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Briggs & Stratton MS-1055 Repair Manual

3 cylinder liquid-cooled diesel engines
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REPAIR MANUAL
For 3 Cylinder Liquid Cooled Diesel Engines
 2002 BRIGGS & STRATTON DAIHATSU LLC
FORM MS-1055-5/02
PRINTED IN U.S.A.

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Summary of Contents for Briggs & Stratton MS-1055

  • Page 1 REPAIR MANUAL For 3 Cylinder Liquid Cooled Diesel Engines  2002 BRIGGS & STRATTON DAIHATSU LLC FORM MS-1055-5/02 PRINTED IN U.S.A.

  • Page 2: General Information

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 1 General Information Section Contents Page ENGINE IDENTIFICATION ............... .
  • Page 3 GENERAL INFORMATION IN THE INTEREST OF SAFETY 16. DO NOT touch hot muffler(s) or cylinder(s) because contact may cause burns. This safety alert symbol indicates that this 17. DO NOT remove the radiator cap while the engine message involves personal safety. Signal is hot.
  • Page 4 GENERAL INFORMATION ENGINE VIEWS Diesel 1. Thermostat 2. Oil filler cap 3. Electric starter 4. Oil pan 6. Injector nozzle 5. Alternator 7. Glow plug 8. Oil drains 9. Oil filter 10. Dipstick 11. Injector pump 12. Engine Date code xxxxxxxx 13.
  • Page 5 GENERAL INFORMATION ENGINE SPECIFICATIONS 582447 Model 432447 522447 @58A447 @588447 Type Diesel, 4-cycle, 3 cylinder, in-line, liquid cooled Valve mechanism OHV, gear driven 68 x 64 68 x 78 72 x 78 Bore x stroke mm (in) (2.680 x 2.520) (2.680 x 3.070) (2.834 x 3.070) Piston displacement...
  • Page 6 GENERAL INFORMATION Type Single piece casting Cylinder Cylinder Head Material Cast Iron Combustion Chamber Swirl Type ° Intake Valve seat angle Valve seat angle ° Exhaust Opens 10° BTDC Valve Valve Intake Intake 235° 235° Closes 45° ABDC Specifications Valve timing Specifications Valve timing Opens 45°...
  • Page 7 GENERAL INFORMATION LUBRICATING SYSTEM Lubricating Method Pressure lube Type Trochoid Oil Pump Oil Pump Drive Gear drive Oil Filter Type Full flow, paper Oil Capacity 3.3 ltr (3.5 qt) Oil Pump Relief Valve Opening Pressure 4.6 Bar (65 psi) Lubrication Oil API SE/CD class or higher COOLING SYSTEM Cooling Method...
  • Page 8 GENERAL INFORMATION TABLE 1 Injection Pump Timing Engine Date Code Before 99010100 Model/Type No. Timing Specification ± ± 0.93 .03 mm (.0365” .001”) 432447-0150-E2 ± ± 0.93 .03 mm (.0365” .001”) 522447-0105-E2 ± ± 0.93 .03 mm (.0365” .001”) 522447-0106-E2 ±...
  • Page 9 INJECTOR PUMP IDENTIFICATION IDENTIFICATION CODE SERIAL 7 : 700 cc DESTINATION U : USA 8 : 850 cc NUMBER J : Japan 9 : 950 cc X : Except for NAME PLATE IDENTIFICATION CODE TABLE 3 Engine Speed Specification Chart Pump Mfg.
  • Page 10 GENERAL INFORMATION Description Wrench/Socket Size Torque Alternator Adjust. Bracket 12 mm 19.0 Nm (170 in. lbs.) Alternator – 14 Amp (to bracket) 12 mm 19.0 Nm (170 in. lbs.) Alternator – 40 Amp (to bracket) 12 mm 61.0 Nm (45 ft. lbs.) Alternator Bracket (to block) 12 mm 19.0 Nm (170 in.
  • Page 11 GENERAL INFORMATION BRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEM All Briggs & Stratton Daihatsu engines have a unique numerical designation system. Each engine is identified by a Model, Type and Code/Serial number. Example: Model Type Code/Serial 432447 0125 01 020521145 This chart explains the numerical model designation system.
  • Page 12 GENERAL INFORMATION MAINTENANCE SCHEDULE More frequent service is required when operating in adverse conditions (note 4 below). Every Every Every Every Every System Maintenance Operation Daily Yearly hours hours hours hours hours Check oil level Check for oil leaks Lubrication Lubrication system Change oil...

  • Page 13: Cylinder Head And Valves

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 2 Cylinder Head and Valves Section Contents Page REMOVE CYLINDER HEAD ............. .
  • Page 14 CYLINDER HEAD AND VALVES REMOVE CYLINDER HEAD ALWAYS disconnect fuel shut off solenoid wire from injection pump before checking compres- sion, to prevent accidental starting. Drain cooling system and disconnect radiator hoses. 1. Remove the following parts from engine, Fig. 1-Fig. 5: a.
  • Page 15 CYLINDER HEAD AND VALVES Fig. 5: k. Fuel injector nozzles Glow plugs Fig. 5 – Remove Glow Plugs And Injectors 2. Set No. 1 piston at TDC, Fig. 6: REFERENCE a. Rotate crankshaft pulley until timing mark on POINT pulley is aligned with reference point on timing cover.
  • Page 16 CYLINDER HEAD AND VALVES DISASSEMBLE CYLINDER HEAD 1. Cylinder Head Assembly 2. Cylinder Head Gasket 3. Valve Stem Cap 4. Valve Spring Retainer Locks 5. Valve Spring Retainer 6. Valve Spring 7. Valve 8. Valve Spring Seat 9. Valve Stem Seal 10.
  • Page 17 CYLINDER HEAD AND VALVES INSPECT AND REPAIR STRAIGHT 1. Check cylinder head mounting surfaces, Fig. 12 EDGE and Fig. 13. Be sure all gasket material is removed from surfaces before checking. Use a gasket scraper if necessary. a. Inspect cylinder head for cracks or damage. b.
  • Page 18 CYLINDER HEAD AND VALVES 3. Install combustion chamber, Fig. 16. Align locating projection on combustion chamber with groove in cylinder head. Use a soft hammer and drive in new combustion chamber until it bottoms. COMBUSTION CHAMBER Fig. 16 – Install Combustion Chamber CHECK AND REPAIR VALVE GUIDES 1.
  • Page 19 CYLINDER HEAD AND VALVES 3. Using bushing driver, Tool #19416, press in new valve guide bushing until tool bottoms on cylinder head, Fig. 19. Fig. 19 – Installing Valve Guide Bushing VALVES AND SEATS 1.0 mm 1. Valve faces may be resurfaced to 45°. See Fig. 20 0.8 mm TO 1.2 mm (.040”) (1/16”...
  • Page 20 CYLINDER HEAD AND VALVES 4. Inspect valve stem cap for wear, Fig. 23. Replace if cap is worn recessed. Fig. 23 – Check Valve Stem Cap 5. Check valve springs for squareness and free length, Fig. 24. Replace if out of square more than 1.0 mm (.040 in.).
  • Page 21 CYLINDER HEAD AND VALVES 2. Check rocker arms and shaft, Fig. 26. a. Check rocker arm-bearing surface. Replace if greater than 10.03 mm (0.395 in.). b. Check rocker arm shaft Replace if less than 9.96 mm (0.392 in.). c. Check rocker arm studs for stripped threads and replace if required.
  • Page 22 CYLINDER HEAD AND VALVES ASSEMBLE CYLINDER HEAD 1. Cylinder Head 2. Cylinder Head Gasket 3. Valve Stem Cap 4. Valve Spring Retainer Locks 5. Valve Spring Retainer 6. Valve Spring 7. Valve 8. Valve Spring Seat 9. Valve Stem Seal 10.
  • Page 23 CYLINDER HEAD AND VALVES 2. Install valve spring seats, Fig. 30. NOTE: Lightly coat valve stems with Valve Guide VALVE SPRING Lubricant #93963 before installing valves. SEATS 3. Install valves. Fig. 30 – Install Valve Spring Seats And Valves 4. Install valve springs with valve spring compressor, Tool #19417, Fig.
  • Page 24 CYLINDER HEAD AND VALVES 3. Lubricate push rods with engine oil then install with recessed end up, Fig. 34. RECESSED END UP Fig. 34 – Install Push Rods 4. Install valve stem caps on valve stems. Install rocker arm assembly, Fig. 35. Install washers and torque nuts to 19.0 Nm (170 in.
  • Page 25 CYLINDER HEAD AND VALVES 7. Install exhaust manifold with new gasket, Fig. 38. a. Torque screws to 19.0 Nm (170 in. lbs.). Fig. 38 – Install Exhaust Manifold GENERAL ASSEMBLY 1. Install water pump with new gasket, Fig. 39. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.).
  • Page 26 CYLINDER HEAD AND VALVES ADJUST VALVES REFERENCE 1. Before adjusting valves, make sure that No. 1 POINT cylinder is at TDC – compression stroke, Fig. 42. TIMING MARK Fig. 42 – Set Cylinder No. 1 at TDC a. Adjust valves and check, Fig. 43. Valve Clearance (cold) IN and EX 0.20 mm (0.008 in.) b.
  • Page 27 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 3 Timing Gears and Gear Case Section Contents Page REMOVE TIMING GEAR COVER AND GEARS ............
  • Page 28 TIMING GEARS AND GEAR CASE REMOVING TIMING GEAR COVER AND GEARS Make sure that #1 cylinder is at TDC, compression stroke. See Section 2, Fig. 6. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injec- tors to prevent dirt entry.
  • Page 29 TIMING GEARS AND GEAR CASE 6. Remove oil pump drive gear, Fig. 5. a. Check oil pump drive gear for damaged teeth. PUMP GEAR Fig. 5 – Removing Oil Pump Gear CHECKING GEARS Inspect gear teeth for wear or damage. CHECK GEARS IN SEQUENCE SHOWN.
  • Page 30 TIMING GEARS AND GEAR CASE 4. Hold idler gear as shown and check gear backlash between injector pump timing gear and idler gear using dial indicator, Fig. 9. Injector pump timing gear backlash must not exceed 0.2 mm (.008”). NOTE: Idler gear must not turn while checking. If gears are worn it is recommended that they be replaced as a set.
  • Page 31 TIMING GEARS AND GEAR CASE REPLACE TIMING GEAR COVER OIL SEAL 1. Drive out oil seal. 2. Use seal driver, Tool #19423, to install new oil seal, Fig. 13. Fig. 13 – Replacing Oil Seal ASSEMBLE TIMING GEAR CASE AND GEARS 1.
  • Page 32 TIMING GEARS AND GEAR CASE 4. Assemble idler gear shaft with arrow up, as shown ARROW in Fig. 17. Fig. 17 – Installing Idler Gear Shaft Engine models 432000 and 582000 after date code 990111007, and all engine models 522000 are equipped with right angle helical timing gears.
  • Page 33 TIMING GEARS AND GEAR CASE 8. Install crankshaft pulley with timing mark at 12 o’clock position (#1 cylinder), Fig. 21. NOTE: Be sure alignment pin in crankshaft gear is seated in hole in pulley. a. Torque screw to 88.0 Nm (65 ft. lbs.). b.
  • Page 34 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 4 Flywheel and Rear Seal Retainer Section Contents Page REMOVING OIL PAN AND FLYWHEEL .............
  • Page 35 FLYWHEEL AND REAR SEAL RETAINER REMOVE REAR SEAL RETAINER Remove rear seal retainer and discard gasket, Fig. 3. Fig. 3 – Removing Seal Retainer REPLACING OIL SEAL 1. Remove oil seal, Fig. 4. Fig. 4 – Removing Oil Seal 2. Lubricate outside diameter of oil seal. a.
  • Page 36 FLYWHEEL AND REAR SEAL RETAINER 2. Install flywheel, Fig. 7. NOTE: Apply Permatex No. 2 or similar sealant to flywheel screws. a. Torque flywheel screws to 47.0 Nm (35 ft. lbs.). Remove flywheel holder. Fig. 7 – Installing Flywheel INSTALL OIL PAN SEALANT 1.

  • Page 37: Cylinder Block Disassembly

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 5 Cylinder Block Disassembly Section Contents Page ENGINE STAND FIXTURE ............... .
  • Page 38 CYLINDER BLOCK DISASSEMBLY ENGINE STAND An automotive type engine stand is recommended when complete engine disassembly is required. See drawings below for dimensions to make an engine stand mounting fixture. The engine stand shown below is manufactured by Snap-On. 215 mm 65 mm 8-3/8”...
  • Page 39 CYLINDER BLOCK DISASSEMBLY CYLINDER BLOCK DISASSEMBLY 1. Remove cylinder head. See Sec. 2. STARTER MOTOR 2. Remove oil pan, oil pick up tube, timing cover, gears and gear case. See Sec. 3. 3. Remove flywheel and rear seal retainer. See Sec.
  • Page 40 CYLINDER BLOCK DISASSEMBLY 8. Remove connecting rod and piston assemblies, Fig. 5. NOTE: Remove carbon or ridge from cylinder and number connecting rod/piston assem- blies before removing from cylinders. a. Remove connecting rod cap with lower bearing. b. Push connecting rod and piston out through top of cylinder.
  • Page 41 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 6 Cylinder Block Inspection and Repair Section Contents Page CHECKING CYLINDER BLOCK ..............
  • Page 42 CYLINDER BLOCK INSPECTION AND REPAIR 3. Check cylinder bores for wear, Fig. 3. MEASURE CYLINDER BORE IN SIX Standard Bore Size: POSITIONS SHOWN Model Series 430000 & 520000: TO DETERMINE TAPER & OUT OF 68.00-68.030 mm (2.6770-2.6783”) ROUND. Model Series 580000: 72.00-72.030 mm (2.8346-2.8358”) TOP OF RING TRAVEL (BELOW RIDGE)
  • Page 43 CYLINDER BLOCK INSPECTION AND REPAIR 2. Install camshaft bearing, Fig. 7. a. Use camshaft bearing driver, Tool #19422. NOTE: Notch on camshaft bearing must face out. Be sure oil hole in bearing is aligned with oil hole in cylinder block. Fig.
  • Page 44 CYLINDER BLOCK INSPECTION AND REPAIR 2. Remove timing gear oil nozzle, Fig. 11. OIL NOZZLE Fig. 11 – Removing Oil Nozzle 3. When re-installing oil nozzle, oil hole must be °" positioned at 45 angle, pointing towards idler gear, Fig. 12. IDLER GEAR Fig.
  • Page 45 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 7 Crankshaft, Camshaft and Bearings Section Contents Page CHECKING CRANKSHAFT ............. .
  • Page 46 CRANKSHAFT, CAMSHAFT AND BEARINGS 3. Check crankshaft timing gear teeth for damaged teeth, Fig. 3. NOTE: See Section 3 for procedure to check crankshaft timing gear for wear. If crankshaft timing gear teeth are damaged or worn, the crankshaft must be replaced. Fig.
  • Page 47 CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CONNECTING ROD BEARING CLEARANCES PLASTIGAGE If connecting rod bearings show signs of flaking or scoring, bearings must be replaced. Connecting rod bearings and crankpin journals must be clean and free of oil. 1. With upper bearing assembled to connecting rod, install connecting rod.
  • Page 48 CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CAMSHAFT 1. Measure camshaft lobe height, Fig. 11. If lobes are not to specification, replace the camshaft. Intake and Exhaust: STD: 30.065-30.135 mm (1.184-1.186”) Reject: 29.965 mm (1.18”) Fig. 11 – Checking Camshaft Lobes 2. Measure camshaft journals, Fig. 12. STD: Front –...
  • Page 49 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 8 Piston, Rings and Connecting Rod Inspection and Assembly Section Contents Page DISASSEMBLE PISTON AND CONNECTING ROD ...........
  • Page 50 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY CHECKING PISTON AND RINGS If the cylinder bore is to be resized there is no reason to check the piston as a new oversized piston will be used. If the cylinder is not going to be resized and the piston shows no signs of scoring, the piston should be checked.
  • Page 51 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY 2. Check piston pin bearing, Fig. 7. Engine Models: 432447, 522447, 582447 a. Replace if greater than 18.03 mm (0.710”) or .01 mm (.0004”) out of round. Engine Models: 58A447, 588447 b. Replace if greater than 21.03 mm (0.828”) or .01 mm (.0004”) out of round.
  • Page 52 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY ASSEMBLE PISTON RINGS TO PISTON 1. Install piston rings using ring expander, Tool MARK #19340, Fig. 11. a. Install oil ring coil expander making sure wire is inserted fully into coil. b. Install oil ring. MARK c.

  • Page 53: Cylinder Block Assembly

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 9 Cylinder Block Assembly Section Contents Page INSTALL CRANKSHAFT ................
  • Page 54 CYLINDER BLOCK ASSEMBLY 3. Install crankshaft with gear facing front of cylinder INSTALL block, Fig. 3. Take care not to damage journals or SHIMS #3 MAIN bearings. BEARING a. Install crankshaft shims on #3 main bearing web with grooves facing out. b.
  • Page 55 CYLINDER BLOCK ASSEMBLY Rotate crankshaft so that crankpin is at bottom of stroke. Then, lubricate cylinder walls, piston and rings, bearings and crankpins. 2. Using ring compressor, Tool #19070, install piston and connecting rod assemblies with arrow on piston facing front, Fig. 6. a.
  • Page 56 CYLINDER BLOCK ASSEMBLY INSTALL TIMING GEAR CASE, CAMSHAFT AND GEARS 1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 10. ID MARK a. ID mark on rotor must face cylinder block. OIL PUMP ROTOR Fig. 10 – Installing Oil Pump Rotor 2.
  • Page 57 CYLINDER BLOCK ASSEMBLY 5. Assemble injector pump to gear case with new O-ring and install nuts and support bracket screw finger tight, Fig. 14. NOTE: Pump must be able to rotate a. Align timing mark on injection pump with timing mark on gear case. NOTE: See Section 10 for injector pump timing procedure.
  • Page 58 CYLINDER BLOCK ASSEMBLY 9. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 18. a. M6 x 55 mm (M6 x 2.5”): 3 b. M6 x 45 mm (M6 x 2.1”): 2 c.
  • Page 59 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 10 Fuel System and Related Components Section Contents Page GENERAL INFORMATION ..............

  • Page 60: Fuel System Components

    FUEL SYSTEM COMPONENTS FUEL INJECTION SYSTEM COMPONENTS FUEL RETURN LINE FUEL FILTER FUEL DELIVERY LINE INJECTOR PUMP INJECTOR FUEL RETURN LINE FUEL LINE FUEL TANK...
  • Page 61 INJECTOR PUMP TABLE 1 Injection Pump Timing Engine Date Code Before 99010100 Model/Type No. Timing Specification ± ± 0.93 .03 mm (.0365” .001”) 432447-0150-E2 ± ± 0.93 .03 mm (.0365” .001”) 522447-0105-E2 ± ± 0.93 .03 mm (.0365” .001”) 522447-0106-E2 ±...
  • Page 62 INJECTOR PUMP Checking Injector Pump Timing NOTE: Clean areas around fuel lines and injec- tors to prevent any dirt from entering injector nozzles or delivery valve ports when fuel delivery lines are removed. 1. Remove fuel delivery lines from injector pump and injector nozzles, Fig.
  • Page 63 INJECTOR PUMP 5. Slowly rotate crankshaft clockwise until timing mark on pulley aligns with reference point on gear case cover (TDC), Fig. 5. Note dial indicator reading. NOTE: Do not rotate crankshaft past TDC. If crankshaft is rotated past TDC rotate crankshaft back to ‘‘0”...
  • Page 64 INJECTOR PUMP 3. While observing dial indicator, slowly rotate injec- tor pump away from cylinder head until indicator shows correct specification. Hold injector pump in this position and tighten outside pump mounting nut, Fig. 9. NOTE: Do not rotate pump past specification. If pump is rotated past specification, rotate pump back toward cylinder head and repeat procedure.
  • Page 65 INJECTORS 4. Remove injector nozzles, Fig. 13. a. Discard injector gaskets. NOTE: Handle injectors with extreme care. Do not drop! Always use new fuel return line and injector nozzle gaskets when servicing fuel system. Fig. 13 – Removing Injectors Checking Injectors Fuel injector nozzle testing requires highly specialized equipment and procedures.
  • Page 66 INJECTORS 3. Check injector for leakage, Fig. 16. Maintain injector pressure at approximately 120 Bar (1707 psi), for about 10 seconds. Make sure there is no leakage from nozzle or retaining nut area. Fig. 16 – Checking Leakage 4. Check spray pattern of nozzle, Fig. 17. Operate tester handle rapidly while observing pattern.
  • Page 67 FUEL FILTER Draining Water Collector Change Fuel Filter 1. Disconnect sensor wire and remove drain plug. When warning lamp comes on, drain water collector Discard O-ring. as follows: 2. Remove fuel filter with a filter wrench. 1. Stop engine. 3. Screw new filter on by hand until gasket contacts 2.
  • Page 68 INJECTOR PUMP IDENTIFICATION IDENTIFICATION CODE 7 : 700 cc DESTINATION SERIAL U : USA NUMBER 8 : 850 cc NAME J : Japan 9 : 950 cc X : Except for PLATE IDENTIFICATION CODE TABLE 3 Engine Speed Specification Chart Pump Mfg.
  • Page 69 ENGINE SPEED ADJUST IDLE SPEED LOCK NUT SPEED IDLE CONTROL Engine should be at operating temperature before SPEED LEVER SCREW adjusting idle speed. Make sure speed control lever contacts idle speed screw with engine at idle. 1. Loosen idle speed screw lock nut and adjust idle speed screw to obtain RPM specified by model and type number shown in chart, Fig.
  • Page 70 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 11 Electrical System Section Contents Page ELECTRICAL SYSTEM COMPONENTS ........... .
  • Page 71 Section Contents (Continued) Page STARTER SYSTEM – GENERAL INFORMATION STARTER CURRENT DRAW TEST – INSTALLED ......... . Test Equipment .
  • Page 72 Electrical System Components (Typical 40 Amp Alternator Shown) FUEL INJECTION FILTER PUMP WATER INDICATOR LIGHT PREHEATING TIMER KEYSWITCH PART NO. GLOW 493625 RELAY GLOW LIGHT SOLENOID GLOW PLUGS KEYSWITCH TERMINAL FUNCTION ACCESSORY & PREHEAT TIMER CHARGE INDICATOR LIGHT SOLENOID & PREHEAT TIMER “IG”...
  • Page 73 GLOW PLUG SYSTEM Glow Plug The glow plug is a self regulating type, consisting of two metal heating element coils; a rush coil and a brake coil, Fig. 2. The rush coil provides rapid heating of the tip of the glow plug. The brake coil decreases current to the glow plug by increasing resistance as the tempera- ture rises, regulating the temperature of the glow plug.
  • Page 74 GLOW PLUG SYSTEM PREHEAT TIMER AND GLOW RELAY The preheat timer and glow relay regulate current to the glow plugs for preheating and starting. When the keyswitch is turned to the “On” position, with the engine cold, the preheat timer activates the glow plugs. An indicator light lights and remains on while the glow plugs are preheating the combustion chamber.
  • Page 75 GLOW PLUG SYSTEM KEYSWITCHES 2 + 5 Two types of keyswitches may be used on Briggs & START 2 + 4 +5 Stratton Daihatsu diesel engines. 1 + 3 + 6 Fixed Timer Preheat Keyswitch – USED Part No. 493625 START Keyswitch, Part No.
  • Page 76 CHARGING SYSTEMS 14 AMP CHARGING SYSTEM The 14 amp charging system consists of two components: 1. The belt driven permanent magnet alternator produces AC voltage, Fig. 11. AC output will vary with engine RPM, from approximately 7 volts AC at 1000 RPM to 32 volts AC at 3000 RPM. NOTE: A loose V-belt will cause low AC output.
  • Page 77 CHARGING SYSTEMS Testing Alternator – AC Output The alternator output test will be performed with the meter in the V~ (AC volts) position, Fig. 14. Disconnect alternator wires at connector. Attach meter test leads to alternator output connectors BEFORE starting engine, Fig. 14. 1.
  • Page 78 CHARGING SYSTEMS Charging Indicator Circuit The green wire from the regulator-rectifier is used to activate the charging indicator light. With the keyswitch in the “ON” position and the engine not running the charge indicator light should light, Fig. 16. With the engine running the light should go out, indicating that the battery is being charged.
  • Page 79 CHARGING SYSTEMS 40 AMP CHARGING SYSTEM “B” “L” Fig. 1 shows wiring diagram for 40 amp charging TERMINAL TERMINAL system. The 40 amp charging system consists of a belt driven, “IG” TERMINAL internally regulated alternator, Fig. 19. The alternator contains a charge light circuit (“L” terminal).
  • Page 80 CHARGING SYSTEMS DISASSEMBLE ALTERNATOR 1. Remove pulley nut using tool #19491 and 10 mm deep socket as shown in Fig. 22. a. Remove pulley and spacer. Replace pulley if damaged or worn. Fig. 22 – Remove Pulley 2. Remove nut and insulator at “B” terminal. 3.
  • Page 81 CHARGING SYSTEMS 6. Remove four stator lead screws from rectifier, Fig. 26. a. Carefully straighten stator leads. b. Remove rectifier. STATOR LEADS STATOR LEADS Fig. 26 – Remove Rectifier 7. Scribe or place a reference mark on drive end and brush end housing so that they may be re-assembled in original position.
  • Page 82 CHARGING SYSTEMS INSTALL BALL BEARING 19226 DRIVER 1. Lightly lubricate bearing O.D. with engine oil. 2. Press in new bearing using bearing driver #19226, Fig. 30. 3. Install retainer and four screws. Fig. 30 – Install Ball Bearing CHECKING ROTOR The following test will be made with the meter in the “Diode Test Position”...
  • Page 83 CHARGING SYSTEMS CHECK REGULATOR The following test will be made with the meter in the “Diode Test Position” 1. Attach BLACK meter test lead to terminal “A” as shown, Fig. 34. 2. Contact terminal “B” with RED meter test lead, Fig.
  • Page 84 CHARGING SYSTEMS 3. Assemble brush end housing to drive end housing with reference marks aligned, Fig. 38. Note: Do not damage stator leads. 4. Install thru bolts and nuts. a. Torque to 5.0 Nm (45 in. lbs.). Fig. 38 – Assemble Housings 5.
  • Page 85 CHARGING SYSTEMS 9. Install brush holder. Important: Length of brush retainer screws are 9.0 mm different. Install as shown, Fig. 42. 11.5 mm Screw “A”: 11.5 mm Screw “B”: 9.0 mm Fig. 42 – Install Brush Holder 10. Install rear cover and three screws, Fig. 43. a.
  • Page 86 STARTER SYSTEM IDENTIFICATION NUMBER IDENTIFICATION NUMBER 28100-87805 28100-87806 Fig. 45 – 1.0 Kw (Standard) Fig. 46 – 1.2 Kw (Optional) STARTER SYSTEM – GENERAL INFORMATION Two different starter motors are used on Briggs & Stratton Daihatsu diesel engines. The standard motor is rated at 1.0 Kw., Fig.
  • Page 87 STARTER SYSTEM Testing Starter – All BLACK NEGATIVE LEAD NOTE: To prevent engine from starting, remove BATTERY CABLE fuel shut off solenoid wire from injector pump. The starter current draw test will be performed with the LEAD meter in the position.
  • Page 88 STARTER SYSTEM STARTER SOLENOID Test Equipment The starter solenoid test is performed with the starter BATTERY removed from the engine. CABLE The following equipment is recommended to test the solenoid. 1. One battery cable with alligator clips. Fig. 50. 2. A jumper wire. JUMPER WIRE 3.
  • Page 89 STARTER SYSTEM Remove Solenoid 1. Remove nut and field coil wire from stud terminal FIELD COIL WIRE on solenoid, Fig. 52. Fig. 52 – Removing Field Coil Wire 2. Remove through bolts and starter motor, Fig. 53. DO NOT remove armature from starter housing or it will be necessary to re-assemble brushes to armature.
  • Page 90 STARTER SYSTEM Check Pinion And Clutch Assembly Check pinion and gear for damage, Fig. 56. Pinion and shaft must rotate in clutch in clockwise direction only. Bearings must turn freely. CLOCKWISE NOTE: The pinion and clutch must be replaced as an assembly.
  • Page 91 STARTER SYSTEM Install Solenoid 1. Insert return spring into solenoid plunger. 2. Align pilot hole in solenoid with drive gear shaft and assemble solenoid to drive housing, Fig. 60. a. Torque screws to 9.0 Nm (80 in. lbs.). DRIVE HOUSING DOWN Fig.
  • Page 92 STARTER SYSTEM 5. Remove two nuts with 14 mm wrench, Fig. 64. 6. Remove components in sequence shown, Fig. 65. Field Wire Terminal Side: (1) G (2) F (3) E (4) D (5) C (6) B (7) A Fig. 64 – Loosen Nuts BEFORE 99010100: 1.0 KW / BEFORE 98083100: 1.2 KW Battery Wire Terminal Side: Before 99010100: 1.0 KW / After 98123100: 1.0 KW...
  • Page 93 STARTER SYSTEM 9. Install new plunger and spring. 10. Place bearing driver, Tool #19422 on plunger and compress plunger to end of travel. Maintain pressure. a. Torque nuts to 17 Nm (150 in. lbs.). Note: This provides proper contact alignment with plunger and contact plates.
  • Page 94 STARTER SYSTEM Use digital multimeter and check for continuity between field coil wire and brushes shown, Fig. 70. The following test will be made with the meter in the “Diode Test Position” 1. Attach either meter test lead to field coil wire. 2.
  • Page 95 STARTER SYSTEM ASSEMBLE STARTER MOTOR For ease of assembly, clamp splined end of armature in a vise as shown. Use soft jaws to prevent damage to spline, Fig. 74. 1. Place green seal protector from Kit #19356 over commutator. Fig. 74 – Assemble Starter Motor 2.

  • Page 96: Starter System

    STARTER SYSTEM Wiring Diagram – 14 Amp Alternator (Typical) 493625 Keyswitch With Fixed Preheat Timer and Glow Relay INJECTION FUEL PUMP FILTER PREHEATING TIMER WATER INDICATOR LIGHT GLOW KEYSWITCH RELAY PART NO. 493625 GLOW LIGHT KEYSWITCH TERMINAL FUNCTION GLOW PLUGS ACCESSORY &...
  • Page 97 STARTER SYSTEM Wiring Diagram – 40 Amp Alternator (Typical) 493625 Keyswitch With Fixed Preheat Timer and Glow Relay FUEL INJECTION FILTER PUMP WATER INDICATOR LIGHT PREHEATING TIMER KEYSWITCH PART NO. GLOW 493625 RELAY GLOW LIGHT SOLENOID GLOW PLUGS KEYSWITCH TERMINAL FUNCTION ACCESSORY &...
  • Page 98 STARTER SYSTEM Wiring Diagram – 14 Amp Alternator (Typical) 825129 Keyswitch – Manual Preheat INJECTION FUEL PUMP FILTER WATER INDICATOR LIGHT KEYSWITCH PART NO. 825129 GLOW LIGHT KEYSWITCH TERMINAL FUNCTION GLOW PLUGS BATTERY SOLENOID SOLENOID CHARGE INDICATOR GLOW PLUG (PREHEAT) LIGHT GLOW PLUG (CRANKING) ACCESSORY...
  • Page 99 STARTER SYSTEM Wiring Diagram – 40 Amp Alternator (Typical) 825129 Keyswitch – Manual Preheat FUEL INJECTION FILTER PUMP WATER INDICATOR LIGHT KEYSWITCH PART NO. 825129 GLOW LIGHT SOLENOID GLOW PLUGS KEYSWITCH TERMINAL FUNCTION BATTERY CHARGE INDICATOR SOLENOID LIGHT “IG” TERMINAL GLOW PLUG (PREHEAT) “L”...

  • Page 100: Lubrication System

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 12 Lubrication System Section Contents Page DESCRIPTION ................. . .
  • Page 101 LUBRICATION SYSTEM DESCRIPTION Briggs & Stratton Daihatsu gasoline and diesel engines use a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter. The filtered oil flows through oil galleries in the cylinder block and is distributed to the main bearings, connecting rod bearings, camshaft bearings and rocker arm shaft.
  • Page 102 LUBRICATION SYSTEM CHECK OIL PRESSURE 1. Oil level should be between the LOW and FULL marks on dipstick. If oil level is low, check for leaks and add to FULL mark. OIL LEVEL SHOULD BE BETWEEN F AND L MARKS ON DIPSTICK.
  • Page 103 LUBRICATION SYSTEM Exploded View DISASSEMBLE GEAR CASE Remove Oil Pump Make sure that #1 cylinder is at TDC, compression stroke. See Section 2. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injec- tors to prevent dirt entry.
  • Page 104 LUBRICATION SYSTEM 2. Remove oil pan screws and nuts. OIL PICK-UP a. Remove oil pan and discard gasket. TUBE b. Remove oil pick-up tube and strainer. Discard gasket, Fig. 7. Fig. 7 – Removing Oil Pan 3. Remove bell housing adapter screw if equipped. and install flywheel holder, Tool #19418.
  • Page 105 LUBRICATION SYSTEM 6. Remove injector pump timing gear with a three jaw puller, Fig. 11. O–RING a. Remove 2 nuts and injector pump. Discard O-ring. Fig. 11 – Removing Injector Pump 7. Remove parts in sequence shown, Fig. 12. a. Remove 3 screws and camshaft retainer. b.
  • Page 106 LUBRICATION SYSTEM ASSEMBLE GEAR CASE Install Oil Pump 1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 15. a. ID mark on rotor must face cylinder block. ID MARK OIL PUMP ROTOR Fig. 15 – Installing Oil Pump Rotor 2.
  • Page 107 LUBRICATION SYSTEM 6. Torque screws as shown, Fig. 19. a. Camshaft gear: 41.0 Nm (30 ft. lbs.) b. Idler gear: 25.0 Nm (220 in. lbs.) c. Injector pump gear: 61.0 Nm (45 ft. lbs.) d. Oil pump gear: 19.0 Nm (170 in. lbs.) Fig.
  • Page 108 LUBRICATION SYSTEM 11. Install Glow plugs, wiring and fuel delivery lines. a. Torque glow plugs to 17.0 Nm (150 in. lbs.). b. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.), Fig. 23. Fig. 23 – Installing Fuel Delivery Lines 12.

  • Page 109: Cooling System

    BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 13 Cooling System Section Contents Page GENERAL INFORMATION ............. . .
  • Page 110 COOLING SYSTEM CHECKING COOLING SYSTEM WARNING: The cooling system is pressurized. Do not remove the radiator cap while the engine is hot. To avoid scalding hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator cap.
  • Page 111 COOLING SYSTEM THERMOSTAT COOLANT OUTLET Removing Thermostat – Engine Cold THERMOSTAT 1. Drain engine coolant. 2. Remove screws and coolant outlet housing. 3. Remove locating screw and thermostat, Fig. 3. 4. Remove all traces of gasket material. LOCATING SCREW Fig. 3 – Removing Thermostat Checking Thermostat °...
  • Page 112 COOLING SYSTEM WATER PUMP VENT HOLES Inspecting Water Pump Inspect water pump for signs of leaking at vent holes, mounting surfaces and water pump pulley shaft, Fig. 6. 1. Remove V-belt, alternator adjustment bracket, fan (if equipped) and water pump pulley. a.
  • Page 113 COOLING SYSTEM Installing Water Pump 1. Install water pump with new gasket, Fig. 10. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.). After installing water pump make sure pump rotates smoothly. Fig. 10 – Installing Water Pump 2.
  • Page 114 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 14 Turbocharger Section Contents Page GENERAL INFORMATION ............... .
  • Page 115 950 CC DIESEL TURBOCHARGED ENGINE General Information Models 588447 and 58A447 are turbocharged equipped diesel engines. Turbocharger Lubrication System Lubricating oil for the turbocharger is supplied from the rear of the cylinder head to the turbocharger via the oil inlet line. The oil supply is regulated by the inlet port diameter of the oil inlet line.
  • Page 116 TURBOCHARGER Turbocharger Cooling System Coolant for the turbocharger is supplied from the rear right of cylinder block and returns to the water pump inlet. COOLANT OUTLET LINE COOLANT INLET LINE Fig. 3 – Cooling System of Turbocharger (1) COOLING WATER TO WATER PUMP INLET COOLING WATER FROM CYLINDER BLOCK...
  • Page 117 TURBOCHARGER Turbocharger Waste Gate The turbocharger is equipped with a waste gate to control turbocharger pressure. WASTE GATE VALVE WASTE GATE ACTUATOR Fig. 5 – Turbocharger Turbocharger Pressure Control System As pressure in the turbocharger rises, the actuator for the waste gate valve opens allowing some of the exhaust gases to bypass the turbocharger.
  • Page 118 TURBOCHARGER Crankcase Blow-by Recirculating System Crankcase blow-by is recirculated as shown in Fig. 7 CRANKCASE BREATHER TUBE FRESH AIR BLOW-BY GASES EXHAUST GASES Fig. 7 – Crankcase Blow-by Recirculating System CHECKING WASTE GATE ACTUATOR 1. Disconnect the waste gate actuator hose at the actuator.
  • Page 119 TURBOCHARGER SERVICING AND OPERATION INFORMATION POINTS TO BE COVERED WITH TAPE 1. DO NOT disassemble the turbocharger. 2. When removing and installing turbocharger: a. Handle the turbocharger carefully. DO NOT drop. b. When removing the air intake system or lubrication system, be careful not to get dust or foreign matter into the turbocharger.
  • Page 120 TURBOCHARGER REMOVE TURBOCHARGER 1. Remove the muffler or exhaust pipe from the turbocharger. 2. Lift tab on tie strap and remove tie strap. Then remove crankcase breather tube at air intake tube. STRAP Fig. 13 – Remove Clamp 3. Disconnect the air intake tube at the turbocharger. AIR INTAKE 4.
  • Page 121 TURBOCHARGER 7. Remove coolant outlet hose. OUTLET HOSE Fig. 17 – Disconnect Coolant Hose 8. Remove coolant inlet line bracket screw. BRACKET Fig. 18 – Remove Clamp 9. Remove two nuts, then remove coolant line assembly from turbocharger . Fig. 19 – Removing Coolant Line 10.
  • Page 122 TURBOCHARGER 11. Remove oil inlet line union screw at rear of cylinder head. Discard washers. Fig. 21 – Removing Union Screw 12. Remove oil inlet line bracket screw at the exhaust manifold. Fig. 22 – Removing Bracket Bolt 13. Remove two screws from turbocharger and pull out the oil outlet tube from the cylinder block.
  • Page 123 TURBOCHARGER 15. Remove nuts (3), and remove the turbocharger assembly from the exhaust manifold. Fig. 25 – Removing Turbocharger Assembly NOTE: When removing the turbocharger assem- bly, DO NOT lift or carry turbocharger by the waste gate actuator rod. Use tape to cover the oil inlet and outlet ports, coolant ports, air intake and ex- haust port.
  • Page 124 TURBOCHARGER INSTALL TURBOCHARGER 1. Install the turbocharger assembly with new gasket. a. Torque nuts (3) to 25 Nm (18.0 ft.-lb). Fig. 29 – Installing Turbocharger Assembly 2. Install the turbocharger bracket with new gasket. a. Temporarily tighten the nuts  and bolts  until the flange surfaces of the turbocharger, exhaust manifold and turbocharger stay in contact each other.
  • Page 125 TURBOCHARGER 4. Install oil inlet line. a. Temporarily install the union screw with washers at the cylinder head. b. Temporarily install the union screw with washer at the turbocharger. c. Temporarily install the inlet line bracket screw. d. Then torque union screws and bracket screw. Union screws: Cylinder head side –...
  • Page 126 TURBOCHARGER 7. Install coolant outlet hose from turbocharger to coolant inlet housing as shown, Fig. 36. Install clamps with tabs as shown. Fig. 36 – Install Coolant Outlet Hose 8. Install coolant inlet hose over inlet tube up to yellow mark on tube. Install clamps with tabs as shown.
  • Page 127 TURBOCHARGER 11. Install breather tube as shown. 12. Install muffler or exhaust pipe. 13. Connect the air hose connecting the air cleaner to the turbocharger. PULL PIPE BREATHER TUBE Fig. 40 – Installing Clamp INSTALLATION OF COOLANT INLET TUBE M10 THREAD 1.

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