sufaces befoe instaa· tion When the compesso cover and tubine housing ae installed make sure that their aignment marks are in aignment with the maks on the beaing housing

Cerbarnaenceweebewandeen afrbin eand o NV 0ngn damerca drecon 5 1®@   &1 7 1 J9 4 1 1110 Obeopa w mared o, refer o e aemb procede decried [email protected] Parts phone: 269 673 1638

8426A

15-28


Assembly Procedure

m

(c) Measuring clearances beween shaf and urbine wheel and urbine housing, and compressor wheel and compressor cover in diamerical direcion

(a) Installing snap rings

Turbine housng

Compesso wheel

�Tubne wheel

84266A

Use pliers (tip diamete 1 mm) in nstalling snap ngs.

NOTE: Insall each snap ring wih is round side oward he bearing. (b) Insalling hrus bearing Locating pn

C95A

Measure each cearance wth a thickness gauge to ceck at it is witin te nominal alue.

NOTE When a clearace is o be measured press he shaf in he axial direcion o minimize he clearance

Locang hole

To nsall the thust beaing, apply engine o o he hrust eceiving side Press i n wth is locang ole n algnmen wit he ocang pin of te bearing housng uni t s in flat contac wit te beaing ousing

15-29

• 5.4.3


3LM Type Turbocharger

See pages describng the TD08 turboarger for dsassembly, nspecton eanng and easseby poedes.

(1) Disassembly

G Turbine hosng 0 Compresso oe 3 ompresso whee 4 Snap rng 5 Inset

Flnger seeve 7 Pston ng 8 O deflecor 9 Thus ng 10 Thst beang 6

11 Beang hosng 12 Shaft and tbne whee 13 son ng 14 Tubne bakng pate 5 Beang

For pas with an eciced umb, f o Dsassly Poe a ws.

NOTE:

1.

2.

3

Beore disassembly, ake alignment marks to indi· cate the positional relationships amon the compressor cover bearin housin and turbine housin The compressor wheel and trbine wheel blades are easily bent Use care not to allow them to all and not to strike them Do not remove the two pins of the bearin housin

B9029A

15-3

INTAKE AND EXHAUST - SERVCE PROCEDURES

m


\"•·

894A 89031A

 Remove he compesso cove. (a) Remove the urbine housing. NOTE: Do not drop and strike the compressor wheel and turbine wheel, as their blades are readily bent.

15-31

m


(2) Cleaning and Inspection

NV  Nominal Vaue L ... Limit

Clean

0 (o be measured in ems of end gap o new pison ing  15 o .8 ·clea

Cean Clean

Cean Beang jona .0. L 8 Sha onenriiy L  oal gage eading)

Clean Beaing ole diamee L 96

NOTE:

The parts may be cleaned by use of a blast equipment o any other effective methods, but a non· corrosive neutra detegent shoud be used. 890348

15-32


m

(3) Reassembly

Bn lock we. 17  17 q

NV  Noa Vae

Sa a ube wee o be ousig eae V 05 o 04

12

Saf ad ube wee ax py V 00 o 03

No-hmfeed sie towa sr

1

 o 20   o 20 f

Tube bg pe o sf  ube wee eae V 04 o 

/ I

/ I

/,t '"  2 Appy gease o oi o soe poo

<sseby seuee> Gase 15 Appy eie o

10 Boze se owad opeso weel

  4  3  2    (H!  9  8     6

]

 4   _ \   J Fo pas wi  eed ube, efe o Reasseby Poeue  oows

NOTE:

1.

2. 3.

The piston rng should always be replaced with a new one. Snce it s easly broken, do not open it more than necessary Apply engine oil to all slding surfaces beore installa• ion. When the compressor cover and turbne housing are installed make sure that their algnment marks are in alignment with the marks on the bearing housing 903

[email protected]


15-33

m

INTAKE AND HAUST - SERVCE PROCEDURES


Locating hle

1 Nm  m

B9031A B9041A

(al Appy engine o to both sides of the thrust bearing nd thrust ring before assembing them on the turbine whee shaft. Then insta the oi defector NOTE:

Install the thrust bearing with the bronze side up. 6.9 Nm (07 kfm)

B9048A

(bl Insta the compressor cover by tighening the bots to the specified torque

15-34

(c) nst the turbne housng tightening the bos to the specfed torque NOTE:

Apply an anti-seizure agent to the ap screw.

INTAKE AND HAUST - SERVCE PROCEDUES

5.5 AFTER COOLER 5.51 Disassembly, Inspection and Reassembly

2 2

3 4

5

Connector Cover Plate Core assembly Inlet maniod

4

Damage, water leaks fin coaminaio scae ad rust isie core



5 C9305B

552

Ar-pressure Tes

Conduct he air-pressure test o check for water leaks due o damaged core. To check, appy an air pressure of 195 kPa ( kg/cm ) to the core Repace the core if i s eakng ar or oherwse defectve 2

NOTE: Nver appy pressure over specfication

5-35

•

INTAKE AND EXHAUST - TROUBLESHOOTING

6. TROUBLESHOOTING Sypto Low otp

Probbl cuse

Rdy

Rf. goup

Jnsucint ta ai •

oadd air cn me

• Air sctio (wih dust nd ohr forig tt o int syst •

C Rpr

Dfctiv tbochrgr • Tubochg rottion fiu •

Sizd bing

Rpc

• Cabo dposit o trbin wh

C

• Trbi wh nd trbi bck pt itrfg

Chc

• rbin wh d tubin hosig ntfig

Chc

• Bnt sht d trb wh • Copsso wh d copsso covr tig • Sid thst sv d/o thst bing • Incorrct sidig btwn insid parts du to coggd brictg o pip

Rpc Chc Rpc C, chc

•

Dagd copsso wh

Rpc

•

Dgd tb wh

Rpc

ow xhast fcncy •

Dod fo pp mu ando  pp rg xhst sistnc)

Rpc

• Dfctiv trbochg • Tubochgr oto fr S bov •

Whitish d ch xhust gs

Dgd ubi w

Chc Rpc

Icorct injcton ing

Adjust

Gop

13

ow copsso pssr

Chc

Gop



Rpc

Gop

3

ow qty f Dfctiv tubochrg

D nd uch xhst gs

Abor noise nd/o vibtion fo int d xhst syst

15-36

• Oi s d to won pson ig do is

Rpc

• Dgd oi s du to coggd o ur pip

Rpc

odd i c t

C

roub in ng pop

Chc

Gop

1

Nonifo f inction ont to cyds

Adjst

Gop

13

Icoct icto iig

Adjst

Gop

3

oo connctio of itk nd xhst systs

Coct

Dfod frot pip uff or ai pp !g xhs sistnc

Rpc

Dfcv tubochg S bov

Chc

•

ENGINE ELECTRICAL CONTENTS

1. GENERAL ...................................... 1.1 STARTER ." 12 ALTERNATOR ••••••••••• 13 SAFETY RELAY •••••••••••••• 14 REGULATOR •••••••••••••••••• 15 INTAKE AIRHEATER ••••••• 16 AUTOMATIC STOP DEVICE 2 SPECIFICATIONS •••••••••••••••••• 3 SERVICE STANDARDS . 31 SERVICE TANDARD TABLE  32 TIGHTENING TORQUE TABLE . 4. SPECIAL TOOL . 5. SERVICE PROCEDURES .. 5.1 STARTER . 511 Removal and Installation ••••••• 512 Disassembly •••••••••••••••• 513 Inspection •••••••••••••••••• 514 Reassembly •••••••••••••••••• 515 Inspection and Adjustment after Reassembly •••••••••••••••• 5.2 STARTER RELAY ...

2  5 8 9 10 10 13 14 14 16 17 17 17 17 18 22 28

32 34

53 30A, 40A, 80A ALTERNATOR  531 Removal and Installation •••• 53.2 Disassembly ........................... 533 Inspection ••••••••••• 534 Reassembly ••••••••••••••• 535 Inspection and Adjustment after Installation ••••••••••• 54 60A ALTERNATOR . 541 Removal and Installation ••••••• 542 Disassembl ••••••••••••••••• 543 Inspection ............................. 544 Reassembly •••••••••••••••••• 545 Inspection and Adjustmnt aftr Reassembly ••••••••••••• 55 SAFETY REAY [Model R8T30171] ••••••••• 56 REGULATOR [Model R7T01071] •••••••••••••••• 57 PREHEATER .... 571 Intake AirHeater ••••••••••• 5.7.2 Heater Relay ......................... 58 AUTOMATIC STOP DEVICE . 581 Energizeto-stop Type ••••••• 582 Energizetorun Type •••••••••• 6. TROUBLESHOOTING ...

34 34 5 38 44 46 49 49 49 50 51 52 53 54 54 54 55 55 55 59 63

16-1

ENGINE EECTRICAL - GENERA

1. GENERAL

Stae elay 60

Alteator

Heate eay

A heate indcato

15 -,

_

p

l

afey eay

(622-T)

Ol bypass O bpass aam aam lamp 5 60 Ammee

Fuse

,-1

5 0.85

' 

0.8 5

�

0.85

5

·c& • ' I

-

i

+

 Bay

hmomee l

O pssu gaug

L � 0 O pssu ut

�

_v

Themomete

l

L_�j

Baey sw

 C 00

ode sze 085 mm o moe 085 5 mm' o moe 5_  5 mm o mo  60 mm o moe 60 2

2

2

B1646F

16-2

ENGINE ELECTRICAL - GENERAL

1.1

Starter

(2) Overrunning Clutch

M;1�pH:{! switch

Ouer r Rl



Field ol Armature

Yke Pion

P

�

B371A

The starter is a reducton starter wth a bult-n reducton gar. Its motor has been downszed wth even hgher speed capablty. Major components of the starter are: motor secton generatng power; the overrunnng clutch secton transmttng armature toque and preventng the engne from overunnng after startup the magnetc swtch secton whch puts the pnon n mesh wth the rng gear and feeds load current nto the motor and, the reducton gear secton reducng armature speeds and transmttng torque to the pnon

B70A

Magntc swh trt

'Rg ge

(1) Reduction Gear Secton

B2

The overrunnng cutch s of roer type Each roller s set n the wedge-shaped groove pro vded by the oter and nner races (pnon) and s pressed by a sprng he roer s pressed aganst the narrower sde o the groove by the sprng transmttng oter race rotaton to the pnon by ts wedge cton On the other hand no torque s transmtted rom the pnon as the roler moves to the wder sde releasng the wedge acton

Ovrrg tch

702A

The end o the armature shaft s shaped as a gear and s n mesh wth the nterna gear. After reducton by the nterna gears the torque s multpled several tmes and s transmtted to the pnon

16-3


(3) Operation

Sarter swich

Se e Sarer ely lge Plunger

Po Pinion

g ge Ring gear 09 83708

While the starter swtch is ON, curren flows fom he terminal "SW" of the starter relay to the erminal "L" and coses the contact "P2". When the contact "P2" coses, current from the battery flows from he terminal "S" of the magnetic switch to the pu-in coi "P" and hoding coi " H Furhermore, the curren that has decreased fows from the termina "M" to the motor section. The punger, attracted by the magnetic fux of the pun coi and hodng co coses the contac "P" and simutaneousy pushes out the pnion turning sowy on weak current

164

When the pnion comes into compete mesh with the ring gear, e conact "P" coses and the large current of the battery directy fows to the otor sect o turn the pinon powerfuy. In ths condion, no curent fows to the pulin coi The punger s retained by the hodng coi alone

ENGINE ELECTRCA - GENERA

�

-

--·  



1.2

ALTERNATOR

( 1 ) 30A, 40A, 80A Alternator Starte swich W

.S,r>�;ka I

�

L

,

Sa ly

8296

Rng g

83710A

When the starter switch s set to OFF, the contact pont P2 opens. The moment the starter swtch s opened, the P1 s stil in cosed positon and the battery current flows fom the B temnal to the pul-n col () and hodng col H) Snce the dection of cuent that flows s reverse, the magnetic fluxes cancel each other, and the etun spng pushes the plunge back to ts oiginal posi ton At the same tme, the contact pont P opens so the current to the moto secton s cut off

he altenator s a brush type n whch a curent flows from the bushes through the sip ing to the fed co n the rotor Major components nclude: the rotor field coil that generates magnetc feld; the sator that generates electromotve force the ectfer that rectfes elec tromote force so generated the regulator that keeps generated voltage constant (a) Rotor

Sp ng

Ro  B20D

When the roto s drven by the pulley otaton a cuent flows fom the brushes, throgh the sip g to the feld coil he otor core tabs then becoe magnetc poles

16-5

•


(b) Stator

(d) Regulatr

Staor core

B78

Brush

B2703A

Togethe� with the rotor core, the stator core forms the magnetic flux path. The magnetic flux lines in the stator core are aected by the passage of the rotor core fied and generate electricty (c) Rectifier

he reguator aters the strength of the fied col feld to stabilize output power which varies with engine speed fluctuations. The regulator is integra wth the brush holder The assembly combnes the C regulator the brushes ad the brush sprngs (e) Charging circuit 1) Seng he starter switch to ON Alernato

B24A The rectifier mainly consists of 3 diode trios 6 dodes and 2 heat sinks. It rectifiers the AC stator output to DC power Each heat sn has the(+) or(-) leads from 3 dodes attached to it, perorming ful wave rectificaton for 3phase AC On the 80A altenator, two of rectifers of this type are provided

BR

OF

Q

Q

I Stater swich 

Safy rla or charge lamp ION)

Atenao R tenal)

leaor (L rnal)

I

166

afet reay or arge amp

Batery

 Groud


2) Starting the engne

(2) GOA Alternator

Alterator

          �- E



Battery

E  

Starter switch

8254H

Wn  ngn  d nd  n  gnn    vg   n " mn bm g n  b vg,  un f  n b. Alteaor IB tminl!

I

Ground

B4007C

T 60 n  n pn p -p n T p C gnd n     nvd n D b  n dd   f 12 dd (6 n  pv d nd 6 n  ngv d)  d n 6  nk  n   nk T n gnd vg  nd b  gu



In   b g  d nd   m m  g mp (f pvdd) g 

16-7

ENGINE ELECTRCAL - GENERAL 1.3

SFY Y

The alternator rpm is detected and when it exceeds the reference level, the saety relay prevents the starter om operatng even  its swtch s accdentay turned on during engine revolution.

B1453A

Operat�on

Charg lmp Sflyty

Ste switch P, +�:ly To tart

Btthy w  - Bty

1

454A

() When the state switch s set to ON current ow om the state eay to temna "S" and to termina "E" o the saety elay closng contact P1 he charge amp aso umnates i provded (2) As the state uns and the engine starts running puses o equency 0th o the altenator speed appear at temina "P" o the aternato he chage amp goes out

6-8

3) When the puse equency at termina "P" ex ceeds the speced vaue contnuty between tem als "S" and "E" s ost hen the state does not operate even i the starte switch s set to ON whie the engne is unnng

•


1.4

REGULATOR (Model R7T01071)

Its functions include: (1) Votage regulator Mantans voltage generated by the generator con stant (2) Safety relay Keeps the starte crcut n OFF state een wth the stater swtch turne on duing opeation of enge. 3 Fed relay Mnimzes discharge curret to the alterator fed col even when the battery swtch s let cosed.

IG F L

} r : t � i

'

/ I

I

A

N

E

Connectons o he alterator to the egulato are shown below. Followng descrpton of operations s keyed to ths figure.

B401B

Ths egulator is combned wth the 60A altenato. Operation of Regulator Safey rla Trnso A

Rgut

I I 

l_ _ j Pio mp

-



>

89A

 The battery swtch in ON positon causes fed curet to fow n the crcut as foows:

powe, causng a curent to flow n the coil C in the folowg sequence

 -  swch  Rguo  m  Rsso R,  Vog go K   Vog go  m  Ao   - d o - oud

Aor N  • Rgo    Co VC,  God

 When the starter swtch s set to ON, the stater reay coil s energze wth ts contact closed When the starte cranks the engine the altenator geneates

As the col VC s enegzed the contact P is opened In ths state settng the starter swtch to ON wth the engne n opeation leaes the starte nopeate.

-9

•

ENGIE .ELECTRICAL - GNERA

(3) Whle the engine is n operaton, fied curent flows n the followng crcuits, wth aternator output voltage controlled by the voltage eguator Alteraor A trminal - Regaor A teria  Coc P2  Volage rgulaor K ternal  Trasir  egao F erinal  Alteror F til  Field col God

If the transistor remans off too long, the aternator N termna outut is deceased and the co VC1 loses its magnetic foce to such an extent that the contact P2 may be opened o P1 closed. The crcut of col VC2 and resstor R2 kees P2 cosed ·and P1 open n such a case

1.5

INTAKE AIR HEATER

Sswit arttech OF

A e

B R1 ACC R2 C

HEAT

ON

And o  t

r �!\  _  ��-o II _!� t

y

o

_

B

y

D8803

he intake ai heater s an electrc heater whch heats the ntake a to facltate engine startng Pace the stater switch to HEAT poston to oeate the heater f curent s supplied fo about 40 to 60 seconds by keeng the starter swtch at HEA osition, the temperature of the intake ar heater wl exceed 800°C The intake ai heater cicut has an indcator to et the dver recognze the heat condton For safety's sake a fuse is povided in the heate relay. 6

AUTOMATIC STOP DEVICE

f the coolant temerature rses o the oil pessue fals whe the engne s runnng ths devce operates the stop ever of the njecton pump governor to cut fue suppy and automatcaly stops te engine

16-10

•

ENGINE ELECTRCAL - GENERAL

(1) Energize-tostop Type

Solenoid ra

,-· ·- i

-·  

.

    



   �

 02

Do

RB

�Thmo-swL A.tetor ·  

- <� ,:

· 



By sc B4926C

(a) Stat cicuit ) When the battery swich is placed at "ON curent lows from the soleoid relay (B) to he RY coil and appes he volage to the collectors of TR4 ad TR but R does ot operate, as hee is no inpu to the base. 2) Curet also ows rom the o pessure switch to the solenoid elay (W) to R4 to R and applies he votage to the base o TR3 Whe the votage is applied to the base o TR3 curret low rom R6 to C ad E o TR3 to the goud and RY does ot opeae as thee is no nput to TR4 ad TR o the stop crcuit.  The engie starts ad a volage o 2V or moe is apped om he ermina L o the aenato hough VR1 to ZD (ee votage 2V), ad charge begs with the time cosat (O pressue ime) determed by VR ad C (At this poit the engine oil pressure iceases beyond the speciied value and the egine enters the operating state) The chage volage passes through R I it becomes highe han the eve o the emitte o TR curet flows from R4 to C and E o TR ad biases TR TR passes cue om R4 to C ad E o TR ad to he goud ad the crcui om R to base o TR3 is caused to be OFF (Oil pessue swich circuit opeed)

)  the coditio o the above ite ) the oil pressure ises as he egie speed icreases and the contact o the oil pessure swich is opeed and o voltage applied rom R4 o TR  this condio the aernato votage s apped up to the base o TR while the engie is runnig

(b) Automatic to· p cicuit When the themo switch ad oil pessure swith detect a abnormal condiion he cicut opeates as ollows: 1)

  @ [ • D1 C2GVR u f Gfu   CEfC,Ef  Gu  ®Y  C   f   RGru _

2)

-

•


3) hus RY contacts cose, the solenoid operates (c) Pushbutton stop and the engine stops. When the engine stops the To stop the engnedurng operaton operate thestop alternator votage goes out At the same time, the switch and the stop operation is peromed as at the stop tme made up of C2 and VR7 holds the soenoid time o an automatic stop. (The engine stops regard ess of whethe the atenator votage is available (2) Energize-torun Type

Soenod ray

\

-� RY

Oil pressue switch Themo swich

Sop swich

DJ

01 Ro

V1

Sarer switch

(a) Start cicuit

849278

Saer swch

1 When the battey swtch is turned ON:

©�

Solnoid rea

®[

Resiso R  Grou _ Diode OJ  RY oldg o H  roun Dode 01  Capaior 

When the capacto C is chaged votage s apped VR to the base of TR actuatng R R contacts do not opeate wth no nput to the base from As votage is apped to TR coecto TR emtte and of TR and TR to TR base a curent fows from TR colecto to TR  When the stae swtch s paced in the STAR emtte esstor R and gound causng the R poston pul-n coil P to cose the R contacts Solenoid relay @  RY pull-n coil P

16-1

t

TR, colletor R olleor

ENGINE ELECTRICAL - GENERAL, SPECIFICATIONS

his causes the current to flow from the starter switch to o pressure switch, thermo switch, solenod relay, RY holding coil H, and to ground, keeping the RY contacts in ON state

3) When the RY contacts un ON: Current flows fom solenoid relay@ to RY, solenoid relay©, and the solenoid, actvating the solenoid and starting he engine. 4 As the engne starts and starter switch is paced in the ON postion voltage to the soenod relay® is cut off; however, TR1 and R2 stay ON for approximately another 30 seconds by the discharge current of the capacitor C During capacitor C's discharging, the oil pressure builds up as the engine speed increases, causing the oil pressure swtch to tun ON

(b) Automatic stop circut

When the thermo switch and o pressure swtch detect an abnormal condition, each switch turns OF and the RY contacts open, deactivating the soenoid and stopping the engine (c) Pushbutton stop

o stop the engine durng operation, operate the stop switch, and the stop operation is performed just as when the automatc stop is performed 2. SPECIFICATIONS Specficaon

Item

24V  () ground

Volage - Poarty tate Msbs Eectrc Cop. oducts!

Tye

Front nose elecromagneic puh-i ye redc er

Mode

M395082

Op

24V5kW

I

M550276

l

M55027 24V6W

M550279

Sngle stage edcton by ntenal spr ga

Reducon ecnim

Sare eay

Mode

Aternator Msbs lecrc Cop oduct

ype

I

Oton U10601

Sandard U06074 Atenao wh un IC regato

Oton  U07076 Altenator wt n C eguaor

Ycnecon

aternaor wt scon dode ecifer

Mode Oupu Regao Votage eguator aety reay

Mode

aety reay

Mode

Intae a eae

ype

Heater reay

Capacty x qaty Model Fuse caacty

A2 2987



A2 72986 24V30A

I

A2 7338

A4 57986



A4 57987

A4 652

I

A4 6573

A6 5386



A6 75387

24V60A

24V80A

-

R7007 RF24H RX2



R8301

-

R8307

24V40A

lecrc eatng type 622, 22· 2 kW x 

l

622C 03 kW x 6

066 9 A

16-3

ENGINE ELECTRICAL - SPECIFICATIOS, SERVICE STANDARDS

Automatic Stop System [Opton] Specificaion

Iem Sop soleoid (Nppon Denso Co., d produc)

Type

Soleod relay Nkko Denki poduc)

Model

Oil pressre swich

Type

Daphragm bu-i elecric conac

Themo swch

Type

Wax ype bilin eecric conac

Eectro magec ype

I

!Energze-o-sop ype 025000-5592

Enegieo-run ype 025000-620

3. SERVICE STANDARDS

3.1

SERVICE STANDARD TABLE Ui:mm Descpio

Sae M3T95082)

Commuao .. Commuao perphey

runot

Nominal vae Basic diameer

Limi

387

38

0 o 003

01

Correcion and emarks Replace Replace o ce.

0 o 09

03

Replace o correc





Replace

25 o 34 N (25 o 35 kg

8 N 8 kgf)

Repace.

 o 3

-

Adjus washes

0 o 05

-

Adjus washers

Volage

23V

-

Check

Crrn

0A or less



3 00 pm or more

-

6V or less

-

Replace

32

22

Replace

0 o 003

0

Deph of groove beween segmens Bus legh Brush sprig

tensio

Pinon gap Gear sha hrust gap No-load characeiscs

Roag spe Mage swich operatg voage Saer M55026 M5502 M55029

Commuaor  Commuaor periphe



0 o 09

03

Repace or corec

23



Replace

25 o 3 N 25 o 35 kgf

8 N 8 kgf)

Replace

M5T5029

 o 3



Ad washers

M55026 M5T502

 o 6 0 o 05

-

Ads washers

Volage

235V

-

Check

Crre

0A or less

-

3 300 rpm or moe

-

6V or ess

-

Deph o goove eween segmens Brush legh Brush spring

tesio

nion gap

Gea sha hrus gap No-load characerisics

Roag speed Magne swich operang voage

[email protected] 16-14

Repace or c


Replace

ENGINE ELECTRICAL - SERVICE SANDARDS

Ut:mm Dcrplio

Nmina v1uc

I Basic diame!

Lm

Cn d mak

Sta lay

Col sae

0.4 

-

Rplac

Altato (A2729871 (A2T729861 (A273387) 30A

Slip ring OD.

40.8 o 4.2

404

Rplace

3.1 o 43 N 032 to 044 kgf

2 N 02 kg

Rpac

23

8

Rpac

-

Rplac

2V

-

Chck

7A o m



 500 m

-

27V



2A o m



2 500 p



28 o 29V

-

Rpac

408 o 42

404

Rpac

3 to 43 N 032 to 044 kg

2 N 02 kg

Rpac

23

8

Rpac

Appox 9 



Rpac

27V



Cck.

2A o m



 00 p

-

27V



37A o m



2 500 p



28 o 29V

-

Rpac

408 to 42

40.4

Rpac

3 to 43 N 032 to 0.44 kg

2 N  2 kg

Rpac

23

8

Rpac

Appo 7.2 



Rplac

27V



Cck

Bh g i

ush ngth Fid col ta (at 2· Load

T voltag

Appox

9 !l



W col

C

Rotag spd oad

a volag

Chck



Wn cod

C

Rotatng spd C gulato gulad votag ang 5 000 p, 5A o ss Alato (A457986 (A457987 40A

Slip ng OD us spng tnsion s ng id coi  (a 2 oad

nal votag

hatt

(wn cold)

Cut Roang spd

oad

al voltag



wn cod

C

Roating spd C gato gulatd votag (5 000 p 5A o ss Atnao (A675386 A675387 A

Sip ng OD s spng tnsion s lng d co t (at 20 C °

oad

na voag

t

wn cod

Cn Roating spd

Load

nal votag

tt

(wn cod

Cn Rotatng spd

C gato guad voag (5 000 p 5A o ss

39A o

more



 500 p

-

27V



7A o o



2 500 p



28 to 29V



Rpac

16-5

•

ENGINE ELECTRICAL - SERVICE STANDARDS

Uit:mm Dscrptio Altr A4T65772) A4T65773) 6A

ts

45.4

Rpc.

37 N _(.8 g

2 N 2 kgf)

Rpc

23

8

Rpc

Apprx 13 



Rpc.

28V

-

Chck.

6A  m

-

2 2 rpm



8 t 29V

-

Rpc

Bush gth Fid ci

resistance

t w·

d

Crrctn nd rmks

4G

Sp g 0. Brush sprig

Lmt

Nominal vaue

!Bas de

Trm vg

hteists

 cd)

Currt Rttg spd

Rgut R7T171)

Rgud vtg Atrtr: 4  rpm)

fty ry R83171)

Rsisc bt L d R trmis

Aprx 2 

-

Rpc

Ik ir hr

Tm rquid fr i htr dct  bcm rd ht

4 t 6 scs

-

Chk

Pitr cc

5 t 2



Rpc

Crc bt stp vr d xtr sppr

4 t 5

-

Hdig c cun

A  ss

-

y tim t strtig fr 285V ppid t trm "B d W d 285 V t tmi A

13  3



y tm t stppig f 24V ppd  trm B d W d  vtg t rmi A)

5  35

Autmatic

stp

Ergiz tstp yp

id

device

id y

-

eod

93 t 97°C



Rpc.

69 t 98 k 7 t 1 kgf/cm2 r ss



Rpc

19  28 

-

Rpc

Mn ptg vtg

16V r ss



itr crc

15  2



Crnc n sp vr nd xr sppr

4 t 5



Hdig ci curnt

1A r ss



26  34 scds



Rpc

Thm sch cuig tmprtu

93 t 97 C

-

Rpc

Oi prssu sic cuig pssu

79  118 k 8  12 kgf/cm  ss



Rpc

Thrm sich ung tmptr O pssur sitch cutg Oi prssur sitch y 24 V) Ergz

Rpc

seconds

d

prssure

C rsstc

Rpc

--r

yp

id ry dy m

3.2

TIGHTENING TORQUE TABLE scripti

Arr puy u

Ar shf ut 16-16

hrd si  X pich mm

ghg tru m kgfm

M17 x 15

83  15 85 t 1)

M2 x 15

135  16 135  165)

-

345  36 35  37)

Rmrks

•

ENGINE ELECTRICAL - SPECIAL OOL, SERVCE PROCEDURES 4. SPECIAL TOOL

Ui: Part No.

Tool name ock

Shp

s

319-06

Rovl d llo of 

Width acros flat 17 852A

5 SERVICE PROCEDURES

51

NOTE: Whenever removing electrical parts from the vehicle, be sure to lace the battery switch in OFF position, disconnect the negative battery cable, and wind the cable end with vinyl inslation tape.

511

STARTER Removal and Instalation

"-@

Stae

C018A

The starter mounting bolt on the inne side (cankcase se) can be easily mounte o emove by use of the speca tool, Socket.

16-7

ENGINE ELECTRCAL - SERVCE PROCEDURS

Disassembly

5.1.2

10 9

b.

Gear shaf hrust gap NV 0.1 o 05 8 Rotating codtio 6

ougheed commuaor surface, seizure ridge wear wor damaged gear I

1

23



Wor ad damaged gear

22



0 NV . Nomia Vale

5 3

4

Deposited brush powder ueve wear movemet 1 o brush  older Mouted codiio o poe ad ield coil

Yoke assemby Re bcket Bush holde Bush spg Bush Amatue Font beng Rea beang Mgetc swtch ete bcket  Ge backet  Gea shaft

@ 14 5 16 17 8 *19   22 *23

Overrnng cltch Packg Pte Spaer Leve Colr Gear shft beang Rng Pno stoppe on bcket Sleeve beng

Par marked wih * shoud o be removed uless deecs are evide For pars wih a ecrc led umber refer o sassemby ocedure ha follows B1104B

16-18

ENGINE ELECTRICAL - SERVICE PROCEDURE

, --

 - 

        

-� Gear shft tust gap NV 0.1 to 05

  - -    - -

-

Roeed ommto sfe, seze de we wo dmed e

Rotin codto

6 Ro odo

Ro odto

14

15

2 19

Wo d dmed e

3 Deosed bs owe eve we moveme of bs  olde

1 Moed odto of bll d fed o

Dsassembly sequence>

( Yoke assemb 2 Rea backet 3 Bsh hode © Bsh sprng ® Brsh 6 Armare *7 Fro beag *8 Rea bearng  Magec swch 10 Cee bracke

(il) @ @ 14

Gear bracke Gear shaf Overig cch Packg 15 Leve 16Gea sha beag  Rg  o soppe 19 Fo bracke 20Seeve beag

Te s mked • sold o be emoved ess ee s y wo wt em O s mked o, efe o e dsssembly oede desbed below B9071C

16-19

ENGINE ELECTRICAL - SERVICE PROCDURES

(3) Remova of Overruning Clutch

Disassembly Procedure The disassembly poceure for te M395082 is described. The poceure or the other startes s te same

(1) Remova of Yoke Assemby

Front bracket assmbl y Gea brakt mounti ng bolt 829548

829518

ront brak

Gar brakt

Remove the magnetic swtch and sepaate the ont backet assemby an yoke assembly

NOTE: Do not drop the armature. Especialy when disassembing wih the armature staying in the yoke, do not tilt the yoke assembly (2) Inspection of Gear Shaft Thrust Gap

829550

a Remove the gear backet mountng bolt and emove the overunnng cutch to which the gea shat and gea backet eman nstaled om the ront backet

Rn R  g groov-� Pnon opr . .

829638 8297A

Beore dsassembly, set the da ndcato as shown to measue the thrust gap n the gea shat I the measuement s out o specicaton use adjustng washes to obtan corect gap [Fo adjustment poce due eer to Secton 1 ()

16-

b) Appy a tool ppe to the pnon stoppe and hamme the pnon stoppe out towad the pno sde Then emove the ng and emove the oveun nng cutch

ENGINE ELECTRICAL - SERVICE PROCEDURES

NOTE:

Overung clc

t

Gear backe Gear shaf

Gear f

82 8414A

When the ring is removed, keep the gear shaft in oerhanging condition.

(d Remove the oveunnng cltch and gea baket fom the gea shaft. (4) Removal of Brush Spring

�Rng �'- Pinon u-

Brh prng

topper

8295A

) Remove the ing fom the ng goove of the gea sh9f. Remove he pnon stoppe fom the gea shaf.

824

To remove the bsh sping, fst elease the sh sping and emove the ush

16-21

• 5.13


nspection

NV

L

M3T

387

381

M5T

43.2

22

Commutator otside crcumference ruout

0 to 003

01

Depth of goove betwee segmets

0 o 09

03

Item Commutaor outside dameter

Short circuit test, coil rod test, ope circut test Coil ope ccui test Meled cotacs Loose coac



0 Coil earth test Ope circt test

tem NV

Nomal Value imi

NV 25 to 34 N (2 to 3 kgf)

18 N 18 kg

M3T



11

M

23

1

Brush spg teso Brush eth

nsatio tes

B1104E

16-22

ENGINE ELECTRICA - SERVICE PROCEDURES

(c) Inspection of commutator


The inspection procedure for te M3T95082 starter is descrbed. On te oter startes, only te differences are jointly desribed. (1) Armature Inspection (a) Coil short circuit test

A

0755A

Place the amatre on a gower tester. Hold a pece of ion in parael wth the armate and slowy trn armatre by and. If te iron piece s attracted or vibrates t means tere is a shot crct Replace te amatre

Measre the rnot of commtator sng a dia gage and trning the armatre by and f te not exceeds te mit correct ensng that the  mit s not exceeded f the commtator srface s rogh developng dge wear corect with sandpaper (No 300 to 00 After corecton make sre to ceck te not agan (d) Commutator O.D

(b) Col ground test

/

8A

Mease te commtator  f te measement exceeds the limit repace the armatre 56A

Check fo continity acoss the commtator and shaft (or coe) f there s a continty ndicating that te coil is gronded replace te armate

16-

ENGINE ELECTRIAL - SERVIE PROEDURES

(e) Mica depth between groove

ead d bh (+) f thee i no contnuty, indcatng an open circuit, eplace the yoe aembly

�Mica depth

(b) o grod tet

�

82563A

Measure. the Mica depth o goove between seg ments I t does not reach the lmt, correct

Sgmn 

�F& Good

�\,qz

D51

Chec that there  no continuty between the yoe and bruh ) If there i continuty indicatng that the coil is gonded chec or poor inulation If epar  mposble repace the yoke assembly (3) nection of Brush

Bad

07598

I the segment ndcates the auty condition a hown ' in the lustaton epace the amatue (2) Inspection of Field Coil (a) Coil open circuit test 1C

a) Meaue the brush lenth and  the measure ment is ess thn the imit replace the brush as a asembly [-) side: yoke assemby; ) side: brush holde assembly b) I the brush is uneveny worn or develops rugh surace, correct with andpaper No 300 to 500 NOTE:

0758

Check that thee i continuty between the terminal 16-24

Correct the brush contact surface to a curve of the commutator.

ENGINE ELECTRCAL - SERVCE PROCEDURES

(4) Inspection of Brush Spring

(6) nspection of Magnetic Switch (a) Coil open circuit test

u

M erminal M temil

D7513A

Measure the instaled oad of the brush spring. Using a new bus read the oad at the moment the spring eaves the bush If the sping tension is below the mt, eplace the spring.

8 erminal

/

S erminal

8256K

Chec that there is a continuty acoss "S and M teminals I thee sn't eplace the magnetic switch

(5) Brush Holder Insulation Test

J

74A

Check to ensure that there s no continuty between the ( +) bush hoder and (- hoder plate  thee is cotinuity, repace the brush holde

Check to ensue that there is a continuity across S and gound terminals.  thee snt, eplace the magnetic switch

1625

•


(7 Inspetion of Overrunnng Clutch

(b) Fused contact check

M erminal (o B temnal)

89608

Check th.at thee is no connuty acoss "B and M termnals If thee is, epace the magnec swch (c) Loose contact test

Insal he gea shaft to the oveunning clutch an check o see if he gea shat tuns smoothy whe uned clocwise (n the drve diecion) and locks when uned counteclockwise If any unusua condon is noed repace he overun ning cuch (8) Adjstment of Gear Shaft Thrust Ga

82578

Cose the conac of he magnetc swich as shown 89648

M eml (or B emin)

In this condon, check ha there s a connuity acoss B" and M" ermnals I hee sn't repace the magnetic switch 16-26

I the thust gap is out of specificaon, nset the adjusting washe into the positon shown [For adusng pocedues refer to Secion 52 (2) (Adjusng washe: 025 05 mm

ENGINE ELECTRICAL - SERVCE PROCEDURE

(9) Replacement of Bearings

b) Repacement of front and rear earin

(emoval)

(a) Repacement of gear bearing

(Removal)

Pes down wth a pes .

eag puer

Cbyolikrca B e a  ng

R e a   e a  ng Amate B6B

0753A

If the bearing of the gea shaf s deective, put a pin o bolt in each of the fo holes (6 mm n diamete) in the interna gear and pess down the bearing out of position with a press. (Installation)

Ie a�,

 , - ' B2962A

Appy a tool pipe to the beaing inner race and hamme t into position

Using the bearng puller emove the beaings from the armatre (Installation)

nstal the rear bearing by stking its nner race niformy with a soft hamme

/�pe '" rnce

m� 

B28A

nstall the font beaing appying a ppe of same diameter as ts nne race and strking it into postion 16-27

•

ENGINE ELECTRICAL - SERVCE PROCEDURE

Reassembl y

5.1.4

Apply grease *1. 14 16 18

Apply gease 2 21

8

4

20

5

J Apply grease •2 j

2

Apply grease 3

6



1

Appy grease *4

13

22

Apply grease  Apply gease *1. Gear NV 01shaftto tust 0.5 gap

N  Nominal ale (Recommended geases) 1: Mystik T-6 (Kyodo Yus or equivaen *2 MUL EMP MS2 (Kyoo Ysi or eqvalent 3 MUMP HD2 yodo Yus o equivalent *4 MOYCOA or eqivalentAS19 (ow Coning

Assembly seqece � 19(}@

'�2

_

fT(l

-6�,1:'®[

6- 7-8 3_ 4  Fo pats wi encircled umber, efe to Reassembly Pocedue tat anfollows D7548C

16-8


9

be•1 grease appliedto

I

be2 gease appedto 17

Ato tbeh appcoatieod t3o outgrease irumeree sde 2

3

N. Nomal ae (*Reommended gea(Kyodoses) Yush) : Myst i k JT6 o equivaleMS- 2 (Kyodo Yush  MULEMP or equivaeHD-t 2 (Kyodo Yushi) : MTMP o equivaletAS-9 (Dow Cog : MOYCOAT or equvalet

5

6

7

19

13

PioMode gap M5T0279 M5T50276 M5T5027

be•4 grease ppliedto be2 grease appedto GeaN 0.sha tto th0rust gap

greaseiedto be2 appl NV 4 ttoo 36

_-'9 20� -   · 67  3  2

l

tFohatpartol sowswth a eirled umber, efer to Reassembly Proedure 89073

16-29

ENGINE ELECTRCAL - SERVICE PROCEDURES

Reassembly Procedure The reassembly procedre or the M3T95082 state s described. On he oher states, ony the dffeences ae descrbed

�Rig -Gea saf Rng goov

(1) Reassembly the Gear Shaft, Overrunning Clutch and Gear Bracket in the Folowng Way

Overuning cch 829

Gea backet Gea saf

c) Ft the ng into he ring goove n he gear shaf

Gease (MULTEMP MS-2 o equivalet)

829598

(a) Coat he porions in gear shaft shown wh the specied geases and nsa the gea backet ad overrunnng cch ove he gea sha

8969A

Pi stoppe

I �.- J

(d) P hard he pnion gea oward he ring a sece it by fttng he ng ino he ring goove i pnon soppe

Gea saft

(2) Instation of Lever (a) Colar fixed type

Fon bcket 8967A

(b) Insa he pnon stoppe to the gea shaf in the decon shown

896C

Insa he eve in he diecion shown ogeher w i he coar ino he on bracke 16-30

•


(b) Pin fixed type

4 Installation of Magnetic witch

Screw Pin

B em

Gese Mgetc swtch (Mystk JT-6 o eqvet

B2956D

B52C

Insert the leve in the diection shown and mount it wth the pi· from outsde the front backet

B tel

 te

(3) nstallation of Overrunning Clutch and Gear haft Oveug clutch

Fot backe

M5

B438B

Coat the porton ndcated wth the specifed gease and istal the magnetc switch to the leve ensug that B temna faces up fo the M3T state and S temina faces up fo the M5 state Gese (Mystk JT-6 o eqvlet)

Oveug clutch

B2955E

B970B

Befoe instang the oveunning clutch and gea shaf to the font backet, be sure to apply the specfed geases to the portons ndcated Upon nstaaton make sue that the leve s wedged nto the oveunnng cutch.

16-3

ENGINE ELECTRICAL - SERVCE PROCEDURES

(5) Instaation o Yoke Assembly

(a) Wire the reassembed state as shown above b Turn ON sitches K and K o project he pnon. c) Turn OF swich K to sop pinion om otang. 1

2

2

Pinion

'r-+l

_ ;, . 1 I -



' : J I,  1

�J - ,lj I I:

rI I

r-

82697A

Apply gr�ase to the spines of the armare beore montng the yoke assemby to the cente backet.

I'

 ,

,

11

1 

non gap

NOTE:

When the yoke assemby and center brack· et are mounted, the ocating notch shoud be aigned with the projection.

M3T9508 M5T5079

  3

515

M5T5076 M5T5077

4 t 6

nspection and Adjustment after Reassemby

(1) Inspection o Pinion Gap

Mode

Nma Vaue

80054

(d) Measre the axal movement (pinon gap) when the pinon s pshed lghtly towad the amate sde

Switch K2 Battery Switc K1

S teminal

16-32

M temia

m


NOTE: 1. Use a wire as thick as possibe and secure each connection firmly 2 Apply voltage gradualy from V up to 24V

Washer Mgntic swc

(b) Measue he curren and oang speed when he specified voltage s apped f he measuremen s out of specification, repace the starer Measue he roang speed by iluminaing the pnion wih stobe ligh B2975B

(e) If the measuemen is ou of specification, in crease o decrease the numbe of washes used a the portion to which magnetc swich is mouned. Washers 025 05, 10 mm

(2) Inspection of No-load Characteristics and Magnetic Switch Operating Vol· tage

Amm Volm Bty

Nomina vaues (No-load chaaceistcs) Modl

Votge

MT



M5

.5

V 

Curn

Roaig sp

10A or 

3 00 rm o or

10A o 

 00  or or

c) Gadually ncease the votage from OV and measue he voltage when he pinion spngs out and uns If he volage exceeds he specificaion, replace the sae Nominal vlue

6V or ls

(tic swih o!  volt)

836218 Ammt Vom B 

B3621E

a Se up a cicuit as shown incudng he ammeter vomete and batery

16-33

ENGINE ELECTRICAL - SERVICE PROCEDURES 5.2

 Y

nspection rocedure

� : "

L termina

S

 a  m , .  l

B

�--1

.

SW

eminal UT07076

L

D8002A

S emina

B temna

Co esstance NV 104  (24V, 20 ) °

D8003H

(1) Check for coninuty between the SW and L termnals an chec to ensue that the co resstace is up to specicaton. (2) Check o ensure ha when he batery voage (24V) is apped across the S and  termnas, there s connuiy beween the 8 and S termnas

5.3 5.3.1

J, 40 80  moval and nstallaton

D8003D

V-be

16-34

B0104H


5.32

•

Disassembly

�-  

    ·  

2

 -       

(1) Rear bracket assembly _ Stator 3 Rectfer @ Recte <80A oy ({l Regulato assembly ® Brush (l Brush sprng 7 Rear bracket 8 Puly and fan @ Pulley @ Fa

Parts marked with • should not be emoved less defects are eviet Fo pars wit a eccled mber, reer o Disassembly ocedre tat ollows.

Spacer 12 Roo assemby 3 Spg *4 Rea beang  Roto ( Fon backe assemby 1 Cover 18 Cover 9 Front bearg ( 2 g Front bracket 1

B3907E

16-35


Disassembly Procedure (1) Separation of Front Bracket Assembly from Rear Bracet Assembly

D8107H

819490

Remove the through bolt and, using a screwdriver, py of the front bracket assembly om the rear bracket assembly.

2. At time of separation, use care not to lose the spring fitted to the outside of the rear bearing (2 Removal of Pulley

NOTE: F

Bearing box

Fot bck

Roo B1029Z

Hold te otor n a vice etc and remove te lley an and ont bacet 81949P

NOTE

1. The rear bearing is tightly fitted Before separation, therefore, preheat the bearing box of the rear bracet by an air dryer to facilitate separation.

oo

102

When holding the rotor in a vice, be sure to hold at illustrated portion 16-36

ENGINE ELECTRICAL

SERVCE PROCEDURES

(4) Separation of Rectifier <80A>

(3) Removal of Stator Coi

Rectifr Stao

B3909A

Sepaae the reciie by nsoldeing he aea shown NOTE

When unsoldering, finish it in a short time (less than 5 seconds) with a soldering iron

To remove the saor coil, unsoder he saor coil eads soldered to e rectifie. NOTE:

When unsoldering, finish it in a short time (less than 5 seconds) with a soldering iron.

16-37

• 5.33

ENGINE ELECTRICA - SERVICE PROCEDURE

nspection

NV

Description Fld coi rsisac Slp rig 

30A, 40A

Approx. 9 

80A

Approx 72  408 o 412

L

40.4

Grou test

Brush sprin pressu NV 0.3 o 0 kg L 0 kg Opn circui s Gron s

NV  Nominl Vl  . imi

83907F

16-38



(2) Inspection of Rotor

(1) Inspection of Stator

(a) Continuity between slip ring and core

(a) Continuity across leads

08130 0858A

Check that there s no contnuty between the slp rng Check that here s continuty across stator leads. If here s no connuty ndcatng a broken wre,

and core f there s, replace he rotor as  s grounded

replace the stator

(b) Field coil rsistance

(b) Continuity across stator leads and core

083 0858

Measre he resstance across slp rngs Repace the Check tha there s conny across he stator leads and core f there s replace he stator as t s gronded

rotor f he resstance s no whn the specfcaton

16-39

ENGINE ELCTRCAL - SRVICE PROCDURS

(c) Slip ring O.D

(b) Inspection of brush spring

D8132C

Measure �he sip ing O.D. If the slip ring has rough surface or is unevenly worn, correct with sandpape or lathe Corecion must be made wthn he limt of sp ing OD (3) nspection of Brush and Brush Spring (a) nspection of brush 7A

f he spng pressure s ower han he lmit repace fC  Q

 3

(c) Repacement of brush and brush spring

E

. C

 

C

C



V

Wear limt n

06A

Replace the brush if it is worn beyond the lm.

76A

1) Unsolde he poston shown n the ilusration and remove the brush and bush spring

, I

16-40


(a) Measurement of diode mounted to heat sink (6 places) Staor coil ead

-: . L:

g

I

82737

2) When soldering the brush, insert a p into the bush hole and fix to the regulator assembly.

NOTE: When soldering or unsoldering, work quickly (within about 5 seconds) with a soldering iron.

He snk B2720A

�I

�

1�=

g -

I

(4) Inspection of Rectifier Measure resistance of each diode Measure both when with the circuit teste (+) probe applied to the diode and when with the -) probe applied to the diode • I esstance s nfnte in both cases the diode is open •  esstance s cose to zeo n both cases the dode is shorted

2721A

easue between the heat snk and stato col lead connections

(b) Measurement of diode trio (3 places)

n the case of open or shorted dode replace the rectifie easure accordng to the folowing pocedures

2722

easue between the plate connectng to the regula to and the stato coi lead connections

16-4

•

ENGINE ELECTRICAL

(5) Inspection of Bearing

SERVICE PROCEDURES

{Installation)

Repace the bearng f defect s evdent

(a) Replacement of front beaing

Apply engn l.

{Removal)

8272A

Cover

Frnt bracket

Frnt beang

Font bracket

82724A

�-1

1) Remove the bearng cove.

83109A

'

Rd n bracke rn bearing nt bracke

1) Appl a ght coat of engne o to the outsde of the bearng and nsta to the nsde of the front bacet sng a pess nsta fsh wth the cover mountng poton

82725A

2) Appy a rod to the spacer on the front sde of the front bracket and strke out the bearng

Spacer nt backe \

Frnt bearng 82730A

) nstal the cover and stre the spacer wth a sof hammer, etc to make sure that the bearng and cover ae n contact wth each othe f not stre the spacer to bng them nto contact

16-42

ENGINE ELECTRICAL

(b) Replacement of rear bearings

SERVICE

PROCEDURE

(Instalaion)

Remval)

Rear bering

Apply gese.

Sig fittig goove

220

82731 D

NOTE: Use care not to cause damage to the slip ring by the bearing puller.

Apply a lgh ca f engne   he nsde  he bearng and usng a pess, nsa wh he spng fng grve f he bearng acng he rr eld cl sde.

16-43

• 5.34

ENGINE ELECTRCAL - SERVCE PROCEDURES

Reassembly

<30A, 40A alteator> 14

Egine ol to be appied to ouide cirumferee of roto shaf

13

3

I 9

135 to 60 Nm (3.5 to 65 kgfm)

5

19

4

6

B290L

<80A alteator> 3

35 to 60 m (35 to 65 kgm)

ge ol to be appled to outde rumfeee of oto aft 5

19

Compoet 1: 3 3A <80A oly> 4 5 6 7 2 3  5 6 17 8 9 20 6 (20  8 7)@ (5 4- j)  8 (  10- 9)  2-  (7 _ ©  6  5   A <80A oly> O ompoet marked o refer to te folowg eaembly proedue.

6-44

B2990M

ENGINE ELECTRICAL

Reassembly Procedure (1) Instaation of Rectifier (80A Aternator)

SERVICE PROCEDURES

Instaation of Front Bracket Assembly nd Rear Bracket Assembly

B2745A

When the rectifers are to be connected ogether by soldering, do the solderng with the regulator as wel as the recfers monted to he rear bracket NOTE:

When sodering, finish it in a short time (ess than 5 seconds). (2) Instaation of Spring

(a) Push n the brush by hand and insert he pn no he brush hoe rom the rear o the rear bracke o ix the brush (b Notng the sprng poston o the roor bearing mounted o the front brace sde, install he rear bracket assembly NOTE

After competion of reassemby be sure to remove the pin and close the hoe

Minimize spring pojectio

D8099E

Install the spring wth ts hghest pon seated in the deepest o he sprng fting groove o the bearing.

16-45


tion and Adjustment after lnion Precautions

the alternator, observe the oowing

084A

c Do ot use a megger or other hgh-votage utimeter or damaged dode ad reguator w resu It D872

ct the battery reversey. of the battery is reversed whe made a arge curret fows from the ator, damagg the dode ad IC

(d o ot expose the aterator to the water f the aterator s exposed to water shortcrcut may resut, causg damaged aterator

D873

:ect the battery terma coec ge s rug or a surge votage )ratg the dode ad reguator.

D86

e Operatg the aterator with ts "B" ad "L" termas shorted resuts  the damaged dode tro

•

ENGINE ELECTRCAL - SERVICE PROCEDURES

2 Whe aduay nceasing the atenaor speed and educng the oad essance measure he curen ale with he specifed termina voage and speed. I the measuement is beow the speciicaion check aternato pars

I / 

Nomnal vaue (when atenaor s cold) <0A altenato> Terminal votg Curent

Rn spd

27V

27V

17A o o

26A o o

1 500 p

2 500 p

7V

27V

6A o o

37A o o

1 600 p

2 500 p

V

27V

39A o o

A o o

1 00 p

2 50 p

D80

(f) When quick-charging the batey wih a quick charger, be sure o dsconnect teminal connections n advance. Ohewise a damaged dode and regula or wi resul.

<40A atenator  o Cu ot spd

(2) Performance Test <80A altenator

(a) Test bench inspecton

n vo C

Ammeter Voltmeter

Ro d

(b) On-vehcle inspecton

Voltmeer B teminal Switch K1 Alter aor �-

Vaiable resitor ' Alternator drive moto

B emnal 3623

R terminal

B3622C

Perfom he tes usng he cicu shown above. 1) Wh the oad resisance se at maxmum (mean ng hat there is amost no load curent f owng), cose swches K and K 2.

) rovide a swtch between he baey and aerna tor "B termina Wih he swich turned of, connec an ammete (wih 60A fulscale o he 30A o 40A aernator and 00A fullscale o he 80A aernaor) and vomee ) Turn on he swtch and make sue ha he votmete indicaes he battey voltage ) Sar up the engne and immediatey un on al lamp swches hen, ncrease he engne speed and read he maximum curen value when he alernao speed eaches 5 000 rpm 67

•


4) If the curen readng is 70% or moe of he nomna output, the alternator may be egarded as in good condition.

NOTE: The on-vehicle test is an easier way of inspection; the test bench inspection is necessary for more accurate results.

b) Onvehicle inspection Vltmete

Amee

(3) Inspection of Regulator (a) Test bench inspection

Ammeter Voltmete

Batey

L temial

1) onnect a vomeer and ammeter and provide  switch as shown ) he rguaor is in good condion if the volmete regisers O when he swich turns ON f the vomete poiner deflecs, the altenaor o wng s defectve ) Wh he ammeer emna shoted to pevent flow of he sae curent through  sart e engine ) ncrease he engine speed o around  000 rpm and ead he egulaed volage value if he charge curren s 5A or ess f he charge cuen is 5A or more coninue chagng or a whie or eplace he baey with a fulycharged one r a / n (5W) resistor may be conneced in sees o he baey o _lmi he chage curen 5) f he measuremen is o of specifcation repace he regulaor assemby

Switch

R teminal 

 temnal /' Aet

L temnal

L eminal

3624C

nspec the eglao egulated volage as foows sng the cicu shown above 1) Use a fully-charged batery Turn on he swich 2) Gadualy ncrease the aernato speed up o 5 000 pm Check that the crent vae a this speed s 5A o ess 3) The egulator is n good conditon f he eguated voltage unde ths condion s wihin specficaton f not eplace the eguato assemby Nominal vaue

168

28  9

625E

•

ENGINE ELECTRCA - SERVCE PROCEDURE

5.4 541

GOA AL TERNATR Removal and Instaation

[Refer to 5.3I

5.42

Dsassemby

1 ,

i

�

�&-

14

.

t

2 3 4  6 7 8

9

Cover Bush hoder assemby Bush hoder Bush Bush sprng End cover Cover Bo se Rea backet

0  2 3 4  6 



Stator Pate Lead we assemby Temna se Connecor Condenser Heat snk se Rea bracke Puey assemby

*9 Puey *20 Fan 2 Roor assemby Roor 23 Rear bearng C} ron backet assemby 2 Cove *26 Font bearng Font backe

@ 

Parts maked * should not be emoved uess anything wrong s evdent On pats marked o. refe to te dssseby rocedure n 532 B4539A

6-49

• 5.43

ENGINE ELECTRCAL - SERVCE PROCEDURES

nspection

Description Field coil esstace Slp g 0.

NV

L

Appox. 13 ! 46

Ope cct test 45.4

Goud test

God est

Bsh spg esse NV 37 N (8 kgf L 2 N  gf)

� B

3

;

Shot test pe test

V  Nmal Vale   t

o he secto ocede, efe to 533 To chec he heat sk fo a shot cc o dsassebly s eqed The sho-cct ca be defed by checkg fo cotty betwee he dvda coecto tea. [Refe o 55J

845398

16-50


5.44

Reassembly

1

16

1

8

7

83 to 105 Nm (8.5 to 1 kgfm) 345 to 360 Nm (35 o 37 gm)

6

27

Componets 2: 3, 4 5 9 11, 12, 13, 15 16, 17 21: 22 23 24 25 26, 2 24 (27  26 25  2 (23  22 -• 8 (20 9)  0  9  1  1 6  15 _ 3  12  11 _ 14  8    6  2 (5  4    B4543A

16-5

• 5.4.5


Inspection and Adjustment after Reassembly

( 1) Simple Procedures for Checking Alter nator from Outside Inspection by Con tinuity Tester Good

Measuring pos

Defectve

F - E

Teste shows cotnty.

No cotty (Brsh n poo contact or el col openccte) Resstace O (el col shortcrcte

N  A

ese shows cotuty whe black s conec1e to N a (re) connecte to A

If tester shows o contuty whe (back) s conecte to N an !re) coecte o A, al o f hree  + oes are opencrcte or stato co opecrcte If tester shows cotty when black s conecte to A a (re) conecte o N ( >) oes are shotccte

N - 

Tester shows coty wen (black) s connece to  an (e) conecte to N

If teste shows o contty whe (back) s conecte to  a (re coece o N, al three () oes ae opencrcte If tester shows contnty whe black s connecte to N an (re coecte to  () oes are sotccte

NOTE: The colors in parentheses show the colors of tester lead rods. All three diodes are rarely open-circuited. Each diode should be tested to determine whether it is good or defective

Load test Icease the load resistance R o a maxmum and cose he swches K1 and K2. Measure the curent vaue when he ateato reaches the specfied seed Nomia vaue (whe altenator is cold) ema voltae Current

Roa spee

Connect

A�F NE

8078A

(2) Performance Test

�.- A

A(dmme e. r SwiK tch ual deflectn){ Botmeer,_I Batey 24V

1-

T

8080A 16-52

28 V

60 A or oe 2 200 rp


5.5

SAFETY RELAY [Model R8T301 71]

Inspection -   ;  ==    ·

bw L d R  ! Res1tanc: 1 V Aprox 200 \! � _J '



S emial NV. ,n ah

814538 Measure voltage at each eminal i he seqence shown below o idetify fauy pas.

(1) O-vehile Test

Squ 

Eg a Sta swic O

tag a ta P" 1   ss • (+ I dd std f s t baty vag 00

.

tag .ats 

ltag a a R  L

terminal

00

00

Tal "R'  A 4      wg s aly Tmal  w ag la)  A   mal  w ag am  A 3   lss   s  bay lag wg  ala s aly

-





Dg akg

3

dlg 6   g

-

 A 13  6 

 A    lss   ls  bay ag saty ay s alty ag mssbl  A bulb c btw baty ad ma S dos not com o   bb ms  ds mal tma  lag sw  l la say lay ad s aga





0

(2) Offvehle Test The esistance vave bewee eminas "R" ad "L" sha be wih specfied age.

16-53

ENGINE ELECTRCAL

5.6

REGULATOR [Model R7T01071]

SERVICE PROCEDURES

PREHEATER

5.7 5 7 1

Inspction

ntake Air Hater

 1) emoval and Installaton [Refer to Gop  Intake and xhaust]

(2) Inspecton

IG F L

#�

A N E

Air heater

84018

State swtch

(6D22, 6D22-TI

OF HEAT 0

N

SAR

() Rgulatd Voltag of Voltag Regulator

Heate elay

Nominal value (between A and E terminas) . 28 to 9V wth atenator at 4 000 rpm Battey overcharged  Votage too hgh Battey dschaged  Voltage too ow

NOTE: Ths rgulator uss a transstor typ volt· ag rgulator, so the regulatd voltage cannot b changd If th egulate vol ag s out of th nomnal alue replac the regulator. (2) Voltag Regulator Rguatd Voltag Masurng Procdure (a) Increase the engine speed unti the ternator eaches the specifed speed (b) Continue charging until the chaging cuent to the battery falls to less than 0 A (the battey fully chaged). (c) Measure the votage acoss the A and E temnas. (d) Measue the voltage acoss the A temnal and the negative terminal of the battery and check to ensure that thee s no dffeence between the value and the vaue measured unde Item (c)

16-54

A eate ndato

f �!\_ y

�  p �-

1v I

Batte

D03C

Perfor the folowing nspection and check the functon of each pat o the wng if necessay (a) Tme requied before ndcato becomes ehot: Stndard tme 40 o 60 seconds (b) heck each temnal of the a heate fo loose ness and the heate eleent fo damage and contact with other parts


5. 7 .2

Heater Relay

5.8

Inspection

AUTOMATC STOP DEVCE

581

Energize,to,stop ype

( 1 ) Stop Soenoid

ClNVeara0.nce4 to 05 Sop\ ' : lever . !

Ampage mrkd

SW trinl

0891A

(1) Check to ensure that thee is contnuty between the terminals "B" and S" when 2.3 A exctng current s apped between termnal SW in the fgure and body earth (2) Chec aso the heate reay fuse and repace wth new one f t has been burnt out When epacng fuses, be sure to use a fuse of specfed capacty



',

PoiNVnte1r5ceoar2ace0

Exe�l I stopper  '



: !( Lock Rod � ?f i n _ \ /

'

- r-

I

u

C �-

�-1 Lock\ u

�l

Oper sideBefaiorge Sop side Sroe 27 to 29 mm Cover Batery atPraCctio Aee atractio (24V) ·  ·cv{) Amme e r I V 5A or ess HC HC I

I

P.C



B412B

(a) Connect the stop ever and soenod usng the od and remove the solenoid cover (b) Push manuay the stop ever to the stop postion and adjust the rod so that the soenod ponter gap becomes as specfied (c) Chec that the stop eve to externa stoppe cearance is as speced when the stop ever is on the opeation sde (d) In the state of (c) above appy specfed votage to soenoid B termna and chec that the ponte gap and ammeter readng ae as specifed (Stop ever stop side) (e) Tghten the ock nut o the od () Check that the soenod ponte coo has not changed and then insta the cove

6-55

•


(2) Solenoid Relay

Ate the tests o the above items ) and 2) allow 5 mntes beore making etests It takes 5 mintes beoe the capacto C 1 whch is an eement o the tme constant o the oi pesse tmer nishes dschargng

(a) Unit test Terminal votg Oi psure Licr

Soenod eay

easrement

DC 28.5V

E

So i e

DC 24 V

B

C

S

W

A

t SW©

nl vl DC 85 

Soe or i oad 30A -, A

SW SW ON O pssue

SW@

18  5"

e

SW 0  5"

Sp   she spo f sybol SW : Snp sw A SW  Sp sw  SW : Ps swt C

D9558A

Make connections as shown above and peom the ollowing checks.

1 J Oi pressure timer Set the snap swtch A to ON Opeate a stop watc as ,soon as the snap swtch Bs set o ON and measure the time reqed beore the soenod s opeated

2) Stop timer Set the snap switch B to OFF 5 seconds after the solenoid has been operated At the same time sing a stop watch measre the time reqred beore the solenod is reset The snap switch B is set to OFF 5 seconds afte opeation o the soenod becase f the solenod is operated it takes 5 seconds beore the alternato voltage disappears

3) Manual stop timer When the psh switch C (stop switch) s set to ON the soenoid wi be operated. Operate a stop watch as soon as the stop switch C s set to OFF and measre the time eqired beoe the soenod s reset

16-56


•

(b) On-vehicle inspecton Check the soenoid relay accordng to the oowing fowcharts and detemne whether t is good or not on the basis of the termina votage, etc. measured in the indivda states • •

The termina symos denoe those of the soenoid eay The votage 24V means the attey votage

TuringOFFeobaery wch1-K 24 Iavaable voage a fo ON acuaes te oleod. A emna/ Yes I Aeao defecve

o

Ege caoby beop toppe wch

24

 Sop wtch defecve

Soeno eay    defecve ov

Measur va a ST > trminal

, 24V  Sop wch deecve Soeo eay    efecve OV

  Soed defecve

Pror ass wh g rg.

Engneeperae oe no opgwt waer an o preure ow

v

 " efecve Soeno reay  Teo wchwc or oefecve preue

Aernaor defecve

Soleod  oaferforced oha OFF ae ope ee

Soenod eay defecve Soeno efecve

Sop wch efecve

Aeao efecve

rf sts wt g rg

Soeno eay  � efecve 

Soeoengne opeate whe is runng.

Soenod efecve

Sop wch defecve

 oa opeaon Thero wtcwc o oa epog oeecve peue o abnoa wae epeae o pee o

16-57

•

ENGINE ELECTRICA - SERVICE PROCEDURES

Conect the pipes as shown above close the cocks A and B and stat the engne Ater the o pressure has rise fuy open the cock A to ead the o pressure to the oi pressure swtch Then cose the cock A to shut of the i passage to the egne and hod the ol pressure directy n the oi reservo Sowy open the cock B to ower the oi pressure and check the o pressure swtch operatng o pressure wth the test ol pressure gauge

(3) Thermo Switch

Item

NV

Opraing 93 o 97"C eperaure ON-OFF dfece

NV .

Tepmeaesesig portio

7 C °

(5) Ol Pressure Swtch Relay

Nomnal Vaue D959A

The ther�o switch won't operate if the temperature sensng portion is not n contact wth coolant. If the cooant leve s low or f there s ony steam, the thermo swtch wont operate competely mmerse the temperature-sensng porton in water heat the water and check the thermo swtch operat ng temperature with a mercury thermometer Heat the water graduay wh the temperaure approaches near the operatig temperature

Whe volage s 24V Item Co essae Mmm oeag voage

NV 90 o 0

n

6 V

0 NV Nomia Vale

(4) Oil Pressure Swth Enge o pesse gag

esg o pesse gage

Cock A

l 5 t

"'  0  ' Q

O eservoi

O pesse swh

u

"

J�-- - t  "  . r . :  UC O

Cok B 960A

Opeatg presse NV 69 o 98 kPa (07 o 10 kgf cm') o ess

NV Nomnal Vae

956A

16-58

96

(a) Check to ensure that there s contnuty between the termnas  and @ (b) Check to ensure that there is no contnuty between the termnals  ad  (c) Check to ensure that there s contnuty between the termnas© and® and that the co resstance has a nomna vaue (d) Check to ensure that when the battery votage s applied across the termnas  and ® there s contnuty between the termnals  and 0 and no contnuty between the termnas  and @

ENGINE ELECTRCAL - SERVICE PROCEDURE

5.8.2

Energize-torun Type

(2) Soenod Relay (a) Unt test

( 1) Stop Solenoid

Cleaance NV 04 to 0.5

Eh �

Pointer ceaance NV 1 to 20

8

Wl

Sop eve

Exenal soppe

Opeatng sie Stop se

oc nt

24V

 ' B emia

SW3

S

Delay time NV 26 to 4 sec

SW2

Solenoi o coil loa 3A ± 3A NV  Nomal Vale

-  

09564A

L.

Stoe 27 o 29 mm - Cove Befoe atction Afe attacton C C

�1· I

'

·'

Battey (24V)

0

H.C

H

-,  Temal volage

Soleno

 Lock u  Rod

C

HC

Ammete NV 1A o less NV  Nomna Vae 84121C

(a) Connect the stop lever and soenoid usng the rod and remove the solenod cover. (b) Push manualy the stop lever to the operaton positon and adjust the rod so that the solenoid pointer gap becomes as specifed. In this sta te, also ch�ck that the stop lever to external stopper c earance s as specfed (c) n the state of (b) above, apply specfed voltage to solenod "B" terminal and check that the ponter gap and ammeter reading are as specifed. (Stop lever operaton side). (d) Tghten the lock nut of the rod (e) Check that the solenoid pointer color has not changed and then install the cover.

Wre as shown and check the folowing. 1) Reay operation and deay time a) Check if the solenoid s energized when switches SW and SW2 are turned ON b) Using a stop watch, measure the time requred or the solenoid to return after switch SW2 is turned OFF ) Reay holding a) urn ON switch SW and SW2 and after the solenoid is activated turn ON the switch SW3. b) Turn OFF the switch S2 and make sure that the solenoid remains activated for more than 4 seconds c) After verifying ) above, turn OFF the switch S to ensure that the soenoid returns

16-59

m


(b) On-vehicle inspection Check he solenoid reay accodng to he folowg fowchart ad deeme whether t s good o not on the bass of he termnal voage, ec. measued  the dvdal saes • •

Temna symbols denoe hose o he soenod eay Voage 24V meas he baey voage

Tuning the battey switch (o key swtch) from OFF to ON actuates soleo.

 -

'-

OV



-

Soenoid relay

      defective

Battey switch (or ey switch efective o miswred

Soenoi oes not opeate when key switch is set fom ON to SAT

Is vol tage 18V o moe avaiabe at s emina wt key swtch at SAR

Check battey.

No

Battey efectiv

N ov

Soleno elay efectve

Soeno efective o s thee swed N cotinuity between emegecy > -            Emergency switch switch emi efctiv als?

I Soeoi opeates whe ey swtch s change back fom SAT to ON

s votage 8V o moe available at S

N

I Battery efective

16-60

Yes Wng efecve

  >

� Soleo eay        efectiv

•


Pefo esemns w g n e dosea ot sop wiEn thwer ow. d ol essu

e does ot swso wOF heeey

V/ Ms' voese e�: H ; votett S - I 24V 2 T sw  ch o Ky sw t   de eve odeet  ss sw    ve /�

defoeeovde ey

ov

./

ese vo1 t  B I oenod deetve



I oeod deeve 



 defoeeovde ey



Peo esees w ee  W s o , soOFFeoese desdfeoed ee sos

deoeeovde ey oleod defeve

deeeny v swt

 ooe o sw o No esod oeo swesse o bo we eee o  deeve o esse

16-6


(3) Thermo Switch

(4) Oil Pressure Switch

Im

NV Oeang 93 o 97 C emeraure ONOF 7C dffence

Eng ol resse gage

ng ol rsr gaug

°



Temprate- � sensing oron

NV . Nomnal Value

Ol esevor Ol ssur swch

Cock A

Cock B D9560A

D95598

The thero switch won't operate if the temperature sensing poon s not in contact wth coolan If the cooant eve s ow or if there s ony steam, the thermo swtch wont operate competey. mmerse he temperature-sensing poron n waer heat the water, and check the hermo swich operat ing temperature with a mercury thermometer Heat the water graduay when the emperare approaches near the operatng temperatre.

Oag ressure NV 79 o 115 kPa (08 o 2 kgf/') o less NV . Nomnal Value

D955A

Connec he pipes as shown aboe, cose he cocks "A" and "B", and sar the engine. Afer te o pressure has risen fuy open the cock "A" to ead the o pressre o he o pressure switch hen cose he coc "A o sh of the oi passage o the engne and hod the oi pressure directy in the oi reseror. Sowy open he coc " to ower he o pressure and chec he o pressure swch operating oi pressure wih he est oi pressure gauge

16-62

ENGINE ELECTRICAL - ROUBLESHOON 6. TROUBLESHOOTING

Sympom Ste w  str.

Prbabl

raus1�

 Dftiv y o lnw capciy l

I

!

·-

Remey Repe or ge

Re gop

Defv wg

. v ev . ev . ectve •

st w

Core

stt  w m swth w h  wg

eev tt swh wg eeve by or btery wt w etve m wch etv st  I Wo. dmgd. dng sh I eve t eeve v u eetve ete ey eeve s wt ss  P t ms wt g ge Se  does o noe voge t mg sw S em It voge  t ey SW tmn Wo o dm  Wo o dmge   •

•

I

•

•

•

•

Repe Repe tu o yoke Repe

Repe sesw ey o se Repe Repe

Gop 1

P mhs wth   but d   •

eetv btey o ow pty

.

  

•

v v



Low V-e teso mged Ve eeve wg eeve no w eev ey Bey s om eeve eo  s ove Open   so o dsged o o nd oe gonded p ng d oo oe gonded eeve ed o Wo sp ng Wo s eeve s spg eeve t eeve egto Aeno s nong nomy  ey s ovedsged

•

•

Cge o epe Repe s s spng o Rep Adjs Repe

Gop 4

oe Repe Repe

•

•

•

•

•

•

•

•

16-63

ENGINE ELECTRICA - TROUBLESHOOTNG

Symptom Chag amp do not come on wen engne  topped (tate wtc ON

Proable cause Defective gato

Dctv atenato (ee "Battey  noma u  mat o of ovedcagd) atty ctoyte. Hgh attey eectoDefectv egato yte tepate Engn  ad to tat

Repac

Repac

Defectv wng •

Defectve a hat wng

•

Defctv eate eay wng

•

Defectve wa tmpeate eo wng

Defctv eate ay o own fe

16-64

Remedy

oect

Repace

Ref gop

CLUTCH CONTENTS

...

2

2. SPECIFICATIONS •••.•••.••••••.•• 3 SERVICE STANDARDS .••....•........ 3.1 SERVICE STANDARD TABLE •. 32 TIGHTENING TORQUE TABLE •. 4. SPECIAL TOOL ••.•.•.•..•..•.•••••••. 5. SERVICE PROCEDURES •......•. 5.1 REMOVAL AND INSTALLA· TION ..............................

3 3 3 3 4 5

1 GRAL

52 CLUTCH PROPER ... 52.1 Disassembly and Inspection ........................ 5.2.2 Reassembly and Adjust ment ......................... 53 BEARING CASE ................ 5.3.1 Disassembly and Inspec tion ........... 53.2 Reassembly .. 6. TROUBLESHOOTING ........

1.................

5

7 7  2 2 3 4

CAUTION: When servicing clutch assemblies or components, do NOT create dust by sanding or by cleaning clutch parts with a dry brush or with compressed air. (A water dampened cloth should be used). The clutch disc contains sbestos Fibers" which can become airborne if dust is created during service operations Breathing dust containing Asbestos Fibers" may cause serious bodily harm

21-1

f

CLUTCH - GENERAL

1. GENERAL

Release ever suppot

Ctch disc

Pesse pate

The clutch is a dry snge disc type which transmts and disconnects engine power through the clutch sht sha. When the operaton or cutch dsengagement is perormed, the cutch reease ever is pushed Snce the clutch release lever pivots round the reease lever pin in the release ever support provded in the cutch cover the pressure sprng is compressed causng the clutch dsc clamped etween the engne lywheel and pressure plate o become ree and cuts transmssion of power. When he operaon or clutch engagement

21-2

Sap pae

E0754A

is perormed the pressure spring orce causes the pressue pate to press the clutch dsc against the engne ywheel to transt power The cutch conssts o a cutch dsc pressure plate and reease ver assemly he cutch dsc has a wove acng he drive system is the strap drive type which uses a strap pate between the cutch cover and pressure pate to couple them Ths system insures smooth engagement and dsengagement o the cutch.

m

CLUTCH - SPECIFICAIONS, SERVICE STNDRDS 2. SPECIFICATIONS Clutch [Opion] Itm

Spifion ·- -



-

1622

Cutch



Dy sngl ds oil sping typ

Dry singl dis oil sping yp

Modl

CW4 o CW43

CW4

Wovn

Wovn

0.. x  m

 x 5 o 4 x 25

Typ

Baring cas



62-, CI

Type Mat

Fng

--�  -

4 X 25

Diopld yp

Mod

PC2

3 SERVICE SANDARDS 3.1

 T TBL

Uni: 

Dsipion

Li

Nominal value

!Bsi dt Ct d

Coion nd eks

Dpt fo ing sf to it d

 o 28



Rpl

lnss

6 o ss



Rp

Ltl unout

. o ss



Rpl

Vt uut

CW4

 o ss

C2W4

 o ss

5

y n t dton

6 to  95

42

Rpl

CW

9.5



Rpl.

C W4

92

-

CW4

 25 o  25  26 o 5.4 kg

 7 N 9 kgf

CW4

 45 o  5  45 to 6 kgf

 2 N 9 kg

CW4

5 o ls

5

C2W4

2 o lss

4.8

nss of ton suf

5 o lss

2

Co o p

iknss

59 o 59.9

568

Rpl

2 o 2

25

Rpl

Cln wn s l pin nd sing

2 6 o 5



Rpl

Cln bwn sp pl nd sp bol

2  o 



Rpl

Rs v ig Dinio o l o op sf)

65 o .5 Diffn ong fo vs  o lss)



Cln bwn ls fok s nd ndl ol bng

  o 8



 ng

Pssu

spng

nstld lod (nstd ngt 6)

Sping sqnss n  lng s) Pss p' 

Sp bol fing ol

2

Rpl

Rpl

Adjst

Rpl

TGHTING TQU TABL Dsipon

d sz   Pi 

gning to N kgf

Sp bo

M  5

9 o 49 4 o 5

Lok p onng bolt

M  5

98 o 5  o 5

Pss pl nd  ssbly oning bo

M  5

 o 49  o 5)

Bing s ontng ol

M6 x 2

4 4 21-3

f

CLUTCH - SPECIAL TOOL

4.   Unit:m Tool ame Cutc algmet abo

Part No.

Shape

se

0376-21000

lmet o ltc dsc a italatio

E001B Clutc stalle

MH06133

Removal ad tallatio f clutc ove

E0007A Cltc leve alge

MH061330

Adjtmet o elease eve egt

37 ±

lai wase

43503900

toe bolt

435039100

eele olle beang nstalle

21-4

445901600

Remova ad installati of tc oe

�

55

M10

x

1.2

30

E0005B Istalatio o needle oe beaing o beang ase

f

CLUTCH - SERVICE PROCDURS

NOTE: 1 Before removing the cutch, be sure to install the stopper bolt and plain washer t prevent the strap plate from being damaged 2 Use the stopper bolt (M10 x 125 - 85 with effective length 30 mm or more and plain washer (for M12 threads) commercialy availbe


5.1


(1) Removal �- -



--



(2) Instalation ,-  

l�

o

3

Pa nu saped  Cu d

1

Flywhe -� 1. Bearing case assembly 2 Pressure plate & leve assemby 3 Cutch disc assemby E0755A

Cu Agme Ab 03620 087

(a) Instal the clutch disc usig the special tool Cutch Alignent Abor

NOTE When instaling the clutch disc make sure that it is installed in the correct direction install it so that· its side with the part number stamped is visible Cluth Alignmen Arb 0376-1000

Plai wase (4 paces)

19B

When removing the pressure plate and ever assemby, secure the pressure plate with the special tools Stopper Bolt and Pain Washer Beore removing the pressure plate and lev er asse by nstal the specia tool Clutch Algnmen t Arbor to prevent the clutch dsc fro dropping

Spe  4 laces: M0 x 1.5)

Kk in O9B

(b Secure the pressure pate of the pressure plate and lever assembly with the stoppe bolts then instal the clutch aligning t with the knock pins in the flywheel

21-5

f

CLUTCH - SERVICE

NOTE: 1. Before installng the clutch, check and clean the flywheel and repar or replace s necessary 2 Tghten bolts evenly, n the dagonal order 3 After nstallaton be sure to remove the set bolt

PROCEDURES

(d) Adjstment after nstallaton of clutch and bearng case

(c) Inspecton of release lever heght

ClMH061330 utch Lever Aligner E756A

Reease eve \ Suppot ut Cluth cve

E0421A

Usng Clutch Lever Aigne (specia too), check he heighs of the cutch cover and reease eve. Use the support nut or adjustment

21-6

The clutch should be set in the os worn posion as wear of the cuch disc during sevce causes the cluch to slp ) Move he leve n the decon that the clutch engages At a poston whee a clck s heard in the clutch tun the adjusng bol A untl i is blocked by the soppe and lock i by tuning down he bot anothe wo or hee threads. 2 Fo the poston whee the eease beang has ouched the release ever, turn the adusing bot Bn he decon tha the cuch dsengages check to see that the clutch s n disengaged postion, and hen lock the bot.

CLUTCH - SERVICE PROCEDRE

5.2 52.1

f

CLUTCH PROPER Disassembly and Inspection

DeNVLph20t..o22 roiv2.8had r-1 II Cl1NVrcaHOn e0d6tofo hub195sp Lj- 047  FLlaaesalsu0no.6 1l2or�    J VNVca11 20ols (C102W431) NV, 12 2t1go 12l22 NV0s0 or le  L 1  12  Th ckes2  NVL 68 o . s10taW 41oa (C12aWl 43loa (NVal1(1220l6ooh1136323.4 kNf NVsal1(1442loo16h10632 0Nf Lr l0h0 N.10 kf FLe e120h N21(1 2 f SqaNV3e2 so  SaNVL r3428 o l VNBeaa0c20e12 foom0.1a la L 0.3 alNVBasa02.c0h6bo w0  L 03 NV·B LNomam DaaVamele r·-- 

f

or or

-

1

13

5

6

Cutch disc assemby Srap bo ° !J  Lock bo Lock pae ( Suppor nu (6) Cuch cover wih stap pae) ] Pressure spring 8 Spring sea

 



10 1 12 3 4

4

3

Reease eve pin Reurn spring Reease ever suppor Reease eve pin Release lever subassemby Bushing Pressue pae

 Pooaswah afolcowl e f o Dsas mby  sco

NOTE: 1.

Since the clutch cover and pressure pate are ba-

2

ance, make alignment marks before disassembly Do not remove the strap plate.

E0A 21-7

f

CLUTCH - SERVICE PROCEDURES

Disassembly and Inspecton Procedure

(2) Inspecton of Clutch Disc

(1) Removal of Cutch Cover

(a) Facing wear

Strap bolt

-�

Depth to rivt had or cp ha

1r Stopper bot (4 places)

E0860A

(a) Compress the pessure spring wth the stoppe bolts and, at the same time, remove the strap bolts support nuts and othe parts. Cluth Installr MH06133

r:

Assembl tikss

E069

Measure the assemby thcness of acing and the depth from facing surface to rivet head or cup head If the measurement is below the lmt, repace the cluth dsc assembly (b) Flatness of clutch disc Dial gage Clth c

Align stoppr bots with plate holes. E0443A

(b Put agnment maks on the clutch cover and pressure pate Compress the pessure sprng using the specal tool, Clutch Instaler and at the same time remove the stopper bolt c) Gradually loosen the handle of Clutch Instaler to remove the clutch cover

21-8

Sface plae

E0695

Measue the flatness of facing surface f t is beyod the limt correct or repace

CLUTCH - SERVICE

(c) Clutch disc runout

f

PROCEDURES

(3) Inspecton of Pressure Plate (a) Measurement of thickness

E696A

Pressue plate 0438

Using the runou ester, measue the cluch disc runou If e measuemen exceeds specicaon corec or epace the cutch dsc.

Measure the pressue plate thickness and  i is below he lim, eplace

(d) Splne play n turnng drection

(b) Measurement of flatness

697B

Usng a pano wre measue the pay in he urning decon of the clutch disc hub splnes and bearng case cuch shaf I he m s exceeded eplace the cutch dsc

43

Measue the atness of he pessure pate ficton suface Regind or repace if he mi s exceeded

21-9

f


5) nspecton o Pressure Spring

(c) Strap bolt fitting hole I.D

Strap bol hoe

Squass

Psu sg E044A

Measure. the 10 or strap bot fittng hole n the pressure pate and, f the mt s exceeded, repace

(4) Inspection o Release Lever

Ras v

Reease eve pin

0441A

Measure the reease ever pn 0 and bushng 10  Repace  cearance exceeds speccaton

21-10

E487A

Measue the free ength, squareess, and nstaled oad of the pressure sprng If the measurement s beow the mt, repace the sprng


5.2.2

m

Reassembly and Adjustment

14IJY12 ]-,190 a .�765432 · 

Fo parts with n enled nmbe, efer t Ressembly Pee t ws.

E0754B

Reassemb Procedure

(1) Whenever the pressure plate ricton suace s coected, nset adjustng washes of thckness equvaent to corecton amount

coretion amou

Adjsng wsher ickess

Less ha 1

No eqe

 o moe nd less h 2

Oe .2

2 or moe ad ess ha 3

Two 2 o one 23

Fiction suface

(2) To nsta the clutch cove agn the agnmen maks ad, usng the specal too Clutch Instaer, tempoary tghten the stoper bots.

1-1

f


Cth ver Agner MH061330

Stopper bolt E0860A

(3) With he pressure spng compessed by he stopper olts, nsta the strap ot suppot nut and oher prs. 5.3

4 After nsang the cuch check he cutch cove and eease eve or hegh usng the speca oo Cutch Leve Agner

BEARING CASE

531

Disassembly and Inspecton

BD ... Basi Diameter NV Nomnal Value L  Limit

Cutch shifter *2 Clutch release beaig 3 Retur sprig 4 Stopper pate 5 Stoppe

eaae BO  mm NV  to 8 mm L 2 mm

Rotag coditio, wea, damage, ezue

6 Cutch reease fork shaft 7 Cutch reease ork 8 Dive shaft fot cove

9 10 11 12 13

Oil seal Clutch shaf Sap rig Ball beang Beaig case

14  seal *5 Needle ole 6

bearig Cutch housig

NOTE:

Parts marked * should not be removed uness they are to be repaced. E76A

21-2


5.32

m

Reassembly

/

Apply sealan THRE BOND 1102C or equivent �

 ·



< Assemly sqence>

Fo parts wih an eiled me, efe o Resebly Proede  oows. E0761A

Installation of Needle Roller Bearing

Using special too, the Neede Roer Bearg Insae, insal the neede roe bearng  he housing. The eede oer bearng shoud be pressed in p o the specified dimension with the oi sea side iard and the inscrbed sde ow ard NOTE:

When installing the needle roller bearig, direct the lip n the correct drecton Needle ole eaig Iied side (ds seal sde) eedle Rolle eaig salle 44590-12600 eedle ole beang

aig  dieio Ds ea �/;;

3 o 5 E02

21-3

f

CLUTCH - TROUBLESHOOTING

6. TROUBLESHOOTING Probable cause

Symptom Clutch drags when dsegaged

Remedy

Defectve clch prope (Disassemble d check cch assemy)

. .

Damaged or poorly lbcaed plot beag Damaged release bearg

•

Ueve hegh o elease leve or ts damage

•

Deectve clutch dsc

•

Damaged or deformed cltc dsc

•

Replace or ubrcate Repae Adjst heght o replace Repace

• Wor or rsty spes ad cltch dsc hu Dsoed o damaged ressre pae

Repace or epar defectve parts Grd or replace

Dstorted or damaged flywhee Cltch sps

Ref group

Gop 11

Defectve cutch prope Dsassembe ad check cch assembly.I •

eve heght of eease leve

Adjst

•

ressre sprg losg proper teso

Repace

•

Defectve cch dsc

Replace

• Wor facg •

Deormed cluch dsc

•

Hadeed facg

•

Ol o acg

•

Dstoed or damaged

Remove hadeed suace o replace Remove ol or replace pressue

plae

Grd or repace

Dstoed or damaged flywheel Cltch s o smoothly egaged

Defecve cltch poper Dsassemble ad check cltch assembly •

Deectve cltch dsc

 Dstored acg •

Hardeed acg

•

Loose rvet

•

Ol o facg

•

Bdg clch dsc sples

Replce Repce Remove hadeed suface or replace Repace Remove ol or replace Correct or lrcate sples

 Cuch dsc oso sprg losg prope teso or broe

Replace

 eve heght of release leve

dus

•

essure sprg losg pope teso

 Dstorted o damaged pressre plae Dstoed or damaged flywheel

21-14

Grop 11

Repace Grd or replace Grop 11

m

CLUTCH - TROUBLESHOOTING

Symptom Ch is osy w sngg

Pobabe caus Worn. damged, o pooly brtd pilt hi19

Rmy

R. group

Rp or ubrit

Wo, aa, o pooy ba a bi Dftv  s •

.

Won t s sis Cut is toso spg osg pro sio o okn

Bt stp  C s osy  ggig

Rp

Rp t ov

v ut s •

t is orsio sprg osig popr nsion o o

•

Wo t s b spins

Rp

Wo sps o  s

Rp

ss spig osig propr sio

Rp

Low i sp

Ajst

Gop

1

21-5

m

SPECIAL EQUIPMENT CONTENTS

1 GENERAL •••.•••••••••••••••••.••••••••• 2 SPECIFICATIONS ••.••.••••... 3. SERVICE STANDARDS ••••••••..• 31 SERVICE STANDARD TABLE •.• 32 TIGHTENING TORQUE TABLE . 4 SPECIAL TOOL ••.•.••••••.•.••

2 4 5 5 6 7

5. SERVICE PROCEDURES ... 8 5.1 AIR COMPRESSOR ... 8 5.11 Removal and Instalation •. 8 5.1.2 Disassembly •••••.•••••.•... 11 513 Inspection and Correction ..••. 14 514 Reassemby •••••.••.•••••..•••..• 19 52 PRESSURE GOVERNOR ..... 22 5.21 Disassembly and nspection

5.22

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

22

Reassemby and Adjust· ment

.............

23

61-1

m

SPECIAL EQUPMENT - SERVICE PROCEDURES

(2-cylinder TypeI

Cracks. 23 scratch

4

Cracks wear of busing, clogged ol hole 26 Damage o cirle, wea

1

Cack we

I

30

:�28 Dmage of circle. wea �_ 27 !

9

Wea damage

akhaft d pay L

1.0

L

i

1 2 3 4 5 6 7 8 9 0

Sensor pate Ijeco pump gea Coa Cyde head Sap rg Uoader vave Vave spg Vave gude Valve hode Sprg hode

eivey vave pg evey vave 13 eivey vave sea (_1 Scon valve hoe 15 Scton vave sping 6 Scion vave 7 Scon vave sea 8 Cyder er (19) Copesson ng ; o ( Oi ng 11

21

12

22 23 24 25 26

27 28 29 30

Sap g Pisto p Pston Beag hode O sea Conecg rod Coecng od cap Coneco rod bearg Cakshaft Cakcase

For ars wth a ecicled ber reer to Dsassembly Procedre ta folows 09253A

he procedures or dsassemby of the 1 ad  cylnder types are much the same. So oly the 6

pocedres o dsassembly o the cynder type ae descbed below

SPECIAL EQUIPMENT - SERVICE PROCEDURES

•


959 D9257A

(1) Using Suction Valve Too (specal tool, remove the suction ave hoder o the bottom surface of the cylnder ead and remove the sucton valve sprng sucton vave and sucton vave seat

NOTE: Since the suction valve holder is staked by punching, do not attempt disassembly un less trouble is evident.

2) Using Piston Ring oo speci too remove the compression ring and ol rng rom the piston.

NOTE When a piston ring is removed do not widen the open ends of the piston ring more than 28 mm for 1-cylinder type and more than 26 mm for 2-cylinder type

6-3

m 5.13

SPECIAL EQUPMENT - SERVIE PROCEDURES

nspection and orrection

(1-cylinder Type]

Tenson oad/ naed engh NV 45 N 046 kgf/95  36 N (037 kg/ 95

Tensio

oa/staed engt NV 44 N 0.45 kg)/ 5  35 N 036 kg/ 5

Ceaance BO 85  Top 02 Skirt 0.18

Pton ring groove to compeion ring cearance  008 on rig open end cearance  0

Cearane BD 18 L 008

Ceance BO 18  0 Connecting rod ed play L 0.5 Cearance BO 34  0 eace BD  L 01 Caka e ay 0 

BD  Basc Diamee NV omina Vaue  mit

95B

61-14


•

(2-cylinder Type]

Tension Load/ntalled engh NV 4.  1046 gf/95  36  1037 gf/95

eion Load/ialed leng V 44  I045 g/ L 3 N 036 g/

Ceaance BO 80 L op 02 Ski 08

Ceaane B  L 008

Connecing od end pay L 05

Ceaane beween pison g and pio ig goove L 008 Pon rng open end leaance 0 L

BD  V L

Bac Damee omina Vaue Limi

9B

61-15

m

SPECIAL EQUIPMENT - ERVICE PROCEDURES

(1) Piston and Cylinder Liner

(a ease e cearance between the pisto ring gove and compesson ing  he clearance is over he imi eace e comresson ng or piston.

NOTE: Measure the clearance all around the piston Piston measuring directio

Mesuring positon

Cylnd in ms e

asing position

D9266A

b) Fi e son ing ove a sandard gauge o new cynde ne and easure e open end ceaance.  te earance is ver he it elace the piston rng D9264A

Measure the cylinder ine inside diamee and pson top and skirt outside diaeter and calculae the cearance. If the clearance is over the lmt, epace he piston o cylinder line 

NOTE: Push the piston in and measure the clearanc with the piston ring in horizonta potion (3) onnecting Rod and Crankshaft

. (2) Piston Ring Msung ositon

Merng iecon

E

D9267A

D9265A

61-16

a Cacae the clearance ro the pison pn out side daeter and connecting rod small end inside diaeter.  the clearance s over he liit epace he pison pn or connecting rod

m

SPECIAL EQUIPMENT - SERVCE PROCEDURES

[Crkha Measuing posto

M.sg deco

 Measre he canshaft jounal ousde damee an earng nsde damee and calculae the cear ance I he ceaance s ove he lm replace pars E play

!Cg  bg Mrg o

09268A Marg poo

927A

d) Measue he end play n the connecng od and cranksha and, f the play exceeds the mt, replace he connectng rod. (4) Piston Pin 413A

(b) Measure the diamee of connecng rod earng sldng secon. f the dameter s smalle han he mt, replace the cankshaft Repace the connectng rod bearng f he platng layer on s nner surace s worn out and copper color mea appears

Measg posto

Msg o

E 971A

Mg 

Measue the pston pn outsde dameer and the pn fng hole nsde dameer of he pston and cacae he clearance f the mt s exceeded, epace the pston pn or pson.

969A

61-17

m

SPECIAL EQUIPMENT

(5) Unloader Valve Assembly

If the unoader valve in nloader vave assembly s bady wor, repace e oade vave asseby.

Snap rig� Uloade vav- t Vave spg  Vav u D9272A

61-18

SERVICE PROCEDURES

•


5.1.4

Reassembly

(1-cylinder Type]

9(80 too11512Nm kgfm)

9( 8 0 512Nm 9 8 o 115 Nm kgfm) 9 � 0 o 12 kgm) 10 15

6 "�

�

(1 55 o20Nm o20 kgfm oAysengine oi

11 /

4

Apl y 0.2NDN03ejiccLockof THREEBO T1323eads or equivaen o hree 1

2152( 2 Nm kgfm

5

23(23 oo225 Nm 6 kgfm)

/' 1414 o18o1Nm 8 kgm 31

30

29

28

31 &'@252 2 2322  1 9_ J4 3   1 32108171  69 -  gFovenreassemb n he foy ofowarsng wih an encirced number, see ocede

B3256C

61-19

m


[2-cylinder Type]

98(0 toto 15 Nm 2 kgfm)

4

9

Aply 0.2 to 03 ccPain THREBOND Lock 323 to thee threads 98 to 5 Nm 8 ( to 2 kgm) 5 6

:�19

12

20

13

5(.5oo2020Nmkgm)



Apply engine oi o lip

4(4oto88Nmkgm

15

25 Nm (22 kgm)

ocaing pin

Ben loc wah 26

27

28

9

30

3

2

1

2323too2526Nmkgm)

3+29242527�2322-2 83•: ,  3 2-  -  0+98 _&5 6 5 J For eassmbly f ps with n ncrcld u,  pd givn in th ollwig.

N27538

61-20


m


Fcp t ts '<.)• :r    g 2nd, <2-ng 3rd copresson L� cylndr> Ol rng 23Nut(2 3toto252.6kgfm) < SOidd_le rrnggg -h/ Bend lock washer 2nd copesson .- t_ rng eds Agmn aks Appr o Appox / /jk  2" Pos t  o n no c h  n o  ad 0 1 te conctg od cap d �

(1) Assembly of Connecting Rod

1_t com presion

Connect rod ing

-� 

cylinder>

/

120

83259A

Make sure th'at the alignment mak on the connecting od s aligned with hat on he connecting rod cap. (2) Installation of Piston Rings

Jr

(

) 0\, ·/: � �rox

3endsd coprsson rng \\;\  s t copr e ss o n ng eds Sendsde Oilrgrng ends Sendsde rng <-cyndr> -cylnder

N44D

Make sre that he right piston rgs ae insalled a the righ positions and heir sides with letters samped face p Keep the compession ig eds 120 apat rom one aoth; place he oil ring ends at the cener between he eds of copressio ings place he side ring eds 45 rhe away o the righ and let fro he oi ring ends °



\

�-

�

0929A

(3) Installation of Sution Valve Holder

6-

m

SPECIAL EQUPMENT - SERVCE PROCEDURES

(4) Installaton of Injecton Pump Gear Punch at three places. excet he head gasket sufac

"U mar,

83251A

Stake he cylinder head at thee places shown ove he sucion vave holde. 5.2 521

8262A

Insal the njecion pump gea, senso pate and nu as nsuced n he fgue

PRESSURE GOVERNOR Disassembly and Inspecton

Damage coroso

Setlg aae

Damage corosio Damage deerorato

 7-

6- i

5

Cove 6 2 Adjusng scew 7 3 Sping 8 4 Sleeve 9 5 Snap ng 10

Fte Sceen Cap Diaphagm Body

Ra Kt: essre Goveror  840

6-

m


5.22

Reassembly and Adjustment

Ui: kPa kgf/m') ar no.

pressur valve

5

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Hgh pess vav oeig essr

Low pesse vave opng ressue

MC802148

34  03 7 (7_3) -0 0 05)

(00 63  4 +05 34 (03

M8010

 34  03) 8 (80 05 00

I 0 (  005) 70 (71 34 (0 35)

0987 ,432

008

Testing sse goveno

Nomina vae

(3) Sowy decrease the air tank pessue and check tha the ai gauge reading stars to incease when the nomina pessure (o pressure vave opening pressure) is reached For adusment, use he adusting screw After adjust men, ighten firmy wih the lock nut (4) After tighenng he lock nu, check again the high and ow pessure vave openng pressures f hey are out of specicaion, adjus agan (5) nsta and sea the cover

Ai gage

A tak 8402A

(1) Connect an air gauge beween the pressure govenor and ai tank. (2) Sat the engine and increase air pressure slowly whie observng he air gauge Check hat the reading of he gauge when it has stabized is as specfed (high pessure vave openng pressure) If no, adjust by adjustng tightening amount of the seeve After adustmen ighten frmly with the lock nut

61-23

Notes: for 6D22 parts call:

Phone: 269 673 1638

or email: [email protected]

Mitsubsh D22 Gaske and Seal Reference Page 1 of 28 Vave Stem Seas, Rocer Shaf Bacet Orings,

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Mitsubish 6D22 Gaset and Seal Referece Page 2 o 28 -6D22 Head Gasket, Cyider Head Soft lgs, I jector Tbe, M E998000 Kit 622 Cylinder Head Soft Plug Kit ( al sof plugs for 6 cylinder heads )

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Mitsubish 6D22 Gaske Gaskett and Seal Refeencence Page 3 o 28 Injector Gaskets and Seas lE997905 n W � E9980 no-T v 0 O( oninE9980 or  ) I

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Mitsubish 6D22 Gaske and Seal Reference Page 5 of 28 6D22 Exhast Manfod Gaskes, Sea Rings

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Mitsubish 6D22 Gasket and Seal Reference Page 6 of 28 6D22 Turbo Mouning Gasket, Ar Intake Plug Sealng Wase

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Mitsubshi 6D22 Gasket and Seal Reference Page 7 of 28 6D22 Turbo Lines Gaskets and Sealing Washes

Mitsubish 6D22 Gasket and Seal Reference Page 6 of 28 6D22 Turbo Mouning Gasket, Ar Intake Plug Sealng Wase

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Mitsubish 6D22 Gasket and and Seal Sea l Reference Page 8 of 28 6D22 6D22 Intake Manifold Gaskets

ntake Manfod Gasket ME099644

ntake Ebow Gasket ME098201 ntake Ebow Gasket with Screen ME0996 ME099649 49

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Mitsubish 6D22 Gasket and Seal Reference R eference Pae 9 of 28 6D22 Intake Heate Gaskets ME999602 Intake eater ME999612 E e ment Intake Mani fold � Gasket, for / eng n es w t h ntake heates. 0

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Mitsubish 6D22 Gasket and Seal Reference Page 10 o 28 6D22 Rea Crankshaft Sea, Three ypes Rea Crankshaft Seal. Mtsubsh 6D Rear Cranksha Seal Refeece Page, Thr ypes Rear Caksha Sea Mtsubsh 1. Re nsh Se Combned wih For Bo Rener Aemb 2 Re Crnh Crnh  Se - T Se Type 3 Rea Crankhaf Sea  One Sea Tpe

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Mitsubish 6D22 Gasket and Seal Reference Page 10 o 28 6D22 Rea Crankshaft Sea, Three ypes Rea Crankshaft Seal. Mtsubsh 6D Rear Cranksha Seal Refeece Page, Thr ypes Rear Caksha Sea Mtsubsh 1. Re nsh Se Combned wih For Bo Rener Aemb 2 Re Crnh Crnh  Se - T Se Type 3 Rea Crankhaf Sea  One Sea Tpe

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00000 Sger

T S Te

ME Seeve

ME08 Ree semby o o O Ses

Oe Se Tpe

ME08 Ree b  Oe O 

Sr ME 0 Re nkh O Se I for Oe Sea ype

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Mitsubish 6022 Gasket and Seal Referece Pag e 11 of 28 6022 Rear Fywheel Housing Gaskets MF931522 Oing

ME96381 Gasket

ME963782 Gasket, Pate to bock

ME963789 Gasket Fywee ousg to plat

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Mitsubish 6D22 Gaske and Seal Reference Page 12 o 28 6D22 Fon Canshaf Sea, Gasket Side Cover Gases.

Front Crankshaft Seal � ME979033'

Mitsubish 6D22 Gaske and Seal Reference Page 12 o 28 6D22 Fon Canshaf Sea, Gasket Side Cover Gases.

Front Crankshaft Seal � ME979033'

Slnge ME971034 Gase \ME942608

Sde Cove Gaskes (3) ME940057

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Upper Cyl i n der L"  n er Seal s ME963597 MiME963608 ddle Cylinde L.ner Sea Lowe Cyl  n d e Li . n er Sea s ME963610 Sof Pug MF998847

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Mitsubsh 6D22 Gasket and Seal Reference Page 14 of 28 6D22 O Cooer Gaskets and Seals

Mitsubsh 6D22 Gasket and Seal Reference Page 14 of 28 6D22 O Cooer Gaskets and Seals

ME969501 Gasket, Ol Cooe Housin g to Block MF969623 Ongs, Oil Cooe Housing to Bock � MF969311 Ong 0/ M969313 Oring ('c ME998629 Seaing Washers @

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Mitsubish 6D22 Gasket and Seal Refeence Page 15 of 28 6D22 nercooer Gases and Seals

Mitsubish 6D22 Gasket and Seal Refeence Page 15 of 28 6D22 nercooer Gases and Seals

ME969904 Gake

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Mitsubish 6D22 Gaske and Seal Reference Page 16 of 28 6D22 Injecton Pump Oi Lne Seas A Ty ni u

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Mitsubish 6D22 Gaske and Seal Reference Page 16 of 28 6D22 Injecton Pump Oi Lne Seas  y in u

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Mitsubsh 6D22 Gasket and Seal Referece Page 17 of 28 6D22 O Pump Gaskets

Mitsubsh 6D22 Gasket and Seal Referece Page 17 of 28 6D22 O Pump Gaskets

,  u    u E990

Mitsubish 6022 Gasket and Seal Reference Page 18 of 28 6022 Oi Pan Gasket and Sealng Washes il n  E995 ln h (   pn plu ) E99 -

Mitsubish 6022 Gasket and Seal Reference Page 18 of 28 6022 Oi Pan Gasket and Sealng Washes il n  E995 ln h (   pn plu ) E99 -

 ln h �    pn plu ) 999 www.6D22com

Mitsubishi 6022 Gaske and Seal Reference Page 19 of 28 6022 Injection Pump Drve Gaskes and Seas

MF969591 Orng

ME9741 Gasket

ME924665 Oi Sea

MF9698 Oing

Mitsubishi 6022 Gaske and Seal Reference Page 19 of 28 6022 Injection Pump Drve Gaskes and Seas

MF969591 Orng

ME9741 Gasket

ME924665 Oi Sea

MF9698 Oing

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Mitsubish 6022 Gas ket and Sea I Reference Page 2 of 28 6022 PTO rve . Gaskets and Seals

Mitsubish 6022 Gas ket and Sea I Reference Page 2 of 28 6022 PTO rve . Gaskets and Seals

www.6D22.com

Mitsubish 6D22 Gasket and Seal Reference Page 21 of 28 6D22 Wate Pump Seals, Teostat Gaset.

ME979604 Oing MF906631 Sealng Washe

ME930669 Gaset for teostat

MH96414 Wate Pup eal Assy M660 ealng Washe

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Mitsubsh 6D22 Gas ket and Seal Referece Page 22 of 28 6D22 Tmg Gear Orngs

MF961701 Ong

Mitsubsh 6D22 Gas ket and Seal Referece Page 22 of 28 6D22 Tmg Gear Orngs

MF961701 Ong

961694 Org

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Mitsubsh 6D22 Gasket and Seal Reference Page 24 of 28 6D22 Water Manfold Gaskes and Seals.

W o O E9790

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Mitsubsh 6D22 Gasket and Seal Reference Page 24 of 28 6D22 Water Manfold Gaskes and Seals.

W o O E9790

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Mitsubishi 6D22 Gasket and Seal Reference Page 26 of 28 6D22 Parts - Notes

Mitsubishi 6D22 Gasket and Seal Reference Page 26 of 28 6D22 Parts - Notes

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Mitsubishi 6D22 Gasket and Seal Reference Page 27 of 28 6D22 Pars - Noes

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Mitsubishi 6D22 Gasket and Seal Reference Page 27 of 28 6D22 Pars - Noes

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Mitsubishi 6D22 Gasket and Seal Reference Page 28 o 28 6D22 Pats - Notes

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Mitsubishi 6D22 Gasket and Seal Reference Page 28 o 28 6D22 Pats - Notes

www.6D22com

Mitsubishi 6D22 Parts Description ( Partial List ) Reference: www.HeavyEquipmentRestorationParts.com ME052488 6D22 Bearing Set ME052489 6D22 Bearing Set ME052490 6D22 Bearing Set MF140258 6D22 Bolt MH000707 6D22 Bolt MH000714 6D22 Bolt ME151450 6D22 Bushing, Connecting Rod ME051187 6D22 Cam Bushing ME051188 6D22 Cam Bushing ME051189 6D22 Cam Bushing ME051190 6D22 Cam Bushing ME051191 6D22 Cam Bushing ME051672 6D22 Cam Bushing ME051673 6D22 Cam Bushing ME051674 6D22 Cam Bushing ME051675 6D22 Cam Bushing ME051677 6D22 Cam Bushing ME051676 6D22 Cam Bushing ME051678 6D22 Cam Bushing ME052330 6D22 Connecting Rod ME150492 6D22 Connecting Rod ME150493 6D22 Connecting Rod

Mitsubishi 6D22 Parts Description ( Partial List ) Reference: www.HeavyEquipmentRestorationParts.com ME052488 6D22 Bearing Set ME052489 6D22 Bearing Set ME052490 6D22 Bearing Set MF140258 6D22 Bolt MH000707 6D22 Bolt MH000714 6D22 Bolt ME151450 6D22 Bushing, Connecting Rod ME051187 6D22 Cam Bushing ME051188 6D22 Cam Bushing ME051189 6D22 Cam Bushing ME051190 6D22 Cam Bushing ME051191 6D22 Cam Bushing ME051672 6D22 Cam Bushing ME051673 6D22 Cam Bushing ME051674 6D22 Cam Bushing ME051675 6D22 Cam Bushing ME051677 6D22 Cam Bushing ME051676 6D22 Cam Bushing ME051678 6D22 Cam Bushing ME052330 6D22 Connecting Rod ME150492 6D22 Connecting Rod ME150493 6D22 Connecting Rod ME999365 6D22 Cylinder Head ME999383 6D22 Cylinder Head ME999793 6D22 Cylinder Head ME999969 6D22 Cylinder Head ME050502 6D22 Cylinder Liner ME050503 6D22 Cylinder Liner ME050504 6D22 Cylinder Liner ME051102 6D22 Cylinder Liner ME051103 6D22 Cylinder Liner ME051104 6D22 Cylinder Liner ME051105 6D22 Cylinder Liner ME051216 6D22 Cylinder Liner ME051217 6D22 Cylinder Liner ME051218 6D22 Cylinder Liner ME051219 6D22 Cylinder Liner ME051220 6D22 Cylinder Liner ME051221 6D22 Cylinder Liner ME051222 6D22 Cylinder Liner ME051229 6D22 Cylinder Liner ME051230 6D22 Cylinder Liner ME051231 6D22 Cylinder Liner ME051232 6D22 Cylinder Liner ME051500 6D22 Cylinder Liner

ME051501 6D22 Cylinder Liner ME051502 6D22 Cylinder Liner ME051503 6D22 Cylinder Liner ME051632 6D22 Cylinder Liner ME051633 6D22 Cylinder Liner ME051634 6D22 Cylinder Liner ME058210 6D22 Cylinder Liner ME058211 6D22 Cylinder Liner ME058212 6D22 Cylinder Liner ME058272 6D22 Cylinder Liner ME058273 6D22 Cylinder Liner ME058274 6D22 Cylinder Liner ME058275 6D22 Cylinder Liner ME058277 6D22 Cylinder Liner ME058278 6D22 Cylinder Liner ME058279 6D22 Cylinder Liner ME157039 6D22 Cylinder Liner ME157040 6D22 Cylinder Liner ME157041 6D22 Cylinder Liner ME998042 6D22 Cylinder Liner ME998045 6D22 Cylinder Liner 855315 6D22 Cylinder Liner Cat Excavator 948319 6D22 Cylinder Liner Cat Excavator 961274 6D22 Cylinder Liner Cat Excavator 969730 6D22 Cylinder Liner Cat Excavator 991240 6D22 Cylinder Liner Cat Excavator 994933 6D22 Cylinder Liner Cat Excavator 30922200102 6D22 Damper ME052337 6D22 Damper ME068269 6D22 Damper ME051697 6D22 Exhaust Valve 3110401103 6D22 Exhaust Valve 3120470200 6D22 Exhaust Valve 3120471101 6D22 Exhaust Valve ME051064 6D22 Exhaust Valve ME979901 6D22 Exhaust Valve ME979033 6D22 Front Crankshaft Seal ME051575 6D22 Head Gasket ME051618 6D22 Head Gasket ME051714 6D22 Head Gasket ME998722 6D22 Head Gasket ME998770 6D22 Head Gasket ME059751 6D22 Injection Pump Body ME722342 6D22 Injection Pump Body ME726267 6D22 Injection Pump Body ME726298 6D22 Injection Pump Body ME727156 6D22 Injection Pump Body

ME742794 6D22 Injection Pump Body ME050825K 6D22 Injection Pump Rebuild Kit ME050850K 6D22 Injection Pump Rebuild Kit ME050861K 6D22 Injection Pump Rebuild Kit ME059604K 6D22 Injection Pump Rebuild Kit ME059623K 6D22 Injection Pump Rebuild Kit ME059629K 6D22 Injection Pump Rebuild Kit ME157069K 6D22 Injection Pump Rebuild Kit ME157071K 6D22 Injection Pump Rebuild Kit ME157227K 6D22 Injection Pump Rebuild Kit ME157281K 6D22 Injection Pump Rebuild Kit ME158009K 6D22 Injection Pump Rebuild Kit ME158010K 6D22 Injection Pump Rebuild Kit ME158012K 6D22 Injection Pump Rebuild Kit ME158014K 6D22 Injection Pump Rebuild Kit ME158241K 6D22 Injection Pump Rebuild Kit ME158242K 6D22 Injection Pump Rebuild Kit ME158246K 6D22 Injection Pump Rebuild Kit ME158247K 6D22 Injection Pump Rebuild Kit ME050883 6D22 Injector ME056275 6D22 Injector ME059621 6D22 Injector ME998662 6D22 Injector 3090400302 6D22 Intake Valve 3090400401 6D22 Intake Valve ME051063 6D22 Intake Valve ME051567 6D22 Intake Valve ME051696 6D22 Intake Valve ME979902 6D22 Intake Valve ME963597 6D22 Liner Seal ME963608 6D22 Liner Seal ME963610 6D22 Liner Seal ME052038 6D22 Main Bearing ME052045 6D22 Main Bearing ME052053 6D22 Main Bearing ME052054 6D22 Main Bearing ME052055 6D22 Main Bearing ME052056 6D22 Main Bearing ME052057 6D22 Main Bearing ME052069 6D22 Main Bearing ME150453 6D22 Oil Cooler ME150866 6D22 Oil Cooler ME157900 6D22 Oil Cooler ME157901 6D22 Oil Cooler ME158045 6D22 Oil Cooler ME158046 6D22 Oil Cooler ME051615 6D22 Oil Jet

ME051709 6D22 Oil Jet 3090711400 6D22 Oil Jet ME998508 6D22 Oil Pan Gasket ME120351 6D22 Oil Pump ME054373 6D22 Oil Pump Cover ME052597 6D22 Piston ME052023 6D22 Piston ME052093 6D22 Piston ME052094 6D22 Piston ME052115 6D22 Piston ME052118 6D22 Piston ME052119 6D22 Piston ME052120 6D22 Piston ME052121 6D22 Piston ME052420 6D22 Piston ME052421 6D22 Piston ME052422 6D22 Piston ME052423 6D22 Piston ME052424 6D22 Piston ME052447 6D22 Piston ME052448 6D22 Piston ME052449 6D22 Piston ME052450 6D22 Piston ME052540 6D22 Piston ME052541 6D22 Piston ME052542 6D22 Piston ME052543 6D22 Piston ME052588 6D22 Piston ME052589 6D22 Piston ME052590 6D22 Piston ME052591 6D22 Piston ME052592 6D22 Piston ME052593 6D22 Piston ME052594 6D22 Piston ME052595 6D22 Piston ME052596 6D22 Piston ME052598 6D22 Piston ME052599 6D22 Piston ME052600 6D22 Piston ME052601 6D22 Piston ME052664 6D22 Piston ME052665 6D22 Piston ME052666 6D22 Piston ME052667 6D22 Piston ME052668 6D22 Piston ME052669 6D22 Piston ME052670 6D22 Piston

ME052673 6D22 Piston ME052674 6D22 Piston ME052675 6D22 Piston ME052676 6D22 Piston ME052677 6D22 Piston ME052678 6D22 Piston ME052679 6D22 Piston ME052730 6D22 Piston ME052732 6D22 Piston ME052733 6D22 Piston ME052734 6D22 Piston ME052735 6D22 Piston ME052736 6D22 Piston ME052791 6D22 Piston ME052792 6D22 Piston ME052809 6D22 Piston ME052810 6D22 Piston ME052811 6D22 Piston ME052812 6D22 Piston ME052813 6D22 Piston ME052814 6D22 Piston ME052815 6D22 Piston ME052818 6D22 Piston ME052820 6D22 Piston ME052821 6D22 Piston ME052822 6D22 Piston ME052861 6D22 Piston ME052862 6D22 Piston ME052863 6D22 Piston ME052864 6D22 Piston ME052865 6D22 Piston ME052866 6D22 Piston ME052902 6D22 Piston ME052903 6D22 Piston ME052904 6D22 Piston ME052905 6D22 Piston ME052906 6D22 Piston ME052907 6D22 Piston ME052908 6D22 Piston ME052910 6D22 Piston ME052911 6D22 Piston ME052912 6D22 Piston ME052913 6D22 Piston ME052983 6D22 Piston ME052984 6D22 Piston ME052985 6D22 Piston ME052986 6D22 Piston

ME052987 6D22 Piston ME052988 6D22 Piston ME052989 6D22 Piston ME052990 6D22 Piston ME052991 6D22 Piston ME052992 6D22 Piston ME052993 6D22 Piston ME052994 6D22 Piston ME052995 6D22 Piston ME058007 6D22 Piston ME058008 6D22 Piston ME058009 6D22 Piston ME058010 6D22 Piston ME058011 6D22 Piston ME058012 6D22 Piston ME058013 6D22 Piston ME058014 6D22 Piston ME058049 6D22 Piston ME058050 6D22 Piston ME058051 6D22 Piston ME058052 6D22 Piston ME058053 6D22 Piston ME058054 6D22 Piston ME058055 6D22 Piston ME058056 6D22 Piston ME058060 6D22 Piston ME058061 6D22 Piston ME058062 6D22 Piston ME058063 6D22 Piston ME058064 6D22 Piston ME058065 6D22 Piston ME058066 6D22 Piston ME058336 6D22 Piston ME058390 6D22 Piston ME058391 6D22 Piston ME058392 6D22 Piston ME058393 6D22 Piston ME150132 6D22 Piston ME150134 6D22 Piston ME150135 6D22 Piston ME150136 6D22 Piston ME150137 6D22 Piston ME150138 6D22 Piston ME150139 6D22 Piston ME157020 6D22 Piston ME157021 6D22 Piston ME157022 6D22 Piston

ME157023 6D22 Piston ME157024 6D22 Piston ME157025 6D22 Piston ME157026 6D22 Piston ME158590 6D22 Piston ME979880 6D22 Piston ME979881 6D22 Piston ME979882 6D22 Piston ME979883 6D22 Piston ME979884 6D22 Piston ME979885 6D22 Piston ME979886 6D22 Piston ME979887 6D22 Piston ME979888 6D22 Piston ME979889 6D22 Piston 861395 6D22 Piston Cat Excavator 960212 6D22 Piston Cat Excavator 969733 6D22 Piston Cat Excavator 969734 6D22 Piston Cat Excavator 969736 6D22 Piston Cat Excavator 969737 6D22 Piston Cat Excavator 1R5828 6D22 Piston Cat Excavator 1R5906 6D22 Piston Cat Excavator 1R5907 6D22 Piston Cat Excavator 1R5908 6D22 Piston Cat Excavator 3091737100 6D22 Piston Ring 3091737101 6D22 Piston Ring 3111702100 6D22 Piston Ring 3111702101 6D22 Piston Ring ME052029 6D22 Piston Ring ME052770 6D22 Piston Ring ME052778 6D22 Piston Ring ME052794 6D22 Piston Ring ME052827 6D22 Piston Ring ME058000 6D22 Piston Ring ME052124 6D22 Piston Ring Set ME052125 6D22 Piston Ring Set ME052126 6D22 Piston Ring Set ME052127 6D22 Piston Ring Set ME058128 6D22 Piston Ring Set ME052787 6D22 Piston Ring Set ME052790 6D22 Piston Ring Set ME052889 6D22 Piston Ring Set ME052890 6D22 Piston Ring Set ME052891 6D22 Piston Ring Set ME052892 6D22 Piston Ring Set ME052893 6D22 Piston Ring Set

ME052894 6D22 Piston Ring Set ME052895 6D22 Piston Ring Set ME052896 6D22 Piston Ring Set ME072788 6D22 Piston Ring Set ME072789 6D22 Piston Ring Set ME072790 6D22 Piston Ring Set ME052750 6D22 Piston Ring Set ME052885 6D22 Piston Ring Set ME058004 6D22 Piston Ring Set ME058046 6D22 Piston Ring Set ME979870 6D22 Piston Ring Set ME979871 6D22 Piston Ring Set ME979872 6D22 Piston Ring Set ME979873 6D22 Piston Ring Set ME979874 6D22 Piston Ring Set ME979875 6D22 Piston Ring Set ME979876 6D22 Piston Ring Set ME979877 6D22 Piston Ring Set ME979878 6D22 Piston Ring Set 3091720010 6D22 Piston Ring Set 861396 6D22 Piston Ring Set Cat Excavator 962014 6D22 Piston Ring Set Cat Excavator 962015 6D22 Piston Ring Set Cat Excavator 990042 6D22 Piston Ring Set Cat Excavator 991648 6D22 Piston Ring Set Cat Excavator 991649 6D22 Piston Ring Set Cat Excavator 991650 6D22 Piston Ring Set Cat Excavator 991651 6D22 Piston Ring Set Cat Excavator 9911652 6D22 Piston Ring Set Cat Excavator 1R5909 6D22 Piston Ring Set Cat Excavator 1R5910 6D22 Piston Ring Set Cat Excavator 1R5911 6D22 Piston Ring Set Cat Excavator ME150909 6D22 Rear Crankshaft Seal ME963604 6D22 Rear Crankshaft Seal ME964441 6D22 Rear Crankshaft Seal ME979990 6D22 Rear Crankshaft Seal ME979994 6D22 Rear Crankshaft Seal ME058006 6D22 Ring Set ME051051 6D22 Rocker Arm ME940057 6D22 Side Cover Gaskets 3092020100 6D22 Slinger ME930669 6D22 Thermostat Gasket 31109-07109 6D22 Thrust Washer ME051120 6D22 Valve Guide ME051122 6D22 Valve Guide ME979603 6D22 Valve Guide ME979607 6D22 Valve Guide

MH964114 6D22 Water Pump Seal Assembly, Internal MH037087 Banjo Bolt 6D22 MH037254 Banjo Bolt 6D22 MH037279 Banjo Bolt 6D22 MH037716 Banjo Bolt 6D22 ME705400 Banjo Bolt 6D22 Injector 3092503800 Bearing 6D22 ME719820 Bearing 6D22 Turbocharger ME052054 Bearing Set ME052055 Bearing Set ME052056 Bearing Set ME052057 Bearing Set ME052491 Bearing Set ME520492 Bearing Set MH052053 Bearing Set MH040026 Bearing, ME704268 Bearing, 6D22 Injection Pump ME704282 Bearing, 6D22 Injection Pump ME705184 Bearing, 6D22 Injection Pump ME705283 Bearing, 6D22 Injection Pump ME719030 Bearing, 6D22 Turbocharger ME719336 Bearing, 6D22 Turbocharger ME719337 Bearing, 6D22 Turbocharger MS556005 Bearing, 6D22 Water Pump MS556125 Bearing, 6D22 Water Pump ME152008 Bolt MF241222 Bolt MH000714 Bolt MH000733 Bolt ME061330 Bolt MF140260 Bolt MH000706 Bolt 6D22 Oil Line MH000713 Bolt 6D22 Oil Line MH000886 Bolt 6D22 Oil Line MF300843 Bolt, 6D22 MF303367 Bolt, 6D22 MF303374 Bolt, 6D22 3091900400 Bolt, 6D22 Connecting Rod ME052765 Bolt, 6D22 Connecting Rod MF300843 Bolt, 6D22 Cylinder Block MF300845 Bolt, 6D22 Cylinder Block MF300847 Bolt, 6D22 Cylinder Block MF300851 Bolt, 6D22 Cylinder Block MF303365 Bolt, 6D22 Cylinder Block MH000706 Bolt, 6D22 Cylinder Block MH000713 Bolt, 6D22 Cylinder Block MH000727 Bolt, 6D22 Cylinder Block

MF300896 Bolt, 6D22 Engine Mount MH000727 Bolt, 6D22 Engine Mount MH000843 Bolt, 6D22 Engine Mount MH000923 Bolt, 6D22 Engine Mount MH000392 Bolt, 6D22 Exhaust MH000679 Bolt, 6D22 Exhaust ME052691 Bolt, 6D22 Flywheel ME052693 Bolt, 6D22 Flywheel MF100031 Bolt, 6D22 Flywheel Housing MF240050 Bolt, 6D22 Flywheel Housing MF300841 Bolt, 6D22 Flywheel Housing MF300843 Bolt, 6D22 Flywheel Housing MF300847 Bolt, 6D22 Flywheel Housing MH000924 Bolt, 6D22 Flywheel Housing MH000927 Bolt, 6D22 Flywheel Housing MH000928 Bolt, 6D22 Flywheel Housing MF243649 Bolt, 6D22 Flywheel Housing, MH000925 Bolt, 6D22 Flywheel Housing, MH000929 Bolt, 6D22 Flywheel Housing, MH000999 Bolt, 6D22 Flywheel Housing, ME704150 Bolt, 6D22 Injection Pump ME705216 Bolt, 6D22 Injection Pump ME705267 Bolt, 6D22 Injection Pump ME705295 Bolt, 6D22 Injection Pump MH000714 Bolt, 6D22 Intake MH000835 Bolt, 6D22 Intake MH000716 Bolt, 6D22 Intake MH000732 Bolt, 6D22 Intake MH000872 Bolt, 6D22 Intake MH001419 Bolt, 6D22 Intake MF140020 Bolt, 6D22 Intake Heater MS146006 Bolt, 6D22 Oil Cooler MS146008 Bolt, 6D22 Oil Cooler MS146014 Bolt, 6D22 Oil Cooler MS146016 Bolt, 6D22 Oil Cooler MS146310 Bolt, 6D22 Oil Cooler MF140011 Bolt, 6D22 Oil Line MF140013 Bolt, 6D22 Oil Line MF140002 Bolt, 6D22 Oil Pan MF300841 Bolt, 6D22 Oil Pan MF300843 Bolt, 6D22 Oil Pan MH000707 Bolt, 6D22 Oil Pan MH000830 Bolt, 6D22 Oil Pan MH001103 Bolt, 6D22 Rocker Cover MH000377 Bolt, Crankshaft Pully MH000922 Bolt, Damper MF000729 Bolt, Exhaust

MF101314 Bolt, Exhaust MF101316 Bolt, Exhaust MF140287 Bolt, Exhaust MF241278 Bolt, Exhaust MH000679 Bolt, Exhaust MH000713 Bolt, Exhaust MH000922 Bolt, Exhaust ME051712 Bolt, for oil jet ME061330 Bolt, Main Cap ME150511 Bracket, 6D22 Rocker Shaft 3090402200 Bushing, 6D22 3092502901 Bushing, 6D22 ME034549 Bushing, 6D22 ME052660 Bushing, 6D22 ME052843 Bushing, 6D22 ME062905 Bushing, 6D22 ME704596 Bushing, 6D22 Governor ME704606 Bushing, 6D22 Governor ME704658 Bushing, 6D22 Governor ME704981 Bushing, 6D22 Governor ME730138 Bushing, 6D22 Governor ME730139 Bushing, 6D22 Governor ME704055 Bushing, 6D22 Injection Pump ME704057 Bushing, 6D22 Injection Pump ME051209 Camshaft, ME151299 Camshaft, ME704094 Camshaft, 6D22 Injection Pump ME704147 Camshaft, 6D22 Injection Pump 3000424302 Cap ME031518 Check Valve, Oil Jet Bolt, ME062573 Collar 3092504400 Collar 3097521400 Compressor Piston ME052330 Connecting Rod ME052763 Connecting Rod ME052825 Connecting Rod ME052919 Connecting Rod ME052920 Connecting Rod ME052921 Connecting Rod ME052922 Connecting Rod ME052923 Connecting Rod ME052924 Connecting Rod ME052925 Connecting Rod ME052925 Connecting Rod ME052926 Connecting Rod ME052927 Connecting Rod ME052928 Connecting Rod

ME052929 Connecting Rod ME052930 Connecting Rod ME052931 Connecting Rod ME052932 Connecting Rod ME052933 Connecting Rod ME052934 Connecting Rod ME052935 Connecting Rod ME052936 Connecting Rod ME058044 Connecting Rod ME058057 Connecting Rod ME058057 Connecting Rod ME157019 Connecting Rod ME979975 Connecting Rod ME157019 Connecting Rod ME157996 Connecting Rod 3091902102 Connecting Rod Bearing, Lower ME052334 Connecting Rod Bearing, Upper ME056100 Coupling, 6D22 Injection Pump ME056242 Coupling, 6D22 Injection Pump ME058609 Coupling, Exhaust Pipe ME150441 Cover, 6D22 Oil Cooler ME157904 Cover, 6D22 Oil Cooler ME158055 Cover, 6D22 Oil Cooler ME996339 Crankshaft 6D22 ME998340 Crankshaft 6D22 ME719270 Deflector, 6D22 Turbocharger ME062523 Director, Cylinder Head Water 6D22 MF472407 Dowel Pin, 6D22 Crankshaft MF472405 Dowl Pin 6D22 Flywheel ME153170 Element, 6D22 Oil Cooler ME153172 Element, 6D22 Oil Cooler ME964223 Exhaust Manifold Gaskets 6D22 ME964643 Exhaust Seal Rings 6D22 ME150048 Flywheel Housing Gasket ME062828 Flywheel Ring Gear ME942608 Gasket ME969980 Gasket ME977030 Gasket ME0988209 Gasket ME942663 Gasket ME942881 Gasket ME942906 Gasket ME942907 Gasket ME963782 Gasket ME963789 Gasket ME963801 Gasket ME969303 Gasket

ME969982 Gasket MH033077 Gasket ME942881 Gasket, 6D22 Block ME997610 Gasket, 6D22 Engine Oil Pump ME998633 Gasket, 6D22 Engine Oil Pump ME969312 Gasket, 6D22 Gear Housing ME704586 Gasket, 6D22 Governor ME704618 Gasket, 6D22 Governor ME704772 Gasket, 6D22 Governor ME705323 Gasket, 6D22 Governor ME727391 Gasket, 6D22 Governor ME727491 Gasket, 6D22 Governor 375117000 Gasket, 6D22 Injection Pump 375124001 Gasket, 6D22 Injection Pump 3126106400 Gasket, 6D22 Injection Pump ME704044 Gasket, 6D22 Injection Pump ME704083 Gasket, 6D22 Injection Pump ME704096 Gasket, 6D22 Injection Pump ME704101 Gasket, 6D22 Injection Pump ME705151 Gasket, 6D22 Injection Pump ME705209 Gasket, 6D22 Injection Pump ME705218 Gasket, 6D22 Injection Pump ME705289 Gasket, 6D22 Injection Pump ME727376 Gasket, 6D22 Injection Pump ME727378 Gasket, 6D22 Injection Pump ME970401 Gasket, 6D22 Injection Pump Drive ME969962 Gasket, 6D22 Intake Heater ME969849 Gasket, 6D22 Intercooler ME969904 Gasket, 6D22 Intercooler ME969501 Gasket, 6D22 Oil Cooler ME998604 Gasket, 6D22 Oil Pump ME969310 Gasket, 6D22 PTO Drive ME977028 Gasket, 6D22 Turbo Oil Return Line ME980061 Gasket, 6D22 Turbocharger to Manifold ME977602 Gasket, 6D22 Water Manifold to Head 3003232100 Gasket, Exhaust Pipe ME063680 Gasket, Exhaust Pipe ME063737 Gasket, Exhaust Pipe ME068375 Gasket, Exhaust Pipe ME120385 Gear and Case 6D22 Oil Pump 3123500044 Gear, 6D22 Oil Pump ME054703 Gear, 6D22 Oil Pump ME150506 Gear, Cam Idler ME151298 Gear, camshaft ME091034 Gear, Crankshaft ME052996 Gear, Inj Pump Drive ME150689 Gear, Inj Pump Idler

ME051515 Head Bolt 6D22 ME051516 Head Bolt 6D22 ME962515 Head Bolt 6D22 ME962516 Head Bolt 6D22 ME704011 Holder, 6D22 Injection Pump ME704041 Holder, 6D22 Injection Pump ME705431 Holder, 6D22 Injector ME705432 Holder, 6D22 Injector ME705441 Holder, 6D22 Injector ME055398 Impeller, 6D22 Water Pump ME157062 Impeller, 6D22 Water Pump ME059655 Injection Pump Body ME059669 Injection Pump Body ME998605 Injector Tube, 6D22 ME098201 Intake Elbow Gasket 6D22 ME099649 Intake Elbow Gasket with screen 6D22 ME999603 Intake Gasket ME999601 Intake Gasket 6D22 ME099608 Intake Heater Element 6D22 ME999602 Intake Heater Elemment 6D22 ME999612 Intake Manifold Gasket ME099644 Intake Manifold Gasket 6D22 ME099632 Intake Manifold Gasket for 6D22 Intake Heater ME099649 Intake Manifold Gasket with screen ME099640 Intake Manifold Gasket with screen 6D22 ME099640 Intake Manifold Gasket with screen 6D22 MS476135 Key, ME996464 Kit ME997089 Kit ME997284 Kit ME997802 Kit ME998000 Kit, 6D22 Cylinder Head Soft Plug Kit ME997018 Liner & Piston Kit ME997031 Liner & Piston Kit ME998905 Liner & Piston Kit ME998906 Liner & Piston Kit ME998907 Liner & Piston Kit ME998908 Liner & Piston Kit ME999594 Liner & Piston Kit ME999905 Liner & Piston Kit 3120434200 Lock , valve keeper 6D22 ME051705 Mitsubishi 6D22 Washer ME705429 Nozzle, 6D22 Injector ME705435 Nozzle, 6D22 Injector ME705903 Nozzle, 6D22 Injector ME705905 Nozzle, 6D22 Injector ME032042 Nut

MF430122 Nut MF430007 Nut, 6D22 Exhaust MF434105 Nut, 6D22 Exhaust MH004054 Nut, 6D22 Exhaust MH004054 Nut, 6D22 Exhaust MH004073 Nut, 6D22 Exhaust MH004073 Nut, 6D22 Exhaust MS430007 Nut, 6D22 Exhaust MS446185 Nut, 6D22 Exhaust ME051197 Oil Jet 6D22 ME051706 Oil Jet 6D22 ME150482 Oil Jet 6D22 MC850069 Oil Pressure Gauge ME924665 Oil Seal, 6D22 Injection Pump Drive ME972338 Oil Seal, 6D22 PTO MF969804 Oring MD000523 Oring MF921633 Oring MF930006 Oring MF931522 Oring MF969640 Oring MH096246 Oring ME979604 Oring 6D22 Thermostat Housing ME701153 Oring, 6D22 Injection Pump ME705152 Oring, 6D22 Injection Pump ME705278 Oring, 6D22 Injection Pump ME705280 Oring, 6D22 Injection Pump ME705281 Oring, 6D22 Injection Pump ME705287 Oring, 6D22 Injection Pump ME717732 Oring, 6D22 Injection Pump ME748413 Oring, 6D22 Injection Pump ME748414 Oring, 6D22 Injection Pump ME748415 Oring, 6D22 Injection Pump MF969591 Oring, 6D22 Injection Pump Drive MF969800 Oring, 6D22 Injection Pump Drive MF969773 Oring, 6D22 Intercooler 3110702401 Oring, 6D22 Liner ME051375 Oring, 6D22 Liner MF969623 Oring, 6D22 Oil Cooler MF969628 Oring, 6D22 Oil Cooler Element MF969630 Oring, 6D22 Oil Cooler Element ME997625 Oring, 6D22 pressure regulator ME150992 Oring, 6D22 Rear Crankshaft Seal MF961694 Oring, 6D22 Timing Gear Shaft MF961701 Oring, 6D22 Timing Gear Shaft ME979604 Oring, 6D22 Water Pump MF969305 Oring, 6D22 Water Pump

MF969332 Oring, 6D22 Water Pump ME998607 Oring, for Injector Tube ME061399 Outer Valve Spring 6D22 ME051094 Packing 3090722300 Packing, 6D22 Liner MH012026 Pin, Crankshaft MF472405 Pin, cylinder block 6D22 MF472406 Pin, cylinder block 6D22 MF474204 Pin, cylinder block 6D22 MH007011 Pin, cylinder block 6D22 3003233030 Pipe, Exhaust 3003233040 Pipe, Exhaust ME157305 Pipe, Exhaust 32261002 Piston Connecting Rod Assembly 6D22 ME052149 Piston Pin ME052149 Piston Pin 6D22 3031900600 Piston Pin Bushing 6D22 3031900690 Piston Pin Bushing 6D22 ME052158 Piston Pin Bushing 6D22 ME052159 Piston Pin Bushing 6D22 ME052159 Piston Pin Bushing 6D22 ME052603 Piston Pin Bushing 6D22 ME052660 Piston Pin Bushing 6D22 3121733100 Piston Pin Retainer ME062326 Plate ME062660 Plate MH037725 Plug MH037137 Plug ME031088 Plug, threaded ME704144 Plunger, 6D22 Injection Pump ME704257 Plunger, 6D22 Injection Pump ME704374 Plunger, 6D22 Injection Pump ME704396 Plunger, 6D22 Injection Pump ME741405 Plunger, 6D22 Injection Pump ME743406 Plunger, 6D22 Injection Pump ME743408 Plunger, 6D22 Injection Pump ME743409 Plunger, 6D22 Injection Pump ME743410 Plunger, 6D22 Injection Pump ME051180 Push Rod, 6D22 ME051199 Push Rod, 6D22 ME705406 Push Rod, 6D22 Injector ME705410 Push Rod, 6D22 Injector ME705414 Push Rod, 6D22 Injector 3093194010K Rebuild Kit for 6D22 Turbocharger ME050738K Rebuild Kit for 6D22 Turbocharger ME058448K Rebuild Kit for 6D22 Turbocharger ME058724K Rebuild Kit for 6D22 Turbocharger

ME157213K Rebuild Kit for 6D22 Turbocharger ME157215K Rebuild Kit for 6D22 Turbocharger ME995231K Rebuild Kit for 6D22 Water Pump ME995234K Rebuild Kit for 6D22 Water Pump MEO95645 Retainer 3121733100 Retainer Ring, 6D22 Piston ME058232 Retainer, 6D22 Rear Crankshaft Seal, specify one or two seal type 3112100201 Ring Gear 4480102200 Ring Gear ME062696 Ring Gear ME053951 Ring Seal ME719056 Ring, 6D22 Turbocharger ME719290 Ring, 6D22 Turbocharger ME719339 Ring, 6D22 Turbocharger ME719383 Ring, 6D22 Turbocharger ME719832 Ring, 6D22 Turbocharger ME719864 Ring, 6D22 Turbocharger 3097502050 Rings, Compressor Piston ME051584 Screw, ME041001 Screw, Valve Adjust MF669804 Seal MF669805 Seal MF669902 Seal MF669909 Seal MF669912 Seal MF669913 Seal MF669914 Seal MF669916 Seal MF669919 Seal ME962485 Seal Grommet, 6D22 Valve Cover ME916402 Seal Ring, 6D22 Injector ME916414 Seal Ring, 6D22 Injector ME063946 Seal Ring, 6D22 Turbocharger ME034997 Seal Ring, Exhaust Pipe ME034998 Seal Ring, Exhaust Pipe ME063946 Seal Ring, Exhaust Pipe ME705228 Seal, 6D22 Governor ME705333 Seal, 6D22 Governor ME705210 Seal, 6D22 Injection Pump ME722347 Seal, 6D22 Injection Pump ME7605286 Seal, 6D22 Injection Pump ME998801 Seal, 6D22 pressure regulator MF969311 Sealing Ring MF969313 Sealing Ring ME979803 Sealing Washer ME998622 Sealing Washer MF969704 Sealing Washer

ME998629 Sealing Washer ME998629 Sealing Washer ME998633 Sealing Washer ME998633 Sealing Washer MF891182 Sealing Washer MF971174 Sealing Washer MF998874 Sealing Washer MH946199 Sealing Washer MF906631 Sealing Washer 6D22 Thermostat Housing MH661202 Sealing Washer 6D22 Water Pump ME051374 Sealing Washer, ME051705 Sealing Washer, ME998629 Sealing Washer, 6D22 Air Compressor ME998551 Sealing Washer, 6D22 Injection Pump ME998601 Sealing Washer, 6D22 Injection Pump ME916490 Sealing Washer, 6D22 Injector ME997905 Sealing Washer, 6D22 Injector MH942197 Sealing Washer, 6D22 Oil Jet ME977020 Sealing Washer, 6D22 Turbo Oil Line ME051353 Seat Exhaust ME051354 Seat Exhaust ME051214 Seat Intake 3093615300 Seat, 6D22 Oil Pump ME051034 Seat, Exhaust ME051354 Seat, Exhaust ME051300 Seat, Intake ME051083 Seat, Valve Spring ME719350 Shaft & Turbine, 6D22 Turbocharger ME719756 Shaft & Turbine, 6D22 Turbocharger 3123500501 Shaft, 6D22 Oil Pump ME054372 Shaft, 6D22 Oil Pump 3092504100 Shaft, Cam Idler ME150519 Shaft, Cam Idler ME150520 Shaft, Cam Idler ME151333 Sleeve ME704024 Sleeve, 6D22 Injection Pump ME704079 Sleeve, 6D22 Injection Pump ME704409 Sleeve, 6D22 Injection Pump ME722346 Sleeve, 6D22 Injection Pump ME723409 Sleeve, 6D22 Injection Pump ME060125 Slinger ME971034 Slinger ME999101 Slinger MF522236 Snap Ring ME704404 Snap Ring, 6D22 Injection Pump MF998840 Soft Plug MF998847 Soft Plug

ME998007 Soft Plug Kit, 6D22 Block ME99809 Soft Plug, Sealing Cap ME998804 Soft Plug, Sealing Cap ME998807 Soft Plug, Sealing Cap ME998810 Soft Plug, Sealing Cap MH012037 Spring pin ME704668 Spring, 6D22 Governor ME704748 Spring, 6D22 Governor ME716095 Spring, 6D22 Governor ME717321 Spring, 6D22 Governor ME705405 Spring, 6D22 Injector ME705409 Spring, 6D22 Injector ME705411 Spring, 6D22 Injector ME705451 Spring, 6D22 Injector 3093615200 Spring, 6D22 Oil Pump ME054393 Strainer ME054526 Strainer ME157586 Strainer ME157587 Strainer MF407035 Stud, 6D22 Exhaust MF407728 Stud, 6D22 Exhaust MF401931 Stud, 6D22 Flywheel Housing MF402541 Stud, 6D22 Flywheel Housing MH002113 Stud, 6D22 Flywheel Housing MF406288 Stud, cylinder block 6D22 MH002131 Stud, cylinder head 6D22 MC840219 Switch 6D22 Oil Pressure ME049107 Switch 6D22 Oil Pressure ME049261 Switch 6D22 Oil Pressure ME049262 Switch 6D22 Oil Pressure ME951940 Switch 6D22 Oil Pressure ME951943 Switch 6D22 Oil Pressure ME061021 Tappet ME704062 Tappet, 6D22 Injection Pump ME722244 Tappet, 6D22 Injection Pump ME151300 Thrust Plate 3090401600 Thrust Plate, 6D22 Rocker Shaft 3120978101 Thrust Washer Set 6D22 3120978101 Thrust Washer Set 6D22 3120978201 Thrust Washer Set 6D22 3120978201 Thrust Washer Set 6D22 3120978301 Thrust Washer Set 6D22 3120978301 Thrust Washer Set 6D22 3120978401 Thrust Washer Set 6D22 3120978401 Thrust Washer Set 6D22 ME056097 Timer, 6D22 Injection Pump ME059662 Timer, 6D22 Injection Pump

ME723117 Timer, 6D22 Injection Pump ME723861 Timer, 6D22 Injection Pump ME726300 Timer, 6D22 Injection Pump ME730855 Timer, 6D22 Injection Pump 3003291300 Turbine Seal ME051410 Upper Valve Spring Retainer 6D22 ME061746 Upper Valve Spring Retainer 6D22 ME051694 Valve Cover ME051372 Valve Cover ME051373 Valve Cover Gasket 6D22 ME962499 Valve Cover Gasket 6D22 ME051208 Valve Spring ME061398 Valve Spring ME092685 Valve Stem Seal 6D22 ME704008 Valve, 6D22 Injection Pump ME704032 Valve, 6D22 Injection Pump ME704145 Valve, 6D22 Injection Pump ME704262 Valve, 6D22 Injection Pump ME704315 Valve, 6D22 Injection Pump ME084527 Valve, Oil Cooler Bypass ME074455 Valve, Oil Pressure Regulator ME719360 Wheel Compressor 6D22 ME719843 Wheel Compressor 6D22 MB110315 MC000039 MC000241 MC000325 MC010080 MC010186 MC011294 MC011362 MC012759 MC041272 MC251843 MC420083 MC429036 MC513075 MC521036 MC840100 MC840110 MC840182 MC840219 ME052868 ME052886 ME052887 ME052888

Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II

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