Mitsubishi MOTORS 6D2 Shop Manual
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Mitsubishi MOTORS 6D2 Shop Manual

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Summary of Contents for Mitsubishi MOTORS 6D2

  • Page 2 ENGINE Shop Manual GROUP INDEX GENERAL FOREWORD ENGINE This shop manual contains the specification, con­ LUBRICATION ......struction, operation, adjustment and service proce­ dures of the Model 6022, diesel engine for service FUEL AND ENGINE CONTROL mechanics engaged in servicing of the Mitsubishi diesel engines.
  • Page 3 ORGANIZATION GROUP CLASSIFICATION 1. GROUP CLASSIFICATION This manual is organized into several groups classified according to the engine basic elements. Group Description name General External view. major specifications. engine outputs classified by application, engine numbers. caution plate. general precautions for servicing. general bolts and nuts tightening torque table Engine proper !cylinder head.
  • Page 4 ORGANIZATION - TERMS AND UNITS, TABLE OF CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS 2. TERMS AND UNITS The following terms and units are used throughout the entire texts of this manual. (1) Front and Rear The terms "front" is the fan side and "rear" the flywheel side of the engine. (2) Right and Left The terms "right"...
  • Page 5 ORGANIZATION - READING THE ILLUSTRATION 4. READING THE ILLUSTRATION (Ex. 1: Disassembly and Inspection) NV ... Nominal Value C)----4 Limit o---s Damage. abnormal wear 0--6 Indicates the service standards. Damage. discoloration :���-3 '-. · � --<) �Piston pro1ect1on NV 0.87 to 1.33 mm Scratches on outer periphery, cracks on top, melted or discolored...
  • Page 6 ORGANIZATION - READING THE ILLUSTRATION (Ex. 2: Reassembly ) NV ... Nominal Value Limit Expander spring 1st compression ring bull portion end gap direction Piston proJecl1on _____ NV O 87 lo 1 33 ____, Flange projection NV O lo 0.08 mm I 2nd compression ring end gap direction ring end gap...

  • Page 8: Table Of Contents

    m· GENERAL CONTENTS 1. EXTERNAL VIEW •..••••••••••••.•.•••••.••.•. 2 3. ENGINE NUMBERS AND 2. MAJOR SPECIFICATIONS •••..•...•••••• 3 CAUTION PLATE .••.••••••••••••••••••.•••••• 4 MAJOR SPECIFICATIONS ••.•.•.••.•. 4. GENERAL PRECAUTIONS 2.2 ENGINE OUTPUTS CLASSIFIED FOR SERVICING •••..•••..•..••••••••••••..••. BY APPLICATION ••...•.••..•...•.•.. 5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE ..•..•••...

  • Page 9: External View

    GENERAL - EXTERNAL VIEW 1. EXTERNAL VIEW ------ - -- - - --- -· <Natural-aspirated engine> A0243A <Turbocharged engine> A0244A 00-2...

  • Page 10: Major Specifications Major Specifications

    Overall length 1 390 1 401 Overall width Overall height k g ' Empty weight 1 010 • Empty weight as measured according to Mitsubishi Motors Corporation standard. ENGINE OUTPUTS CLASSIFIED BY APPLICATION 6022-TC 6022-T 6022 (Turbocharged, with (Turbocharged) after coolerl...

  • Page 11: Engine Numbers And Caution Plate

    • GENERAL - ENGINE NUMBERS AND CAUTIO N PLATE 3. ENGINE NUMBERS CAUTION PLATE ( 1 ) Engine Number VALVE CLEARANCE(COLDlj 0.4rnrn(0.016i n) .:--U.-- INLET EXHAUST0.6rnrnW.024i n ) Fl RING ORDER 1-5-3-6-2-4 FUELINJECTION 11MINGdBTDC Valve clearance Firing order 3 Fuel injection timing 89012A E0143 The engine number is stamped on the position as...

  • Page 12: General Precautions For Servicing

    4. GENERAL PRECAUTIONS FOR SER· VICING Before starting the service procedures, check the vehicle for total time driven, use conditions. and MITSUBISHI MOTORS user's complaints and requests to know exactly the GENUINE PARTS engine conditions. Record information where neces­ sary.

  • Page 13: General Bolts And Nuts Tightening Torque Table

    • GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE 5. GENERAL BOLTS AND NUTS TIGHT· NOTE: ENING TORQUE TABLE 1 . Threads and seat surf aces must be in dry state. Unless otherwise specified, the parts and equipment 2. When there is a difference between the of vehicle must be tightened by the following stan­...
  • Page 14 ENGINE CONTENTS 1. GENER· A L ........FLYWHEEL, TIMING GEAR AND 2. SPECIFICATIONS •••••••••••.•.•••••••••••• ........ 30 CAMSHAFT 3. SERVICE STANDARDS ....5.3.1 Disassembly ......30 SERVICE STANDARD TABLE ..5.3.2 Inspection ......34 TIGHTENING TORQUE TABLE ... 12 5.3.3 Disassembly ...._ ..38 4.

  • Page 15: General

    • ENGINE - GENERAL 1. GENERAL (1) Combustion Chamber Injection nozzle B0376A Piston For more effective cooling of the combustion cham­ ber, water directors which direct coolant flow are pressed into the bottom of the cylinder head. (2) Valve Mechanism Valve ca ·...
  • Page 16 ENGINE - GENERAL (a) Both inlet and exhaust valves are made of surface-treated heat-resistant steel. The valve seat angle is 45. A valve stem seal is provided on the stem of valve to control the quantity of lubricant of the valve and valve guide sliding portions.
  • Page 17 ENGINE - GENERAL (5) Connecting Rod and Connecting Rod A Niresist piston ring insert is cast into the 1st piston Bearing ring groove to increase durability. Stamped on the top surface of the piston are a size mark (or oversize dimension on oversize pistons) for <6022-T C >...
  • Page 18 ENGINE - GENERAL (6) Crankshaft and Main Bearing ·-- ··-·-·--- ---·-··----- ------ � ·· Rubbe r type (single m ass ;;>/ Torsio nal damp er ·-, hole Journal sectin11 Torsional damper � Balance weight Crankshaft pulley 84206A (a) The crankshaft is a high-rigidity die forging integ­ ·...
  • Page 20 ENGINE - GENERAL (8) Flywheel Each gear is a carbon steel helical gear having a high-prescision tooth surface machined by the shav­ ing machine and given surface treatment to improve durability. A timing mark is stamped on each timing gear. Correct meshing can be achieved by aligning the timing marks at reassembly.

  • Page 21: Specifications

    • ENGINE - SPECIFICATIONS 2. SPECIFICATIONS Item Specifications Engine model 6022 6022-T 6D22 - TC Type Water cooled, Water cooled, Water cooled, 4 - cycle diesel 4 - cycle diesel 4 - cycle diesel Number of cylinders - arrangement 6 - in - line 6 - in - line 6-in-line Valve mechanism...

  • Page 22: Service Standards

    ENGINE - SERVICE STANDARDS 3. SERVICE STANDARDS SERVICE STANDARD TABLE Unit:mm Description Nominal v;tlue Limit Correction and remarks !Basic diamete, I Compression pressure 2.75 MPa 1.96 MPa Difference between cylinder within 20 kgf/cm lat 200 rpm) (28 kgt/cm 0.39 MPa (4 kgf/cm Replace bushing.
  • Page 23 • ENGINE - SERVICE STANDARDS Unit:mm Description Nominal value Limit Correction and remarks [Basic diameter[ Flywheel Eccentricity Correct installed condition. (Flywheel housing) Friction surface distortion or less Correct. Depth from clutch cover mounting 49.5 Replace. surface to friction surface Between crankshaft gear and 0.12 to 0.26 Replace.
  • Page 24 ENGINE - SERVICE STANDARDS Unit:mm Limit Oesc.r1pt1on Nom111al value Correction and remarks [Basic d1amclcr[ 130.014 10 Cylinder 1.0. 130.054 130.25 Replace o� correct to oversize. ·- liner Cylindricity 0.02 or less (diameter basel from crankcase Projection O to 0.08 surface 6022 Piston to 1 130[...

  • Page 25: Tightening Torque Table

    • ENGINE - SERVICE STANDARDS TIGHTENING TORQUE TABLE Tightening torque Description Thread size Remarks 0.0. Pitch mm Nm (kgfm) Engine Cylinder For tightening proper head bolt procedure refer lo 5.2.3 (6). 34 (3.5) Rocker shaft bracket bolt Rocker cover bolt 9.8 (1) 1.25 Rocker adjusting screw lock nut...

  • Page 26: Special Tool

    ENGINE - SPECIAL TOOL 4. SPECIAL TOOL Part No Tool name Sh;,pe MH0614GI Compression gauge adapter Measurement or c01npression pressure ::�me<e,s Distance between centers 46 85001A Thickness gauge MH061359 Adjustment of valve clearance 85011A Valve liher MH061668 Valve lifter Removal and installation of valve cotter Valve lifter MH061679 Hook...
  • Page 27 • ENGINE - SPECIAL TOOL Part No. Tool name Shape MH061236 Rocker bushing puller Removal and installation of rocker bushing B5311A 30091-08100 Valve guide puller Removal and installation of valve guide B5111A Caulking tool body Valve seat insert Installation and caulking of valve seat MH061360 caulking tool insert...
  • Page 28 ENGINE - SPECIAL TOOL P,irl No. Shape Tool name MH061490 Removal of cylinder liner Cylinder liner extractor B5131A Cylinder liner installer MH061759 Press-fitting of cylinder liner MH061238 Connecting rod bushing puller Removal and installation of connecting rod bushing B5321A MH061652 Rear oil seal slinger installer Press-fitting of rear oil seal slinger Froni oil seal slinger installer...
  • Page 29 • ENGINE - SPECIAL TOOL Part No. Tool name Shape MH061229 Nozzle tube stamp Installation of nozzle tube MH061416 Nozzle tube installer flange MH061231 Nozzle tube installer bolt between centers 46 Diameter 8 85181A Valve stem seal installer ME067431 Press-fitting of valve stem seal Diameter 12 Diameter 24...

  • Page 30: Service Procedures

    • ENGINE - SERVICE PROCEDURES 5. SERVICE PROCEDURES NOTE: Cover the mounting holes and injection MEASUREMENT OF COMPRESSION pipes to prevent entry of dust and dirt. PRESSURE Compression pressure must be measured prior to disassembly of the engine. Measure the compression pressure at regular inter­ NV..

  • Page 31: Cylinder Head And Valve Mechanism

    ENGINE - SERVICE PROCEDURES CYLINDER HEAD AND VALVE MECHANISM 5.2.1 Disassembly Oil hole � -!ear Wear. damaged threads Water leaks. gas leaks Wear. damage Carbon deposition, cracks, scale deposition, damage Carbon deposition, burn. cranks. damage, ridge wear Water leaks, oil leaks, gas leaks <Disassembly sequence>...
  • Page 32 • ENGINE - SERVICE PROCEDURES (2) Removal of Cylinder Head Assembly Disassembly Procedure (1) Removal of the Rocker Shaft Bracket Assembly Rocker cover Cylinder head Rocker shah bracket Cylinder head mount1n� bolt gasket Knock pin Cylinder head bolt Adjusting B9014B screw The cylinder head is held in position by the dowel C1543B...
  • Page 33 ENGINE - SERVICE PROCEDURES (4) Removal of Nozzle Tube Nozzle Tube Remover MH061232 Nozzle tube C1527A NOTE: The nozzle tube need not be removed unless water leaks, gas leaks, etc. are evident. 11-20...

  • Page 34: Inspection

    • ENGINE - SERVICE PROCEDURES 5.2.2 Inspection -------------------- - - --- �---- - - - - - - - --- - - - -- - - ------ ·-··-- BO ... Basic Diameter Nominal Value Clearance Free length Limit BO 28 NV 89.38 NV 0.03 to 0.08 Load/installed length...
  • Page 35 ENGINE - SERVICE PROCEDURES (3) Inspection of Valve Spring Inspection Procedure ( 1) Rocker to Rocker Shaft Clearance Squareness !inner spring only) � C2701A Measuring position C2734A Mesure the free length and installed load of the spring and replace if the measurement exceeds the limit. For If the limit is exceeded, replace the bushing in the the inner spring, check also for squareness.
  • Page 36 ENGINE - SERVICE PROCEDURES ( 5) Runout of Push Rod (7) Valve Stem O.D. Measuring position C2747A C3102A Check for runout and replace if the reading on the dial Replace the valve if the measurement is below the indicator exceeds the limit. limit.
  • Page 37 • ENGINE - SERVICE PROCEDURES · (9) Replacement of Valve Guide Valve Guide Puller 30091-08100 Valve guide Good C2707A To install C3113A If any unusual contact pattern is noted, correct as follows. Using Va!. v e Guide Puller (special tool), replace the valve guide.
  • Page 38 ENGINE - SERVICE PROCEDURES (12) Correction of Valve Seat Insert (13) Replacement of Valve Seat Insert Since the valve seat insert is installed by expansion fit, replace it by the following procedures. C31 27 A Valve Valve Valve seat sinkage margin angle 0.5 to 1.0...
  • Page 39 • ENGINE - SERVICE PROCEDURES NOTE: (d) Install the valve seat insert using the Caulking 1. Make sure that no compound sticks to Tool Body, Caulking Ring and Caulking Tool (special the valve stem. tools) and caulk the periphery of the valve sert insert. 2.

  • Page 40: Reassembly

    ENGINE - SERVICE PROCEDURES 5.2.3 Reassembly � - - - - � �--- - · - - - - - - - - - -· --· -·- ---------- - - - - - - - - - Close-coiled end on the cylinder head side 14 10 59 Nm...
  • Page 41 • ENGINE - SERVICE PROCEDURES Reassembly Procedure (3) Installation of Valve Stem Seal (1) Installation of Water Director Water director aling cap Align notch with this line. Cylinder head 6 mm 2 mm ® g Valve stem seal � Cylinder head �...
  • Page 42 ENGINE - SERVICE PROCEDURES (5) Installation of Rocket Shaft Bracket (6) Tightening of the Cylinder Head Bolts and Cylinder Head C6649A Tighten the cylinder head bolts in the sequence shown above to 175 Nm (18 kgfm). Cylinder head -----��;;rc=-j, gasket After tightening, verify the correct torque, then re­...

  • Page 43: Flywheel, Timing Gear And

    • ENGINE - SERVICE PROCEDURES FLYWHEEL, TIMING GEAR AND CAMSHAFT 5.3.1 Disassembly <With mechanical tachometer drive> <With electrical speed sensor> � o S J �' Damage, unusual wear in gear Oil leaks Wear, deterioration Streaks on worn surface, cracks, taper wear <Disassembly sequence>...

  • Page 44: Camshaft

    • ENGINE - SERVICE PROCEDURES ��- minal Valu Limit acklash -�·Timing gciir b· . Crankshaft - , c11er gear .. B .. NV O 12 0.26 · · · Oil l lrller g�:r "A" shaft gear � . 26 NV 0.13 to 0 .
  • Page 45 • ENGINE - SERVICE PROCEDURES Disassembly Procedure (3) Measurement of Gear Backlash (1) Removal of Flywheel Threaded hole for removal C1930A C1928B If the backlash exceeds the limit, check idler gear bushing and gears and replace parts as necessary. Thread the mounting bolt into the removing threaded NOTE: hole to remove the flywheel.
  • Page 46 wwparts@gmail.com Phone: 269 673 2313...
  • Page 47 • ENGINE - SERVICE PROCEDURES 5.3.2 Inspection NV... Nominal Value Depth from clutch cover Limit mounting surface to friction surface NV 48 49.5 Distortion of friction surface NV 0.1 or less C2758C 11-34...
  • Page 48 ENGINE - SERVICE PROCEDURES - - - -- - - - - - - - -� � - - - - -- - -- --- ----�---- - - - - - - · - -- · BO .. Basic Diameter NV..
  • Page 49 • ENGINE - SERVICE PROCEDURES (2) Correction of Flywheel Friction Surface Inspection Procedure ( 1 ) Distortion of Friction Surf ace Clutch cover mounting surface Friction surface C35098 Correct the friction surface with a surface grinder. Make sure that the friction surface is parallel to Place the flywheel on a surface plate and move a dial surface A within 0.1 mm.
  • Page 50 ENGINE - SERVICE PROCEDURES (4) Replacement of Idler Gear Bushing (6) Camshaft Jour.nal to Crankcase Cam• shaft Bushing Clearance Pressure Pressure Idler Gear Bushing Puller MH061228 (for idler gear "A") MH062046 (for idler gear "C") � Bushing Idler gear To remove To install C4102A C3808A...

  • Page 51: Disassembly

    ENGINE - SERVICE PROCEDURES 5.3.3 Disassembly Mounting condition Eccentricity Bend lock washer Idler gear end play NV 0.1 to 0.28 265 Nm (27 kgfm) (wet) Camshaft gear end play NV 0.05 to 0.22 /19A 155 Nm --(16 kgfml 315 Nm (32 kgfmHwet) 98 Nm (10 kgfm)
  • Page 52 ENGINE - SERVICE PROCEDURES Reassembly Procedure (3) Installation of Camshaft Gear ( 1) Installation of Rear Plate L� fo_fel_ 264 Nm ' ( 27 kgfm) (Wet) Lock washer (to be bent) 84227A C6230C I Install the camshaft gear so that the side having stamped numbers "4"...
  • Page 53 • ENGINE - SERVICE PROCEDURES (7) Installation of Rear Oil Seal Slinger (9) Installation of Flywheel Housing Locating pin Rear oil seal slinger Threaded groove C5529B C6230D (8) lnst�llation of Ring Gear Install the flywheel housing and gasket so that they are aligned with the locating pins in the crankcase.
  • Page 54 ENGINE - SERVICE PROCEDURES (11) Installation of Oil Seal ( 1 2) Flywheel Runout Check Oil seal Seat oil seal end on the retiliner positively all around. 315 Nm (32 kgfm) (Wet) Flywheel C6209A C6236B When press-fitting an oil seal to the retainer, apply Install the flywheel to the crankshaft by tightening to force uniformly to the entire periphery.
  • Page 56 ENGINE - SERVICE PROCEDURES - - - - - - - -- · � - --- - - - -- --- · ·· --·- ------------- - - - - - ----� Oil hole clogging 5.4.) Main bearing 18, 20 Nominal Value Limit Scratches, cracks, indentation, seizure, plugged oil hole,...

  • Page 57: Disassembly

    ENGINE - SERVICE PROCEDURES Disassembly Procedure (3) Removal of Piston (1) Piston Projection The piston projection must be up to specification, as it affects engine performance and is also necessary for preventing interference with the valve. �o Measuring point C2341A When the withdrawing the piston from the crankcase by pushing up together with the connecting rod.
  • Page 58 ENGINE - SERVICE PROCEDURES (5) Removal of Piston Ring (7) Removal of Main Bearing Cap ______ Slide hammer Piston Ring Tool 31191-02900 80180A 801838 (6) Crankshaft End Play The rearmost main bearing cap is held in position by dowel pins. Remove it by use of a slide hammer. (8) Removal of Crankshaft Gear Rear oil seal slinger...
  • Page 59 ENGINE - SERVICE PROCEDURES 5.4.2 Inspection Open end clearance NV 0.4 to 0.6 Clearance BO 50 Piston ring groove to piston ring NV 0.01 to 0.02 clearance 1st ring NV 0.06 to 0.11 0.25 2nd ring NV 0.05 to 0.08 <6022> 0.07 to 0.10 <6022-T, 6022-TC>...

  • Page 60: Inspection

    ENGINE - SERVICE PROCEDURES Bend NV 0.04 or less Out of roundness NV 0.01 or less 0.08 Cylindricity NV 0.006 or less Tension when free Less than 106.5 BD ... Basic Diameter NV ... Nominal Value ... Limit Oil clearance BD 100 NV 0.08 to 0.15 0.25...
  • Page 61 '. NN G I N E - SERVICE CCIEDURES � ------ � � � - -- -- - � =- ---------- --� : = =- Cylinder L " NOTE : ,ner Flange Projection ca � e is groun d, m a k e sure When the cran k...
  • Page 62 ENGINE - SERVICE PROCEDURES ------ - - - - - - - - - -- - - 1 (b) Installation Strike in. Cylinder Liner Installer MH061759 Cylinder liner Size rnark Piston Cylinder liner C4427B C4813C Securely seat the cylinder liner on the crankcase by lightly striking the flange portion, using Cylinder 1) When replacing the cylinder liner, use a cylinder Liner Installer {special tool).
  • Page 63 ENGINE - SERVICE PROCEDURES (6) Selection of Piston and Cylinder Liner (b) Oversize piston A piston may be standard or oversize, depending on Bore the cylinder liner as follows according to the which the cylinder liner is to be selected as follows. type of piston ( +0.5, +0.75, + 1.00 mm).
  • Page 64 ENGINE - SERVICE PROCEDURES (8) Piston to Piston Ring Clearance (9) Piston Ring Gap Piston '- - - - .-.. Piston ring Cylinder liner C4806A 848078 Measure the piston to piston ring clearance. If the Measure the piston ring gap with the piston ring limit is exceeded, replace the piston rings or piston.
  • Page 65 ENGINE - SERVICE PROCEDURES ( 11) Piston Pin to Connecting Rod Small (a) Align the oil hole of the bushing with the oil hole End Clearance of the connecting rod. (b) Press the bushing in from the chamfered side of connecting rod end.
  • Page 67 • ENGINE - SERVICE PROCEDURES (19) Correction of Crankshaft to Under- (17) Crankshaft Roundness and Cylindri­ size city If the journal or pin is damaged or seized, grind the crankshaft by the following procedures. Replace the Roundness Cylindricity bearing with an undersized one. Measuring direction Measuring position 54.0...
  • Page 68 • ENGINE - SERVICE PROCEDURES Finishing Grinciing Whestone or sand paper Crankshaft C5509A (e) To grind the crankshaft with grinder, the grinder and crankshaft should be turned clockwise as viewed from the crankshaft front end. (f) To finish the crankshaft with a grindstone or sandpaper, turn the crankshaft counterclockwise.

  • Page 70: Reassembly

    ENGINE - SERVICE PROCEDURES Reassembly Procedure (3) Installation of Upper Main Bearing and Thrust Plate Upper main bearing (1) Installation of Oil Spray Plug �--- - - - -------- - - - - \� •1 ·. f�is� - ';:i)' :--:: · (e l) f'i: Thrust plate -;;..'...
  • Page 71 • ENGINE - SERVICE PROCEDURES (7) Installation of Lower Main Bearings and (b) Locate the gear so that the dowel pin of the Main Bearing Caps crankshaft will fit in the notch of the gear and fit the gear by lightly striking the gear end with a soft Follow the procedure given below.
  • Page 72 ENGINE - SERVICE PROCEDURES (c) Only to both sides of the rearmost main bearing (f) Check to see if the end play of the crankshaft is cap, install the thrust plates facing their oil grooveless within nominal value. side toward the cap. [Refer to Item (6), Section 5.4.1.] NOTE: (8) Installation of Connecting Rod Bolt...
  • Page 73 • ENGINE - SERVICE PROCEDURES (9) Reassembly of Piston and Connecting (1 O) Installation of Piston Ring : � ;� ,,.- Piston Arrow showing front Ends Manufacturer mark stamped Connecting rod C5841B Snap ring Piston pin Etched cylinder Stamped or etched weight mark Direct lug groove _-,,--,..,...
  • Page 74 · 111 ENGINE - SERVICE PROCEDURES NOTE: (11) Installation of Upper and Lower Con­ necting Rod Bearings 1 . Make sure that the size symbol of the piston is the same as that of the cylin­ Lower connecting der liner. t h es e.

  • Page 75: Inspection And Adjustment Of Valve Clearance

    • ENGINE - SERVICE PROCEDURES (13) Installation of Connecting Rod Caps INSPECTION AND ADJUSTMENT OF VALVE CLEARANCE The valve clearance should be checked and adjusted Connecting rod cap as described below while the engine is cold . Front of engine Alignment mark -- _- -----...
  • Page 76 ----- - - - - ------ - - - -- ENGINE - SERVICE PROCEDURES (3) Measure the rocker arm to cap clearance valve with a thickness gauge to determine whether the Valve clcar<1ncr. lwhr.n colcll clearance is up to specification. Inlet O 4 mm Exhaust 0.6 mm...

  • Page 77: Troubleshooting

    • ENGINE - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Inadequate oil viscosity Replace Group 12 Engine will not start Incorrect fuel in use Group compression pressure • Adjust Incorrect valve clearance • Defective head gasket Replace • Worn valve and valve carbon deposit seat, •...
  • Page 78 ENGINE - TROUBLESHOOTING Symptom Probable c,l\1se Remedy Ref. group Inadequate oil viscosity output Replace Group Group Incorrect fuel in use Defective cooling system Correct or replace Group Intake/exhaust system not functioning properly • Clogged Correct or replace Group 15 air cleaner •...
  • Page 79 ENGINE - TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Noise produced from cylinder head or crankcase Abnormal • engine noise Low compression pressure !See "Engine will no! start" I • Incorrect injection liming Group 13 Adjust • Incorrect spray condition Correct or replace •...
  • Page 80 LUBRICATION CONTENTS 1. GENER· A L •••••••.••••..•••.•.••.•..•.•.••••.••• DISASSEMBLY, INSPECTION AND REASSEMBLY ••••••••••••••••.•••.••.••.. 13 2. SPECIFICATIONS •••••••••••••••••.•..••••• 10 3. SERVICE STANDARDS •••••••..••••••••• 10 4.2.1 Oil Pump ......... SERVICE STANDARD TABLE •.••. 10 4.2.2 Oil Filter ••••••••••••••••••••••.••..••.••.. 16 4.2.3 Oil Cooler •••••••••••••.••..•...•..••.•••. 1 7 TIGHTENING TORQUE TABLE .•.

  • Page 81: General

    LUBRICATION - GENERAL 1. GENERAL Engine lubrication is accomplished by forced lubrica­ tion system using gear pump. The engine oil in the oil pan is drawn up through the oil strainer by the oil pump and force-fed to the oil filter and oil cooler to lubricate all parts.
  • Page 82 LUBRICATION - GENERAL (1) Oil Pump Oil pump gear Oil pump idler gear Drive gear Driven gear From oil strainer 81541A At the time, the engine oil is drawn in from the suction side by the negative pressure produced as the gear turns along the inside of the pump case, and is carried Oil pump along the gear and case inside wall to the delivery...
  • Page 83 • LUBRICATION - GENERAL (2) Oil Filter Oil filter · head Element Oil filter case Center bol t Drain plug !Bypass filter! !Full-flow filter! 815448 81543A When the oil filter element is clogged and the difference in pressure between the filtered and unfil­ The oil filter is a double oil filter consisting of a tered oil exceeds the limit specified, the valve in the full-flow filter made integral with bypass filter.
  • Page 84 LUBRICATION - GENERAL (3) Oil Cooler Oil cooler element Coolant� To main oil gallery 81545A (4) Bypass Valve The shell-and-plate type (multi-plate type) oil cooler is mounted in the coolant path on the left side of the crankcase. Engine oil forced through the oil filter flows inside the oil cooler element;...
  • Page 85 LUBRICATION - GENERAL (b) Camshaft (5) Regulator Valve Regulator valve Main oil �1allery 81529A 81547A The reguliJtor valve is mounted in the main oil gallery Lubrication of the camshaft bushings is accomplished in the crankcase to make sure that no excessive by the oil flowing through the oil holes from the pressure acts on the lubrication system.
  • Page 86 LUBRICATION - GENERAL Engine oil fed to the cylinder head flows through the (e) Cooling the piston (oil jet) oil holes in the rocker shaft bracket and rocker shaft to lubricate each rocker bushing. The engine oil is also sprayed out of the rocker arm oil holes for lubrication of the sliding surfaces of valve cap and valve stem as well as the sliding surfaces of push rod and adjusting screw.
  • Page 87 • LUBRICATION - GENERAL (7) Lubrication of Turbocharger The injection pump and air compressor are lubricated as follows: Oil m ain gallery �I l � ___ _ �- --' n _ i e _ c _ t i o n - p r _ __ _ _, P __ _ - o - l...
  • Page 88 LUBRICATION - GENERAL (9) Lubrication of Water Pump To oil pan ' From main oil gallery 00052A The engine oil drawn by the oil pump is routed The engine oil is then forced back from the drain port through the crankcase oil passage to the water pump. to the crankcase and returns to the oil pan.

  • Page 89: Specifications

    LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS 2. SPECIFICATIONS Item Specifications Engine oil Quality !Without turbocharger! AP\ classification Class CC or better IWith turbocharger ! AP\ classification Class CD or better I For general powerl \For construction machinery ! Oil pan capacity Approx.

  • Page 90: Tightening Torque Table

    LUBRICATION - SERVICE STANDARDS Description Nommal val11c Limit Correction and remarks !Basic <i,amctcrl Relief valve 1180 kPa Replace spring. valve opening pressure 112 kgflcm:) pump Relief valve spring load 150 to 165 N (Installed length: 46.3) 115.3 to 16.9 kgfl Oil bypass alarm valve opening pressure 345 to 390 kPa Replace.

  • Page 91: Service Procedures

    • LUBRICATION - SERVICE PROCEDURES 4. SERVICE PROCEDURES NOTE: 1. To remove the oil cooler, remove the injection pump beforehand. At idle NV 145 kPa (1.5 kgf/cm') 2. After the element has been installed, or more start the engine and check connections 49 kPa (0.5 kgf/cm') for oil leaks.

  • Page 92: Disassembly, Inspection And Reassembly

    LUBRICATION - SERVICE PROCEDURES DISASSEMBLY, INSPECTION AND REASSEMBLY 4.2.1 Oil Pump (1) Disassembly and Inspection Clearance between idler Relief valve opening shaft to idler gear pressure BD 22 NV 1 180 kPa NV 0.03 to 0.05 (12 kgf/cm') 0.15 'Backlash Installed load of spring NV 0.11 lo 0.24 (Installed length: 46.3)
  • Page 93 LUBRICATION - SERVICE PROCEDURES Disassembly and Inspection Procedure (a) Before disassembly, measure and record the backlash between the oil pump gear and the idler gear. C9521A 2) Measure the clearance between the drive and dri\len gear tooth end and the oil pump case with a thickness gauge.

  • Page 95: Oil Filter

    LUBRICATION - SERVICE PROCEDURES 4.2.2 Oil Filter Cr a cks Clogging, deformation <Disassembly sequence> Drain plug Center bolt ------ Washer Cracks, deformation Oil filter case Oil filter element Element retainer Oil filter head Oil bypass alarm C9705C Inspection of Oil Bypass Alarm P ressure g a __ ___ �...

  • Page 96: Oil Cooler

    LUBRICATION - SERVICE PROCEDURES 4.2.3 Oil Cooler Damage, cracks, scale, oil leaks Cracks, scale Oil cooler element 2 Bypass valve 3 Oil cooler cover " ""' � � NV ... Nominal Value Bypass valve opening pressure NV 175 to 215 kPa (1.8 to 2.2 kgf/cm') C9804C (2) Air Pressure Test...

  • Page 98: Troubleshooting

    LUBRICATIONS - TROUBLESHOOTING 5. TROUBLESHOOTING Probable cause Symptom Remedy Ref. group Abnormal oil level pressure • does not increase leaks into coolant Correct and fill to specified level Oi l leaks Incorrect oil viscosity • Oil out of life Replace •...
  • Page 100 FUEL AND ENGINE CONTROL CONTENTS 1. GENERAL ........FEED PUMP ........ 2. SPECIFICATIONS ......22 5.3.1 Disassembly, Inspection and 3. SERVICE STANDARDS ....23 Reassembly ......81 SERVICE STANDARD TABLE ..23 5.3.2 Test and Adjustment ....82 TIGHTENING TORQUE TABLE ... 25 AUTOMATIC TIMER ....

  • Page 101: General

    FUEL AND ENGINE CONTROL - GENERAL 1. GENERAL Injection pipe Injection nozzle Fuel feed Fuel pump filter Governor Fuel leak-off pipe Fuel feed pipe pipe Water Fuel feed Fuel return separator pu mp pip e (Option! Fuel tank NOTE: The figure shows the AD improved version injection pump.
  • Page 102 FUEL AND ENGINE CONTROL - GENERAL ( 1) Injection Pump Proper (a) Injection pump AD type --6022> P type <6022· T, TC> Delivery valve holder Delivery valve holder --� ·'.] Delivery valve spring Delivery valve seat Delivery valve seat Plunger barrel Control rack Oil sump Control sleeve...
  • Page 103 FUEL AND ENGINE CONTROL - GENERAL (b) Plunger The plunger has an oblique groove and a vertical groove, while the plunger barrel has 2 inlet-outlet holes. Pressurized feeding of fuel oil begins when the plunger, pushed up by the cam of camshaft, closes the inlet-outlet holes of plunger barrel.
  • Page 104 FUEL AND ENGINE CONTROL - GENERAL A delivery valve stopper, provided on the top of the delivery valve spring, limits the lift of the delivery Eff P.ctive strokP. valve to prevent the surging of the valve during high speed operation. It also reduces the dead volume between the delivery valve and nozzle and stabilizes the injection rate.
  • Page 105 FUEL AND ENGINE CONTROL - GENERAL ( 2 ) Governor ( a) RSV type governor Supporting lever Guide lever shaft Governor housing Tension lever Start spring �Control rack Shackle -Adjusting lever Control lever Governor spring Camshaft Flyweight Ungleich spring Stop lever Full-load stopper bolt 826578 The RSV type governor is a centrifugal type all-speed...
  • Page 106 FUEL AND ENGINE CONTROL - GENERAL When the governor spring receives tension, the bottom end of the tension lever touches the adjust­ Start spring able full-load stopper bolt. When the angle of the adjusting lever is changed, the angle of the swivel lever is also changed and the rack tension of the governor spring changed.
  • Page 107 FUEL AND ENGINE CONTROL - GENERAL 3) Maximum speed control At that time, the flyweights are stationary, and the start spring with weak tension pulls the control lever ------------ - --- - - - ------� in the direction that fuel is increased. At the same time, the control block and governor Adjusting lever sleeve push the flyweight roller to the left.
  • Page 108 FUEL AND ENGINE CONTROL - GENERAL 4) Ungleich operation The air intake rate of the engine falls as the engine speed increases. The injection pump, on the other hand, increases the per-stroke injection as the speed When max. injection is set increases, even with the control rack at the same at low-speed operation position.
  • Page 109 FUEL AND ENGINE CONTROL - GENERAL 5) Stopping of engine Full load Adjusting lever Tension lever Control rack Shifter Stop 82665A Stop lever 82666A As the engine speed increases, the centrifugal force of flyweight increases. If it becomes larger than the When the stop lever is moved to the stop position, the pressure of the Ungleich spring, the Ungleich spring control rack is moved to the stop position to stop the...
  • Page 110 FUEL AND ENGINE CONTROL - GENERAL When the adjusting lever is fixed in the lever set At the time, the tension lever pin pushes the bottom position, a sudden increase of load, if no torque of the torque control lever, and the lever moves with spring is provided, will move the control rack along the pin "A"...
  • Page 111 FUEL AND ENGINE CONTROL - GENERAL 1) Start of engine and control of idling Increase.- Injection rate --- Decrease Increase� Injection rate - Decrease Floating lever Tension lever N•r-«:>'41:::::� Lo ad cont ro I Load control lever lever Idling spring Idling spring B2605A B2603A...
  • Page 112 FUEL AND ENGINE CONTROL - GENERAL At the same t ime, the fulcrum B will also slightly As the engine speed increases, the centrifugal force of move toward the pump housing to push the control the flyweight will increase, and the flyweight will rod back in·...
  • Page 113 FUEL AND ENGINE CONTROL - GENERAL Movement of the shifter will move the point B, and movement of the tension lever will move the point D, With smoke s' e t and will also move the point C with the point E as the assembly fulcrum.
  • Page 114 FUEL AND ENGINE CONTROL - GENERAL 5) Engine stop The floating lever A pushed by the floating lever link turns in such a way as to make the cancel spring bend Stop lever over the shaft B. So no load is placed on the floating lever C blocked by the idle stopper bolt outside the governor.
  • Page 115 FUEL AND ENGINE CONTROL - GENERAL When the pressure of the pressure chamber or the Outlet delivery pressure e x ceeds specification, the piston Piston spring cannot be brought back by the pressure of the piston spring, so the pump action stops and the fuel pressure in the fuel filter does not rise more than necessary.
  • Page 116 FUEL AND ENGINE CONTROL - GENERAL The two flyweights have a hole at one end. The pins of the flyweight holder fit in the holes. The flange legs At maximum Spring touch the curved surfaces of the flyweights. Timer advance angle springs are mounted to the flyweight pins and flange legs.
  • Page 117 • FUEL AND ENGINE CONTROL - GENERAL (b) SP type automatic timer [6D22· T, TC] Oil seal 0-ring Cover Spring seat Timer housing B3201A Two flyweights are fitted on the pins of the timer Timer springs are held between the spring seats fitted housing and are held in the timer housing.
  • Page 118 FUEL AND ENGINE CONTROL - GENERAL (5) Coupling �-------- - --- � --- -------- [For AD type] Timer snring Flange Cross coupling Driving coupling Air compressor crankshah Advance angle Coupling plate Cotter bolt 83405A [For P type] Cross coupling "· Driving coupling 83202A Crankshaft,...
  • Page 119 FUEL AND ENGINE CONTROL - GENERAL (6) Pump Drive Case The high pressure fuel which has forced the needle valve up is injected from the orifice at the end of the nozzle into the engine combustion chamber. Some of the high pressure fuel lubricates the needle valve, etc.
  • Page 120 FUEL AND ENGINE CONTROL - GENERAL (8) Fuel Filter (9) Water Separator [Option] � - - - - - - - - - - - - � To injection pump cover From fuel feed pump 1 1 1 1 1 �...

  • Page 121: Specifications

    FUEL AND ENGINE CONTROL - SPECIFICATIONS 2. SPECIFICATIONS Specification Item (Diesel Kiki Co., ltd. product) [6D22[ \6022-T[ \6D22-TCJ (Standard) (Option) (Standard) (Option) Injection pump proper Bosch in-line Bosch in-line Type Bosch in-line Bosch in-line Bosch in-line type type type type type Model Clockwise...

  • Page 122: Service Standards

    FUEL AND ENGINE CONTROL SERVICE STANDARDS 3. SERVICE STANDARDS SERVICE STANDARD TABLE ( 1) Injection Pump Unit: mm Description Limit Nominal value Correction and !Basic diameter! remarks Fuel injection start timing IBTDCI Adjust. Dependent on specification Eccentricity with respect lo air compressor crankshah Adjust.
  • Page 123 FUEL AND ENGINE CONTROL SERVICE STANDARDS Unit:mm Nominal value Limit Description Correction and !Basic diameter! remarks Feed Tightness !when 195 kPa (2 kgf/cm') of O cc/min. Replace. air pressure pump is applied! Lifting No. of strokes required before 25 strokes or less capacity lifting when operated at 60 to 100 strokes per minute...

  • Page 124: Tightening Torque Table

    FUEL AND ENGINE CONTROL SERVICE STANDARDS TIGHTENING TORQUE TABLE Tightening torque Thread size Remarks Description Nm lkgfm) 0.0. X pitch Imm) pump bracket M10 x 1.5 35 to 53 13.6 to 5.41 Injection Injection AD type Delivery valve holder 64 to 69 16.5 to 71 injection pump pump...
  • Page 125 FUEL AND ENGINE CONTROL SERVICE STANDARDS Descriplion Thread size Tightening torque Remarks 0.0. X pitch Nm lkgfml (mml to cylinder head) MS x 1.25 15 11.51 Injection nozzle bolt !for attaching P type M14 x 29 131 Injection On pump side --- �...

  • Page 126: Special Tool

    FUEL AND ENGINE CONTROL - SPECIAL TOOL 4. SPECIAL TOOL Unit: mm Tool name Part No. Shape Injection pump centering tool MH061270 Centering of bracket of AD type injection pump B5032A MH061340 Centering of bracket of P type injection pump B5031A MH061572 Filter wrench...
  • Page 127 FUEL AND ENGINE CONTROL - SPECIAL TOOL KIKI The part numbers are the DIESEL part numbers. Part No. Special Tool Name Stand 105781-0430 Test and adjustment of injection pump 105782-6010 Measuring device 105782-4020 157931-4400 Holder 157916-8220 Nozzle holder wrench (2) P Type Injection Pump Proper KIKI The part numbers are the DIESEL part numbers.
  • Page 128 FUEL AND ENGINE CONTROL - SPECIAL TOOL ( 3 ) RSV Type Governor KIKI The part numbers are the DIESEL part numbers. Part No. Special Tool Name 157910-1120 Handle Removal anrl installation of lock nut 157914-0500 Socket wrench 157915-0100 Wrench Removal nnd installation of round nut Extractor...

  • Page 129: Service Procedures

    FUEL AND ENGINE CONTROL - SPECIAL TOOL, SERVICE PROCEDURES (6) SP Type Automatic Timer The part numbers are the DIESEL KIKI part numbers Special Tool Name Part No. SP type automatic timer special tool set 105790-5050 Disassembly and reassembly 157915-2320 Removal and installation of round nut Box spanner Box wrench...

  • Page 130: Injection Pump

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES INJECTION PUMP 5.1 .1 Removal <P type> Fuel hose 89147A Injection pipe Overflow pipe Oil pipe Note: Injection pump Never remove the injection pump bracket unless it is (5.J Injection pump bracket unavoidable due to cracks, etc. B9153C Wooden block 86120C...

  • Page 131: Ad Type Injection Pump

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.1 .2 AD Type Injection Pump ( 1) Disassembly NV ... Nominal value L ... Limit Damage, worn seat Damage, seizure 1 ��';' '!�� :'"�I � Bend, broken tooth �� ,,b.,.,.-c� *Sliding resistance ' ;1 (when stationary) 1.5 N (0.15 kgf) or less Damage, wear, seizure...
  • Page 132 FUEL AND ENGINE CONTROL SERVICE PROCEDURES --·------ ------ -�--- - - --- - -- Tappet Pin 157931-7320 B9089A - - --�- '----- - - - - - - -- - - - - - (a) Install the injection pump in Universal Vice (spe­ (f) Remove the housing cover.
  • Page 133 FUEL AND ENGINE CONTROL SERVICE PROCEDURES ,--------- ------- - -- - -- Wrench 157910-1120 89093A 89095A (h) Remove the screws at the bottom of the injection (j) Push the tappets up from the bottom of the pump with Wrench (special tooll. injection pump with Roller Pincers (special tool) and remove the Tappet Pins (special tools).
  • Page 134 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (n) Use Wrench (special tool) to remove the delivery valve holder. NOTE: Wrench 157914-0500 Immerse the delivery valve combined with delivery valve seat and the plunger com· bined with plunger barrel in gas oil without changing their combinations.
  • Page 135 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (b) Delivery valve (d) Replacement of taper roller bearing Inner race Extractor 157925-6520 01525A B9105A Clean theyalve and valve seat portions of the delivery valve in gas oil and check worn condition. To remove, use Extractor (special tool). Seal off the bottom of the valve seat portion with a To install, put the ring and shims and then install the finger tip and press down the valve portion with a...
  • Page 136 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (3) Reassembly ·- - ·-- · - --------------- ---·-·-· · -·-- -------- --- - ---; 4.5 to 5.8 Nm �jq.-:i· (0.45 to 0.6 k\j(ml 64 to 68 Nm (6 5 to 7 kgfml l--20 �!--:B: �...
  • Page 137 FUEL AND ENGINE CONTROL SERVICE PROCEDURES !--- - ---� Manufacturer mark inscribed Plunger number inscribed 89109A 89111A NOTE: (c) Place the pump housing on its side and set the Install the plunger with the stamped model control rack so that the punched marks of the control number toward you (the housing cover).
  • Page 138 FUEL AND ENGINE CONTROL SERVICE PROCEDURES �----- -- ---�--��--- - ---� Wrench Inscribed 157910-1120 line 89114A 89093A NOTE: (h) Install the screws, using Wrench (special tool). when the camshaft is inserted, face the (i) Install the following parts. Governor (Refer to 5.2.1. or 5.2.2.) inscribed line on the end of the camshaft Feed pump toward the timer.

  • Page 139: P Type Injection Pump

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.1.3 P Type Injection Pump ( 1) Disassembly ---- --------------- -- -- � Rotating condition Cracks, damage 7� Overflow valve opening pressure NV 255 kPa (2.6 kgf/cm') <Disassembly sequence> (i� Overflow valve Plunger block assembly Deflector Bottom cover Delivery...
  • Page 140 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (a) Remove the feed pump. ··- -··- - · --- · ·--- - - - - - - - - - � ------- - - ---- ·-· --·- ·-- D1507A (e) Remove the screw plug, turn the camshaft to place the tappet at the top dead center position, and (b) Install Fitting Plate (special tool) in Universal Vice insert Tappet Holder (special tool) into the screw plug...
  • Page 141 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (I) Remove the plunger, u sing Plunger Insert (special .----- - - - - - - - - ·· - ----- too!). NOTE: Put the removed plungers orderly in a tray containing clean gas oil. Plunger Clamp Device 157921 ·5620 (j) Install Tappet Mounting Device (special tool) to...
  • Page 142 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Fitting Plate 157944-3520 (o) Disassemble the plunger block assembly by the (q) Remove the governor side screw bushing with following procedure. special Wrench (special tool) and remove the pin and bushing. a) Mount Pitting Plate (special tool) in the vice. Then remove the control rod and bushing from the timer side.
  • Page 143 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (2) Inspection and Correction The inspection procedure is the same as that for the AD type except the following. Sliding condition check NV... Nominal Value Limit Overall tappet clearance of roller portion 0.2 mm D1523C Replacement of taper roller bearing Outer race...
  • Page 144 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (3) Reassembly Control rod sliding resistance (when stationary) NV 1.3 N (0.13 kgO or less Align guide groove with .,. J � 7� End play adjusting shim Camshaft end play NV 0.02 to 0.06 Overall clearance of roller area NV ...
  • Page 145 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 110 to 115 Nm (11 to 12 kgfm) (Tighten in three stages.) D1540A (a) Mount the pump housing in Universal Vice (spe­ (c) Using Socket Wrench (special tool), tighten the cial tooll. delivery valve holder to the specified torque (tighten Then install bushings and control rod, pin and screw in three stages).
  • Page 146 FUEL AND ENGINE CONTROL SERVICE PROCEDURES -------------- (e) Mount Tappet Mounting Device (special tool) to (g) Install the governor housing. At this time, perform the pump housing. the following operation. Mount Measuring Plate (spe­ Then install the tappet by operating the Tappet cial tool) to the timer side taper portion of the Mounting Device.
  • Page 147 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 01550A (h) Measure the camshaft end play. (i) Install a spring balance to the control rod and Install Camshaft Measuring Device (special tool) to check to see that the control rod slides smoothly over timer' side of the camshaft to measure the end the entire stroke without exceeding the standard...

  • Page 148: Adjustment After Reassembly

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.1 .4 Adjustment after Reassembly For fuel injection rate adjusting standard, see Service Information published separately. ( 1 ) AD Type Injection Pump Total stroke of control rack NV 21 or mor e Injection start interval °...
  • Page 149 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (c) Checking stroke of control rack Move the control rack to confirm that the total stroke is over the specified value. In addition, check to see that the start spring and Measuring Device 105782-6010 idling spring smoothly move the control rack in the maximum injection direction.
  • Page 150 FUEL AND ENGINE CONTROL SERVICE PROCEDURES NOTE: The pressure of the fuel forced into injection pump must be higher than delivery valve opening pressure. Inscribed line of timer 81912A 7) After adjustment of the prestroke, check to see that, at the static injection beginning, the inscribed lines of the pointer and timer are in alignment.
  • Page 151 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Measure the stroke of the tappet from the top dead center to the point where the plunger barrel is touched. If the tappet clearance is less than the nominal value, adjust within the extent permitted by the injection start interval.
  • Page 152 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 2. The injection amount varies on diffe. (h) Adaptation to engine rent nozzles and pipes. Make sure that After the governor has been adjusted, measure the the measuring conditions are observed. fuel injection rate adaptable to the engine. 3.
  • Page 153 FUEL AND ENGINE CONTROL SERVICE PROCEDURES <With RFD governor> Fix the load control lever at the idling pos1t1on. Let the pump run at 500 to 600 rpm and tempor­ arily fix the speed control lever so that the governor will begin to provide control at the speed. Press the end of the measuring device all the way toward the governor and adjust the position of point "O"...
  • Page 154 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5) Slowly turn the flywheel of the pump tester clockwise until the fuel ceases to flow out from the overflow pipe (until static injection begins). Prestroke 035188 (d) Adjustment of prestroke 1) Remove the governor side No. 1 cylinder delivery 03414A valve holder;...
  • Page 155 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Static injection beginning 03427A 8) After adjustment of the prestroke, check to see Slowly turn the flywheel of the pump tester that the inscribed line of the timer and that of the clockwise until the fuel ceases to flow out from the pointer are in alignment.

  • Page 156: Installation

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES Loosen the two nt1ts tightening the flange sleeve. Minimum injec- Average injec­ tion amount in - tion amount of Turn the flange sleeve by lightly striking. each cylinder each cylinder 3) Tighten the nuts to the specified torque to secure Uneven ratio (-1 100 (%) the flange sleeve.
  • Page 157 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (1) Adjustment of Injection Pump Bracket � - - - -------- - - - ---------· [P type] [AD type] Injection Pump Injection Pump Centering Tool Centering Tool MH061340 · , MH061270 Air compressor Air compressor --..
  • Page 158 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Keyway COGOOA (c) If the eccentricity between the mandrel and air (b) At this point, check to ensure that the keyway of compressor crankshaft is in excess of the nominal the crankshaft of the air compressor (or injection dimension, adjust by adding or removing injection pump drive) is in the uppermost position.

  • Page 159: Bleeding The Fuel System

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 9 . 8 t o 13 Nm 29 Nm (3 kg f m l (AD typ e ] (AD type ] Cross coup ling (: to 1.3 kgf m ) Driving coupling 20 to 29 Nm "- /,:·-...

  • Page 160: Inspection And Adjustment Of Fuel Injection Start Timing

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.1. 7 Inspection and Adjustment of Fuel Injection Start Timing -- - - ---- - - - - - - - - - - --� ,;- \ .'·· -.._, , - r - - I·...
  • Page 161 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.1 .8 Inspection and Adjustment of No­ [AD type injection pump) Maximum load Minimum Speeds ( 1) RSV Type Governor Full speed positi Idling positi \\- r11 leve ontrol pper bolt ". A " pper '"- bolt "8"...
  • Page 162 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (2) RFD Type Governor (e) In the above condition (d), measure the maximum speed to determine whether it is within the specified limits. (f) If it is not within the specified limits, adjust the fixed position of the speed control lever with the stopper bolt.

  • Page 163: Governor

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES GOVERNOR 5.2.1 RSV Type Governor (1) Disassembly, Inspection and Reassembly Cracks, deterioration Cracks, deterioration Damaged or unevenly worn contacting surface � 17 Worn chrome plating of shifter portion -�� � <Disassembly sequence> Closing cover Tension lever shaft Bushing...
  • Page 164 FUEL AND ENGINE CONTROL SERVICE PROCEDURES NOTE: (b) Removal of flyweight 1. Do not disassemble the shackle and Using Special Wrench (special tool), remove the governor sleeve from the guide lever, round nut tightening the flyweight. At this time, hold unless replacement is necessary.
  • Page 165 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Shim Sleeve Bearing Shifter Chrome plated surface 19 to 19.2 81357A 02054A (c) Replacement of sleeve or guide lever assembly 6) When the shim has to be replaced, assemble all related parts correctly and select the right shim 1) Remove the bearing from inside the shifter, using thickness to make sure that the dimension from the a press.

  • Page 166: Rfd Type Governor

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.2.2 RFD Type Governor (1) Disassembly, Inspection and Reassembly -- --� ---- ---- ----- - - - - - � Cracks, deterioration Cracks. deterioration Oil leaks Cracks, damage Damaged contacting surface L� �18 <Disassembly sequence> Governor cover Governor spring Lock nut...
  • Page 168 FUEL AND ENGINE CONTROL SERVICE PROCEDURES --- - - - ---------- Shim Sleeve Washer Washer Bearing Snap ring 33 to 33.4 02023A 02025A (d) Replacement of sleeve or guide lever assembly (e) Assembly dimension of shifter To disassemble the shifter and sleeve, remove the When the shifter and sleeve are assembled, be sure snap ring in t he sleeve, and the shifter and sleeve can...

  • Page 169: Adjustment After Reassembly

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.2.3 Adjustment after Reassembly ( 1) RSV Type Governor For governor performance curve, see Service In­ formation published separately. Adjustment of torque spring Adjustment of high speed control Adjustment of idling spring or ungleich spring Adjustment of stopper bolt...
  • Page 170 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Full position Special Wrench 157916-2620 Maximum speed stopper bolt 89169A 89166A (c) Temporary adjustment of high speed control (e) Adjustment of Ungleich spring (governor with Ungleich spring only) With the adjusting lever in full position, adjust the maximum p eed stopper bolt so that high speed 1) Keep the pump running at a speed which is a...
  • Page 171 FUEL AND ENGINE CONTROL SERVICE PROCEDURES -·---- ---------------- - --- -------- (g) Adjustment of low speed control --·--------------- ---' 89170A (i) Adjustment of speed regulation 89167A Check that the rack is pulled back to position "Re" when the pump speed is increased from "Nd" to Adjus .
  • Page 172 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Fix the adjusting lever at the full position and set the pump speed at "Nk". Screw in until the torque spring contacts the lever and fix temporarily. Adjust the torque spring so that the rack is positioned at "R/ "...
  • Page 173 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (2) RFD Type Governor For governor performance, curve, see Service In­ formation published separately. Adjustment of high speed control start point Adjustment of damper spring Adjustment of idling ------ ·,-._ ., Adjustment of idling spring Adjustment of stopper bolt Load control lever angle Adjustment of flyweight lift...
  • Page 174 FUEL AND ENGINE CONTROL SERVICE PRCEDURES ·;;; Nu 700 to 800 Nt Pump speed lrpml 84061A 819158 (c) Adjustment of flyweight lift and full load position Lower the pump speed to "Nu" and adjust the high speed lift "L" with the stroke adjusting screw. Divide the flyweight full lift into the lift necessary for high speed ·...
  • Page 175 FUEL AND ENGINE CONTROL SERVICE PRCEDURES c------ - - - - --- - - --- -- ·.; Na Nb Pump speed (rpm) 04434B Check of speed regulation Lower the pump speed to "Ne" and adjust the idling spring using the special tool, Wrench so that Increase t_ h e pump speed slowly until the control rack the rack is positioned at "Re".
  • Page 176 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (f) Adjustment of Ungleich spring (Vehicles with Ungleich spring only) Nf NgNh N � Pump speed (rpm) 84581A Pump speed (rpm) 84580A B4582A Special Wrench 157916-2620 Slowly increase the pump speed from "Nf" to 84317A "Ng"...
  • Page 177 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (g) Measurement of load control lever angle Check that when the load control lever is held at the idling position· and the full load position, the lever angle at the respective positions is up to specification. If the lever angle is out of specification, replace the shim installed between the shifter and sleeve.
  • Page 178 FUEL AND ENGINE CONTROL SERVICE PRCEDURES Adjustment of rack limit After adjustment, install the cap nut securely. Cap type Screw type / t ()) � Guide Screw 157976-3100 � B3767A B4583A Remove· the guide screw from the back of the Place the load control lever in the full load pump housing and install the special tool, Guide position and keep the pump speed at "Nv".

  • Page 179: Inspection And Adjustment Of No-Load Minimum And Maximum

    FUEL AND ENGINE CONTROL SERVICE PRCEDURES With the load control lever set at the full load Locking with wire position, set the smoke set assembly adjusting nut at O to 4 mm from the stopper tip. Adjust to make sure that when the pump speed is changed to "Nd", the rack position will change from ·...

  • Page 180: Feed Pump

    FUEL AND ENGINE CONTROL SERVICE PRCEDURES FEED PUMP 5.3.1 Disassembly, Inspection and Reassembly <Disassembly sequence> Plug gauze filter) Eye bolt (suction side: with Piston spring Eye bolt (delivery side) Piston Priming pump Snap ring Check valve plug Tappet valve spring Check Feed pump housing...

  • Page 181: Test And Adjustment

    FUEL AND ENGINE CONTROL SERVICE PRCEDURES 5.3.2 Test and Adjustment The feed pump t e sts are as follows. Lifting capacity Air tightness test Condition No. of strokes No leaks from required before push rod sliding lifting when pressure area operated at 195 kPa 60 to 100...

  • Page 182: Automatic Timer

    FUEL AND ENGINE CONTROL SERVICE PRCEDURES AUTOMATIC TIMER 5.4.1 SA Type Automatic Timer (1) Disassembly and Inspection For disassembly and reassembly of the automatic timer, use SA Type Automatic Timer Special Tool (105790-5010). Wear of pin section Damage on curved surface <Disassembly sequence>...
  • Page 183 FUEL AND ENGINE CONTROL SERVICE PRCEDURES Special Spanner /157916-5320 89176A 89179A (b) Mount Special Spanner (special tool) in the cou­ (e) Remove the timer plug and place the automatic timer on Base (special tool). pling mounting threaded hole to prevent turning, and remove th' e round nut.
  • Page 184 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (2) Reassembly After reassembly, pack AUTO MA TIC TIMER GREASE (Diesel Kiki product) or equivalent 150 g. 0-ring <Assembly sequence> 10 -· 9· 03153A Thrust Bushing 157924-1500 Guide Bolt Guide Bushing 157924-0200 157924-1200 Base 157924-0110 Oil seal Flange...
  • Page 185 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (e) After placing Support (special tool) on the flyweight, install the shim and spring. Thrust Bushing 157924-1500 Thread Guide (special tool) onto the guide bolt. Guide Bushing 157924-1300 NOTE: Select the proper shim thickness suitable for the advance angle of the automatic �...
  • Page 186 FUEL AND ENGINE CONTROL SERVICE PRCEDURES (i) Inject approx. 150 g of automatic timer grease from the timer plug hole. After grease has been injected, tighten the timer plug. Special Spanner 157916-5320 89180A (h) After the oil seal guide has been removed, turn down the timer case onto the holder with Hand B9190A Spanner (sp .

  • Page 187: Sp Type Automatic Timer

    FUEL AND ENGINE CONTROL SERVICE PRCEDURES 5.4.2 SP Type Automatic Timer ( 1) Disassembly and Inspection For disassembl y and reassembly of the automatic timer, use the special tool, SP Type Automatic Timer Special Tool (105790-5050). Wear <Disassembly sequence> Cap screw Deformation Round nut Damage on...
  • Page 188 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Base 157924-2520 8 � D3106A (d) Mount Base (special tool) in a vice. (f) Mount Special Spanner (special tool) to the flange. With the timer spring compressed, remove the washer, roller and bushing. (e) Fix the timer to Base (special tool) 13-89...
  • Page 190 FUEL AND ENGINE CONTROL SERVICE PROCEDURES Cover side Roller side 03113A NOTE: (d) Remove the plug at the rear end of the timer and When the washer is installed, direct it as supply 250 to 270 cc of engine oil. shown.
  • Page 191 13-92...
  • Page 192 FUEL AND ENGINE CONTROL SERVICE PROCEDURES PUMP DRIVE CASE For removal and installation of the pump drive case, refer to 5.1.1 in Group 61 Special Equipment. 5.5.1 Removal and Installation Pun1p drive case J " " ' " 5.5.2 Disassembly and Inspection Cracked Worn <Disassembly sequence>...

  • Page 193: Reassembly

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.5.3 Reassembly 215 Nm (22 kgfm) <Assembly sequence> 10 -• 8 � 6 � 3 � 4�7-5J For assembly of parts marked o, refer to the following section. B4197A Installation of Injection Pump Gear Align marks "O"...

  • Page 194: Injection Nozzle

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES INJECTION NOZZLE 5.6.2 Disassembly 5.6.1 Removal and Installation (1-spring nozzle) � � � Settling Wear f' �5 � 9 � 7 Wear 8 Carbon deposited © Disassembly sequence Cap nut Connector Adjusting screw Retaining nut Needle valve Spring Nozzle...

  • Page 195: Cleaning And Inspection

    • FUEL AND ENGINE CONTROL SERVICE PROCEDURES 5.6.3 Cleaning and Inspection (1) Cleaning Nozzle Cleaning Tool 105789-0010 07004A (b) Insert, while turning, a cleaning needle into the 07012A injection orifice of the nozzle to remove carbon. Use the needle of proper size for injection orifice. After washing the nozzle in gas oil, remove deposited carbon using the Nozzle Cleaning Tool (special tool) by the following procedures.
  • Page 196 FUEL AND ENGINE CONTROL SERVICE PROCEDURES ( 1) Injection Pressure Next, pull up the needle valve vertically about 1/3 of its entire stroke and check that it falls under its own Injection pressure (lever opcratin�J weight. If it does not fall, replace the nozzle. at 60 to 100 strokes/minute) 5.6.4 Reassembly and...

  • Page 197: Reassembly And Adjustment ( 1-Spring Nozzle)

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES (2) Spray Condition 5.6.5 Reassembly and Adjustment (2· spring nozzle) Adjust while assembling the parts by the following procedures. Poor Poor Good Good Poor Poor As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt �...
  • Page 198 FUEL AND ENGINE CONTROL SERVICE PROCEDURES 39 lo 49 Nm (4 lo 5 kgfm) (1) Adjustment of Nozzle Valve Opening ·1 20 to 25 Nm ( 2 to 2.5 kg Pressure 5 49 10 59 Nm 15 ,o 6 kglml 1 ·...
  • Page 199 FUEL AND ENGINE CONTROL SERVICE PROCEDURES NOTE: 1. When using a shim, be sure to check its Set screw thickness by a micrometer. 49 to 59 Nm (5 to 6 kgfm) 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 Spacer...
  • Page 200 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (e) Remove the adjusting device from the nozzle holder. (3) Adjustment of 2-spring Adjusting Press· Dial Gauge holder (hold this holder to stroke up and down) 20 to 25 Nm � - - - -1 (2 to 2.5 kgfm) Intermediate screw Adjusting screw...
  • Page 201 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (4) Checking Full Lift of Needle Valve NOTE: Never loosen the lock nut as loosening it changes the 2-spring adjusting pressure. ,r--l1 \ "0- (b) Install the prelift shim selected in (2) between the Dial Gauge 157954-3800 spacer and 2nd push rod.
  • Page 202 FUEL AND ENGINE CONTROL SERVICE PROCEDURES (7) Checking Adjusting Allowance of 2- (b) Spray condition spring 2-spring adjusting pressure (lift 0.05 mm) NV 23 to 23.5 MPa Good Good Poor Poor Poor Poor (235 to 240 kgf/cm') Nozzle Tester 105785-1010 -�...

  • Page 203: Fuelfilter

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES FUEL FILTER <Standard> <Option> Cracks, damaged threaded portion Fuel filter head Fuel filter head 25 Nm Cracks, damaged thread ,,,,. s ec � � � Before installation, apply . _ i f" � a thin coat of engine 011 �...

  • Page 204: Water Separator

    FUEL AND ENGINE CONTROL SERVICE PROCEDURES WATER SEPARATOR Drain plug Ring nut Case 7----Q :� Baffle plate Isolation plate Screen assembly Water level ring Cover 1--® 07405C If the red water level ring in the translucent case rises to the level of the red line marked on the outer circumference of the case, immediately loosen the drain plug to discharge water.

  • Page 205: Troubleshooting

    FUEL AND ENGINE CONTROL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Engine is Defective feed pump hard to start • Clogged gauze filter Clean Replace • Check valve inoperative Replace • Binding or worn piston • Binding push Replace •...
  • Page 206 FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause Symptom Remedy Ref. group Poor quality fuel in use Replace Smoky exhaust and engine Defective injection nozzle knocking • Valve opening pressure too low Adjust Broken spring Replace • Clogged injection orifice Clean Defective injection pump Unstable...
  • Page 207 • FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause Remedy Symptom Ref. group Defective governor Engine cannot • develop maximum Governor spring too weak Adjust speed • Adjusting lever (or load lever! poorly adjusted Adjust control Defective injection nozzle • Clogged injection orifice Clean •...
  • Page 208 COOLING CONTENTS 1. GENERAL •.••..•••••••.•..••••.•..•...•••..FAN DRIVE ......... 2. SPECIFICATIONS ••.•.••.•.•..•..••..5.4.1 Disassembly and lnspec- 3. SERVICE STANDARDS ..••...••...•.• ......... tion SERVICE STANDARD TABLE •.•.• 5.4.2 Reassembly •.••.•.••.••.•••••••.••••••• TIGHTENING TORQUE TABLE ... TENSION PULLEY ...... 4. SPECIAL TOOL ••••..•...•••..•..•.. Disassembly and lnspec- 5.5.1 5.

  • Page 209: General

    COOLING - GENERAL 1. GENERAL (2) Thermostat The engine is cooled by forced circulation of coolant by the water pump. The illustration below shows the coolant flow. Radiator cap When coolant temperature is high (bottom bypass ,--- valve is closed I ,---, r---, ,---, ,---, ,---, l Oil cooler �...

  • Page 210: Specifications

    COOLING - GENERAL, SPECIFICATIONS Considerations are, therefore, paid to the fan dia­ The pressure cap regulates the pressure in the meter, radiator capacity and other factors. Some units cooling system. When the pressure builds up in the for construction plants are equipped with an oil cooler system that exceeds a predetermined level, the to cool hydraulic oil.

  • Page 211: Service Standard Table

    • COOLING - SERVICE STANDARDS, SPECIAL TOOL 3. SERVICE STANDARDS SERVICE STANDARD TABLE Unit:mm Description Nominal value Limit Correction and remarks !Basic diameter! Valve opening start 74.5 to 78.5"C Thermostat Replace. temperature Valve lift/temperature 10 or more/90"C Interference between pump 125 1 Reassembling Water pump...

  • Page 212: Service Procedures

    COOLING - SERVICE PROCEDURES 5. SERVICE PROCEDURES WATER PUMP REMOVAL AND INSTALLATION OF 5.2.1 Removal and Installation COOLING FAN B9019B 5.2.2 Disassembly and Inspection Tightening margin BO 11.8 NV 0.03 to 0.06 Reassembly up to Tightening margin BO 25 NV 0.05 to 0.08 Reassembly up to two times allowed <Disassembly sequence>...
  • Page 214 COOLING - SERVICE PROCEDURES 5.2.3 Reassembly Apply engine oil to lips. Apply engine oil to external cylinder. Installation load 39.2 kN (4000 kgO Impeller must be flush with water pump shah when installed. <Assembly sequence> Apply engine oil to lips. 8-->...

  • Page 215: Inspection

    COOLING - SERVICE PROCEDURES THERMOSTAT Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use 5.3.1 Removal and Installation the following procedures. (1) Slowly heat water to the thermostat valve open­ ing temperature. The valve opening temperature is stamped on the thermostat.

  • Page 216: Fan Drive

    COOLING - SERVICE PROCEDURES FAN DRIVE 5.4.1 Disassembly and Inspection � - --- - --- - - -- - - - - - --------- --- -----, - ---- - -- <Disassembly sequence> Fan pulley Flange Snap ring Fan drive shaft Ball bearing Spacer Ball bearing...

  • Page 218: Inspection And Adjustment Of V-Bel T Tension

    COOLING - SERVICE PROCEDURES 5. 7 INSPECTION AND ADJUSTMENT OF (a) Alternator section V-BEL T TENSION Slightly loosen the alternator mounting bolt and (1) Inspection adjusting bolt, then move the alternator to right or left by inserting a tool such as wrench handle. <...
  • Page 219 COOLING - SERVICE PROCEDURES (a) Discharge coolant from the radiator, and crank­ 300 ppm or less Total hardness case. Sulfate SO - , 100 ppm or less (b) After draining the system, fill it with tap water (preferably hot water) and, with the water tempera­ 100 ppm or less Chloride Cl °...
  • Page 220 COOLING - SERVICE PROCEDURES Replace the coolant once every two years to retain its anti-freeze and anti-rust effects. For usage of Long Life Coolant, refer to its instruction manual. NOTE: 1. Be sure to use FUSO Diesel Long Life Coolant. 2.

  • Page 221: Gas Leak Test

    COOLING - SERVICE PROCEDURES 5 .10 BLEEDING THE COOLING SYSTEM GAS LEAK TEST Air or exhaust gas leaked into the coolant promotes ( 1) With the pressure cap removed from the radiator, corrosion and rust formation. Perform the following let the engine run at idle with coolant temperature of °...

  • Page 222: Troubleshooting

    COOLING - TROUBLESHOOTING 6. TROUBLESHOOTING Probable cause Remedy Ref. group Symptom Overheating Defective V -bell Adjust Incorrect tension Broken bell Replace Clogged cooling Clean system thermostat Defective Replace water pump Defective shaft to flange engagement Replace Loose • shaft impeller engagement Loose Incorrect impeller to case clearance...
  • Page 224 INTAKE AND EXHAUST CONTENTS 1. GENERAL ••••••••••.•••••••••.•••••.•••••..•••• 5.3 AIR CLEANER ......13 2. SPECIFICATIONS •••.•••••••••••••••••••••• 5.3.1 Disassembly and 3. SERVICE STANDARDS •••••.•••••••••••• Reassembly •••••••••.•••••.•••••••.•••• 1 3 3.1 SERVICE STANDARD TABLE ••••• 5.3.2 Inspection and Cleaning •••.•••• 14 TIGHTENING TORQUE 5.4 TURBOCHARGER ......

  • Page 225: General

    INTAKE AND EXHAUST - GENERAL 1. GENERAL ( 1 ) Air Cleaner <Single element type> To engine Vacuator valve Guide vane 80620A The air cleaner uses a filter paper type element. 80618A Because of plastic coating and heat treatment, the element is highly resistant to water and oil.
  • Page 226 INTAKE AND EXHAUST - GENERAL ( 3) Vacuator Valve After the element has been cleaned or replaced, depress the reset button on the top, and the si g nal will return to its original position. Warning lamp Starter switch Electrical �...
  • Page 227 INTAKE AND EXHAUST - GENERAL 4LF Type TDOB Type Bearing housing Turbine cover wheel ,'l \.j��� Back plate Turbine wheel B1213A B1202A The exhaust gases discharged from the engine cylin­ 3LM Type ders are delivered through the exhaust manifold to Compressor cover the turbocharger, accelerated in the turbine housing, and blown against the turbine wheel.

  • Page 228: Specifications

    • INTAKE AND EXHAUST - GENERAL, SPECIFICATIONS The intake air cooler system, incorporating a plate­ (6) After Cooler and-corrugated-fin type heat exchanger with a built-in inlet manifold, transfers heat from the intake air to the engine coolant. The system cools off the intake air, whose tempera­ ture has gone high due to compression by the Turbocharg e r turbocharger, through heat exchanging with the...

  • Page 229: Service Standards

    INTAKE AND EXHAUST - SERVICE STANDARDS 3. SERVICE STANDARDS SERVICE STANDARD TABLE Unit:mm Description Nominal value Limit Correction and remarks (Basic diameter! 1.0. of bearing inserting portion Turbocharger 19.06 Replace. of bearing housing (3LM) Shaft and Bearing journal Replace. 11.18 turbine wheel 0.0.

  • Page 230: Tightening Torque Table

    • INTAKE AND EXHAUST - SERVICE STANDARDS, SPECIAL TOOL Unit:mm Oescript1on Nominal value Limit Correction and remarks !Basic diameter! Piston ring groove width of flinger sleeve Turbocharger Replace. (4LFI to turbine Shaft and turbine wheel 0.84 1.75 Replace. housing clearance Shaft and turbine wheel end play 0.08 to 0.

  • Page 231: Service Procedures

    • INTAKE AND EXHAUST - SERVICE PROCEDURES 5. SERVICE PROCEDURES REMOVAL AND INSTALLATION OF INTAKE SYSTEM <6022> Install the air heater with the embossed arrow directed to the inlet manifold side. 35 Nm (3.6 kgfm) Earth plate 2 Inlet pipe 3 Air heater 4 Inlet manifold NOTE:...
  • Page 232 INTAKE AND EXHAUST - SERVICE PROCEDURES <6D22-T> �� � � 35 Nm �nstall the air heater with the (3.6 kgfml embossed arrow directed to downward. Earth plate Inlet pipe Rubber hose Air heater Inlet manifold NOTE: Remove all harnesses before disassembly. Pay attention to air heater mounting direction.
  • Page 233 INTAKE AND EXHAUST - SERVICE PROCEDURES <6022-TC> Install the air heater with the embossed arrow directed to the cylinder head side. Inlet pipe pipe Air escape Water inlet pipe Water return pipe After cooler assembly Earth plate Air heater Rubber hose NOTE: Remove all harnesses before disassembly.

  • Page 234: Removal And Installation Of Exhaust System

    INTAKE AND EXHAUST - SERVICE PROCEDURES REMOVAL AND INSTALLATION OF EXHAUST SYSTEM <6D22> Stamped mark "TOP" To be installed with stamped mark toward manifold. Seal ring Ends • Install the seal ring so that the ends of each ring are positioned °...
  • Page 235 INTAKE AND EXHAUST - SERVICE PROCEDURES <6D22-T, TC> 35 Nm (3.6 kgfml � ----®L. 26 Nm (2.1 kgfml 41 Nm � (4.2 kgfml ---.._ ic o_. (�1 [t] � --- � ', �� J� Expansion ring � - �"- \ 1- � tf}} -- r- ------ - ----- Stamped mark "TOP"...

  • Page 236: Air Cleaner

    INTAKE AND EXHAUST - SERVICE PROCEDURES AIR CLEANER 5.3.1 Disassembly and Reassembly <Single element type> Assembling direction mark Clarnp Dust indicator Baffle Air cleaner body Clip Gasket Element Wing nut Cover Air cleaner body <Double element type> Dust cup Outer Air cleaner body Dust Assembling...

  • Page 237: Inspection And Cleaning

    • INTAKE AND EXHAUST - SERVICE PROCEDURES 5.3.2 Inspection and Cleaning (3) Inspection of Element (1) When there is Dry Dust on the Element C7209A C7207A After the element has been cleaned, put an electric lamp inside the element to check for damage and pin If there is dry dust on the element, clean the dust by holes.

  • Page 238: Turbocharger

    INTAKE AND EXHAUST - SERVICE PROCEDURES TURBOCHARGER 5.4.1 TD08 Type Turbocharger ( 1) Disassembly '&. Interference with turbine wheel, cracks due to overheat, pitching, deformation Blade bend and damage, corrosion, marks of interference on back surface Interference with turbine wheel, damage Bearing hole surface roughness, damage, gas corrosion, turbine side flange deformation...
  • Page 239 • INTAKE AND EXHAUST - SERVICE PROCEDURES Disassembly Procedure (c) Removal of compressor cover Alignment ma r k Turbine Compressor cover housin g Bearing housing 828190 C8982C Remove the compressor cover by tapping it with a (a) Befo�e disassembling the turbocharger, make alignment marks on the compressor cover, bearing plastic hammer with the snap ring loosened.
  • Page 240 INTAKE AND EXHAUST - SERVICE PROCEDURES (e) Remove the insert. C8983C 88978A 2) While holding the shaft and turbine wheel boss, remove the lock nut that secures the compressor 1) Remove the snap ring. wheel. NOTE: Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pliers.
  • Page 241 • INTAKE AND EXHAUST - SERVICE PROCEDURES (2) Cleaning and Inspection Piston ring end gap NV 0.05 to 0.25 Clean Clean 0.0. 20.382 1.0. Clean Bearing journal 0.0. 11.996 Shaft concentricity 0.015 (total gauge reading) Clean Bearing inserting portion 1.0. 20.506 Nominal Value Limit...
  • Page 242 INTAKE AND EXHAUST - SERVICE PROCEDURES (a) Cleaning Turbocharger manufacturers use a blasting equip­ ment for cleaning parts at their workshops. As an alternative effective method for overhaul at the dealer's workshop, use the following procedures. When a commercially available neutral detergent is used for cleaning, make sure that it does not contain corrosive component.
  • Page 243 INTAKE AND EXHAUST - SERVICE PROCEDURES Measure I.D., O.D., and length of the bearing. If the measured values exceed the service limit, replace the bearing. B9036A 6) To prevent rust, apply engine oil to the entire internal and external surfaces of the bearing housing, C8913A turbine housing and turbine backing plate and the shaft portion of the shaft and turbine wheel.
  • Page 244 INTAKE AND EXHAUST - SERVICE PROCEDURES Insert Insert a new piston ring securely in the bore in the Insert insert and measure the end gap of the piston ring. Ends If the end gap is out of specification, replace the ring insert.
  • Page 245 • INTAKE AND EXHAUST - SERVICE PROCEDURES (b) Installation of snap ring Reassembly Procedure (a) Installation of piston ring Thrust sleeve Oil deflector C8978C Piston ring B0472C Set the thrust sleeve into the oil deflector, and install the piston ring. NOTE: 1.
  • Page 246 INTAKE AND EXHAUST - SERVICE PROCEDURES (c) Measurement of clearance between Coat threads in the shaft and turbine wheel with shaft and turbine wheel and turbine molybdenum disulfide base grease (NLGI No.2) Li housing soap and mount the compressor wheel onto the shaft. Holding the boss on the turbine wheel side, tighten the compressor wheel lock nut to the specified torque.
  • Page 247 INTAKE AND EXHAUST - SERVICE PROCEDURES (h) Installation of turbine housing and com­ Using two thickness gauges, measure the clearance between the turbine back plate and turbine wheel pressor cover back surface. If the clearance is out of specification, disassemble and check to locate the cause. NOTE: Be sure to use two thickness gauges and take measurement at the tip of the blades.

  • Page 248: 4Lf Type Turbocharger

    INTAKE AND EXHAUST - SERVICE PROCEDURES 5.4.2 4LF Type Turbocharger See pages describing the TD08 turbocharger for disassembly, inspection, cleaning and reassembly procedures. (1) Disassembly covering layer, Interference with turbine wheel, damage 20 7 Interference with turbine wheel, cracks due to overheat, pitching, deformation Blade bend and damage,...
  • Page 250 INTAKE AND EXHAUST - SERVICE PROCEDURES (a) Measurement of piston ring groove (b) Measurement of flinger sleeve groove width width piston ring C8914A C8916A Install a new'piston ring in the piston ring groove and Measure the piston ring groove width of the flinger measure the clearance.
  • Page 251 • INTAKE AND EXHAUST - SERVICE PROCEDURES (3) Reassembly Clearance between compressor wheel 11 Nm and compressor cover (1.1 kgfm) in diametrical direction Clearance between shaf t Molykote grease or equivalent NV 0.15 and turbine wheel and to be applied to screw and turbine housing seating surface Engine oil to be...
  • Page 252 INTAKE AND EXHAUST - SERVICE PROCEDURES Assembly Procedure (c) Measuring clearances between shaft and turbine wheel and turbine housing, (a) Installing snap rings and compressor wheel and compressor cover in diametrical direction Turbine housing Compressor � Turbine wheel wheel 84266A C8925A Use pliers (tip diameter 1 mm) in installing snap rings.

  • Page 253: 3Lm Type Turbocharger

    • INTAKE AND EXHAUST - SERVICE PROCEDURES 5.4.3 3LM Type Turbocharger See pages describing the TD08 turbocharger for disassembly, inspection, cleaning and reassembly procedures. (1) Disassembly <Disassembly sequence> G) Turbine housing Bearing housing Flinger sleeve cover Compressor Shaft and turbine wheel Piston ring Compressor wheel...
  • Page 254 INTAKE AND EXHAUST - SERVICE PROCEDURES Disassembly Procedure \"• · 89048A 89031A (b) Remove the compressor cover. (a) Remove the turbine housing. NOTE: Do not drop and strike the compressor wheel and turbine wheel, as their blades are readily bent. 15-31...
  • Page 256 INTAKE AND EXHAUST - SERVICE PROCEDURES (3) Reassembly Bend lock washer. Shaft and turbine wheel to NV ... Nominal Value 17 Nm 11.7 kqf m l turbine housing clearance NV 0.53 to 1.04 Shaft and turbine wheel Non-chamfered side axial play toward insert NV 0.05 to 0.13 17 to 20 Nm...
  • Page 257 INTAKE AND EXHAUST - SERVICE PROCEDURES Reassembly Procedure Locating hole 17 Nm (1.7 kgfm) B9031A B9041A (c) Install the turbine housing tightening the bolts to the specified torque. (al Apply engine oil to both sides of the thrust NOTE: bearing and thrust ring before assembling them on Apply an anti-seizure agent to the cap the turbine wheel shaft.

  • Page 258: After Cooler

    INTAKE AND EXHAUST - SERVICE PROCEDURES AFTER COOLER 5.5.1 Disassembly, Inspection and Reassembly Connector Cover Plate Damage, water leaks, Core assembly fin contamination, Inlet manifold scale and rust inside core C9305B 5.5.2 Air-pressure Test Conduct the air-pressure test to check for water leaks due to damaged core.

  • Page 259: Troubleshooting

    • INTAKE AND EXHAUST - TROUBLESHOOTING 6. TROUBLESHOOTING Remedy Symptom Probable cause Ref. group output Jnsutticient intake air • Loaded air cleaner element Clean • Air suction (with dust foreign matted and other from intake system Repair • Defective turbocharger •...
  • Page 260 • ENGINE ELECTRICAL CONTENTS 30A, 40A, 80A AL TERNA TOR ..34 1. GENER. A L ........Removal and Installation ••..•.• 34 ...... ".... 5.3.1 STARTER 1.2 AL TERNA TOR ..•..••.•••••••..•..5.3.2 Disassembly ......35 5.3.3 Inspection •••..•..••.••••...•••• 38 1.3 SAFETY RELAY •••••••••..••••..•. 5.3.4 Reassembly ••••••.•.•..•.••••..•..•..

  • Page 261: General

    ENGINE ELECTRICAL - GENERAL 1. GENERAL Starter relay Alternator Air heater indicator Heater relay <Except 6022-TC> ---, _,__ Safety relay (6022-TC) Oil bypass Oil bypass alarm alarm lamp , - -1 Ammeter Fuse · c& · Battery switch • 0.85 0.8 5 -=...

  • Page 262: Starter

    ENGINE ELECTRICAL - GENERAL Starter (2) Overrunning Clutch M;1�pH:{!i; switch Outer race Roller Pinion Field coil Armature Pole Yoke Pinion B3711A �ear B3703A The starter is a reduction starter with a built-in Magnetic reduction gear. Its motor has been downsized with switch attraction even higher speed capability.
  • Page 263 ENGINE ELECTRICAL - GENERAL (3) Operation Starter switch Starter relay Starter relay Plunger Plunger Pinion Pinion Ring gear Ring gear 837098 837088 When the pinion comes into complete mesh with the ring gear, the contact "P1" closes and the large While the starter switch is ON, current flows from the current of the battery directly flows to the motor terminal "SW"...

  • Page 264: Alternator

    ENGINE ELECTRICAL - GENERAL ALTERNATOR � - ---·--- - --�-- - - - - - - - - - - � ( 1 ) 30A, 40A, 80A Alternator Starter switch aj ,, .--<CS , r>--1� ;� � � L Starter relay 82976A The alternator is a brush type in which a current flows from the brushes through the slip ring to the field coil...
  • Page 265 • ENGINE ELECTRICAL - GENERAL (b) Stator (d) Regulator B2708A Brush Stator core B2703A The regulator alters the strength of the field coil field to stabilize output power which varies with engine Togethe� with the rotor core, the stator core forms the speed fluctuations.
  • Page 266 ENGINE ELECTRICAL - GENERAL 2) Starting the engine (2) GOA Alternator Alternator �-� �--<E Battery Starter switch B4007C 82542H When the engine is started and the alternator starts The 60A alternator is an open type three-phase generation so that the voltage at the alternator "B" alternator.

  • Page 267: Safety Relay

    ENGINE ELECTRICAL - GENERAL SAFETY RELAY The alternator rpm is detected and when it exceeds the reference level, the safety relay prevents the starter from operating even if its switch is accidentally turned on during engine revolution. B1453A Operat�on Charge lamp Starter switch Battery switch...

  • Page 268: Regulator

    • ENGINE ELECTRICAL - GENERAL REGULATOR (Model R7T01071) Its functions include: (1) Voltage regulator Maintains voltage generated by the generator con­ stant (2) Safety relay Keeps the starter circuit in OFF state even with the starter switch turned on during operation of engine. (3) Field relay Minimizes discharge current to the alternator field coil IG F L...

  • Page 269: Intake Airheater

    • ENGINE ELECTRICAL GENERAL INTAKE AIR HEATER (3) While the engine is in operation, field current flows in the following circuits, with alternator output voltage controlled by the voltage regulator. S t arter Alternator A terminal Regulator A terminal Contact P2 Voltage switch regulator K terminal...
  • Page 270 • ENGINE ELECTRICAL - GENERAL (1) Energize-to-stop Type ,-·- - · - · -··----- - -- ----- - - - - -------� Solenoid relay - - - ·-- --- -- ·-. ---· - - - � Alternator � Thermo switch®-i ---<k-�...
  • Page 271 • ENGINE ELECTRICAL - GENERAL (c) Pushbutton stop 3) Thus RY contacts close, the solenoid operates, and the engine stops. When the engine stops, the To stop the engine during operation, operate the stop alternator voltage goes out. At the same time, the switch, and the stop operation is performed as at the stop timer made up of C2 and VR7 holds the solenoid.

  • Page 272: Specifications

    ENGINE ELECTRICAL - GENERAL, SPECIFICATIONS This causes the current to flow from the starter@ 3) When the RY contacts turn ON: Current flows from solenoid relay@ to RY, solenoid switch to oil pressure switch, thermo switch, solenoid relay©, and the solenoid, activating the solenoid and relay@, RY holding coil H, and to ground, keeping the starting the engine.

  • Page 273: Service Standards

    ENGINE ELECTRICAL - SPECIFICATIONS, SERVICE STANDARDS Automatic Stop System [Option] Item Specification Stop solenoid Type Electro magnetic type (Nippon Denso Co., Ltd. product) Model !Energize-lo-slop lype l !Energize-to-run typel Solenoid relay 0-25000-5592 0-25000-6720 (Nikko Denki product) Oil pressure switch Type Diaphragm, built-in electric contact Type Thermo switch...
  • Page 274 ENGINE ELECTRICAL - SERVICE STANDARDS Unit:mm Dcscriplion Nominal vc1luc Limit Correction and I Basic diameter! remarks Starter relay Coil resistance 10.4 !! Replace. Alternator Slip ring O.D. 40.8 to 41.2 40.4 Replace. (A2T729871 (A2T729861 Brush spring tension to 4.3 N Replace.

  • Page 275: Tightening Torque Table

    • ENGINE ELECTRICAL - SERVICE STANDARDS Unit:mm Nominal value Description Correction and Limit ! Basic diameter! remarks Alternator Slip ring 0.0. 45.4 Replace. (A4T65772) tension (A4T65773) spring 3.7 N _(0.38 kgfl Brush Replace. (0.2 kgf) Brush length Replace. Field coil resistance !at w·cl Approx.

  • Page 276: Special Tool

    • ENGINE ELECTRICAL - SPECIAL TOOL, SERVICE PROCEDURES 4. SPECIAL TOOL Unit:mm Tool name Part No. Shape 31191-06100 Socket Removal and installation of starter Width across flats 17 85021A 5. SERVICE PROCEDURES STARTER NOTE: 5.1.1 Removal and Installation Whenever removing electrical parts from the vehicle, be sure to place the battery switch in OFF position, disconnect the negative battery cable, and wind the cable...

  • Page 277: Disassembly

    ENGINE ELECTRICAL - SERVICE PROCEDURES 5.1.2 Disassembl y <M3T> Gear shaft thrust gap NV 0.1 to 0.5 8 Rotating condition Roughened commutator surface, seizure, ridge wear, worn damaged gear Worn arid damaged gear Deposited brush powder, NV ... Nominal Value uneven wear, movement of brush in holder Mounted condition of...
  • Page 279 ENGINE ELECTRICAL - SERVICE PROCEDURES (3) Removal of Overrunning Clutch Disassembly Procedure The disassembly procedure for the M3T95082 is described. The procedure for the other starters is the same. (1) Removal of Yoke Assembly Front bracket assembly Gear bracket mounting bolt 829548 Front bracket Gear bracket...
  • Page 280 ENGINE ELECTRICAL - SERVICE PROCEDURES NOTE: Overrunning clutch Gear bracket Gear shaft Gear shaft 82959A 84141A (d) Remove the overrunning clutch and gear bracket from the gear shaft. When the ring is removed, keep the gear shaft in overhanging condition. (4) Removal of Brush Spring Ring �...

  • Page 281: Inspection

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.1.3 Inspection Item Commutator 38.7 38.1 outside diameter 42.2 43.2 Commutator outside 0 to 0.03 circumference runout Depth of groove 0.7 to 0.9 between segments Short circuit test, coil ground test, open circuit test Coil open circuit test Melted contacts Loose contact...
  • Page 282 ENGINE ELECTRICAL - SERVICE PROCEDURES (c) Inspection of commutator Inspection Procedure The inspection procedure for the M3T95082 starter is described. On the other starters, only the differences are jointly described. (1) Armature Inspection (a) Coil short circuit test 07507A Measure the runout of commutator using a dial gauge and turning the armature by hand.
  • Page 283 ENGINE ELECTRICAL - SERVICE PROCEDURES (e) Mica depth between groove lead and brush (+). If there is no continuity, indicating an open circuit, replace the yoke assembly. Mica depth � (b) Coil ground test � 82563A Measure. the Mica depth of groove between seg­ ments.
  • Page 284 ENGINE ELECTRICAL - SERVICE PROCEDURES (4) Inspection of Brush Spring (6) Inspection of Magnetic Switch (a) Coil open circuit test <MST> M terminal 8 terminal M terminal D7513A S terminal 82586K Measure the installed load of the brush spring. Using a new brusli read the load at the moment the spring Check that there is a continuity across "S"...
  • Page 285 • ENGINE ELECTRICAL - SERVICE PROCEDURES (7) Inspection of Overrunning Clutch (b) Fused contact check M terminal (or B terminal) 829608 Check th. a t there is no continuity across "B" and "M" Install the gear shaft to the overrunning clutch and terminals.
  • Page 286 ENGINE ELECTRICAL - SERVICE PROCEDURES (9) Replacement of Bearings (b) Replacement of front and rear bearings (a) Replacement of gear bearing (Removal) (Removal) Press down with a press. Bearing puller Rear bearing Armature Cylindrical block B2576B Bearing 07503A Using the bearing puller, remove the bearings from the armature.

  • Page 287: Reassembly

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.1.4 Reassembl y <M3T> Apply grease *1. Apply grease *2. 21 20 J Apply grease •2. j Apply grease *3. Apply grease * 1. Apply grease *2. Apply grease *4. Gear shaft thrust gap NV 0.1 to 0.5 NV ...
  • Page 288 ENGINE ELECTRICAL - SERVICE PROCEDURES <M5T> •1 grease to be applied •2 grease to be applied A thin coat of •3 grease to be applied to outside circumference •2 grease to be applied Pinion gap •4 grease to be applied Model M5T50279 1 to 3...
  • Page 290 • ENGINE ELECTRICAL - SERVICE PROCEDU RES (b) Pin fixed type <MST> (4) Installation of Magnetic Switch Screw Grease B terminal Magnetic switch ( Mystik JT-6 or equivalent) B2956D B2952C Insert the lever in the direction shown and mount it B terminal S terminal with the pin·...

  • Page 291: Inspection And Adjustment After Reassembly

    ENGINE ELECTRICAL - SERVICE PROCEDURES (5) Installation of Yoke Assembly (a) Wire the reassembled starter as shown above. (b) Turn ON switches K and K to project the pinion. (c) Turn OFF switch K to stop pinion from rotating. Pinion _ _ ;...
  • Page 292 ENGINE ELECTRICAL - SERVICE PROCEDURES NOTE: 1. Use a wire as thick as possible and secure each connection firmly. Washer 2. Apply voltage gradually from OV up to Magnetic switch 24V. (b) Measure the current and rotating speed when the specified voltage is applied.

  • Page 293: Starter Relay

    ENGINE ELECTRICAL - SERVICE PROCEDURES STARTER RELAY �- - 11 Inspection Procedure , m m L terminal l , . � : " � : terminal U1T07076 D8002A B terminal Coil resistance ° S terminal NV 10.4 n (24V, 20 (1) Check for continuity between the SW and L D8003H terminals and check to ensure that the coil resistance...
  • Page 294 • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.3.2 Disassembly ------------··--- - �--------------·--·- ------ ---- - ---� <Disassembly sequence> (1) Rear bracket assembly Spacer (2_i Stator Rotor assembly (31 Rectifier Spring @ Rectifier <80A only> Rear bearing Regulator assembly Rotor ® Brush Front bracket assembly (16) Brush spring...
  • Page 295 ENGINE ELECTRICAL - SERVICE PROCEDURES Disassembly Procedure (1) Separatio n of Front Bracket Assembly from Rear Bracket Assembly D8107H 2. At time of separation, use care not to lose the spring fitted to the outside of 819490 the rear bearing. (2) Removal of Pulley Remove the through bolt and, using a screwdriver, pry off the front bracket assembly from the rear...
  • Page 296 ENGINE ELECTRICAL SERVICE PROCEDURES (4) Separation of Rectifier <80A> (3) Removal of Stator Coil Rectifier Stator B3909A Separate the rectifier by unsoldering the area shown. NOTE: When unsoldering, finish it in a short time (less than 5 seconds) with a soldering iron. To remove the stator coil, unsolder the stator coil leads soldered to the rectifier.

  • Page 297: Inspection

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.3.3 Inspection Description 30A, 40A Approx. 9 n Field coil resistance Approx. 7.2 n Slip ring 0.0. 40.8 to 41.2 40.4 Ground test Brush spring pressure NV 0.32 to 0.44 kg 0.2 kg Open circuit test Ground test NV ...
  • Page 298 ENGINE ELECTRICAL - SERVICE PROCEDURES Inspection Procedure (2) Inspection of Rotor (1) Inspection of Stator (a) Continuity between slip ring and core (a) Continuity across leads 081300 08058A Check that there is no continuity between the slip ring and core. Check that there is continuity across stator leads.
  • Page 299 ENGINE ELECTRICAL - SERVICE PROCEDURES (c) Slip ring O.D. (b) Inspection of brush spring D8132C Measure �he slip ring O.D. If the slip ring has rough surface or is unevenly worn, correct with sandpaper or lathe. Correction must be made within the limit of slip ring O.D.
  • Page 300 ENGINE ELECTRICAL - SERVICE PROCEDURES (a) Measurement of diode mounted to heat sink (6 places) Stator coil lead -:::==1 L:c:: g 827378 Heat sink 2) When soldering the brush, insert a pin into the brush hole and fix to the regulator assembly. B2720A NOTE: 1 �...
  • Page 301 • ENGINE ELECTRICAL SERVICE PROCEDURES (5) Inspection of Bearings {Installation) Replace the bearing if defect is evident. (a) Replacement of front bearing Apply engine oil. {Removal) 82728A Front bearing Cover Front bracket 82724A Front bracket -.l...,.�---=-1--1- 1) Remove the bearing cover. 83109A 1) Apply a light coat of engine oil to the outside of the bearing and install to the inside of the front...
  • Page 302 ENGINE ELECTRICAL SERVICE PROCEDURES (b) Replacement of rear bearings (Installation) (Removal) Rear bearing Apply grease. Spring fitting groove 827320 82731 D Apply a light coat of engine oil to the inside of the bearing and using a press, install with the spring NOTE: fitting groove of the bearing facing the rotor field coil Use care not to cause damage to the slip...

  • Page 303: Reassembly

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.3.4 Reassembly <30A, 40A alternator> Engine oil to be applied to outside circumference of rotor shaft 135 to 160 Nm (13.5 to 16.5 kgfm) B2990L <80A alternator> 135 to 160 Nm (13.5 to 16.5 kgfm) Engine oil to be applied to outside circumference of rotor shaft...
  • Page 304 ENGINE ELECTRICAL SERVICE PROCEDURES Reassembly Procedure Installation of Front Bracket Assembly and Rear Bracket Assembly (1) Installation of Rectifier (80A Alterna­ tor) B2745A (a) Push in the brush by hand and insert the pin into the brush hole from the rear of the rear bracket to fix When the rectifiers are to be connected together by the brush.

  • Page 306: Alternator

    • ENGINE ELECTRICAL - SERVICE PROCEDURES While gradually increasing the alternator speed and reducing the load resistance, measure the current value with the specified terminal voltage and speed. If the measurement is below the specification, check alternator parts. Nominal value (when alternator is cold) <30A alternator>...
  • Page 307 • ENGINE ELECTRICAL - SERVICE PROCEDURES (b) On-vehicle inspection If the current reading is 70% or more of the nominal output, the alternator may be regarded as in good condition. Voltmeter NOTE: The on-vehicle test is an easier way of inspection;...

  • Page 308: Disassembly

    • ENGINE ELECTRICAL - SERVICE PROCEDURES GOA AL TERNA TOR 5.4.1 Removal and Installation [Refer to 5.3.1.I 5.4.2 Disassembly �&- � <Disassembly sequence> Cover Pulley Stator holder assembly Brush Plate holder Rotor assembly Brush Lead wire assembly Rotor Brush Terminal set Rear bearing Brush spring...

  • Page 309: Inspection

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.4.3 Inspection Description Approx. 13 !! Field coil resistance Open circuit test Slip ring 0.0. 45.4 Ground test Ground test Brush spring pressure NV 3.7 N (0.38 kgf) 2 N (0.2 kgf) � Short test Open test NV ...

  • Page 311: Reassembly

    • ENGINE ELECTRICAL - SERVICE PROCEDURES 5.4.5 Inspection and Adjustment after Reassembly ( 1) Simple Procedures for Checking Alter­ nator from Outside Inspection by Con­ tinuity Tester Measuring Good Defective points F - E Tester shows continuity. No continuity (Brush in poor contact or field coil open-circuited) Resistance O (Field coil short-circuited) N - A Tester shows continuity when...

  • Page 312: Safety Relay

    ENGINE ELECTRICAL - SERVICE PROCEDURES SAFETY RELAY [Model R8T301 71] Inspection ----------- ----- - ;==-=-====- ===-==--·· Res1stanc1: between L and R � V Approx 200 \! S terminal No,rnnal Vah,e 814538 Measure voltage at each terminal in the sequence shown below to identify faulty parts. (1) On-vehicle Test Sequence Engine...

  • Page 313: Regulator

    ENGINE ELECTRICAL SERVICE PROCEDURES REGULATOR [Model R7T01071] PREHEATER 5. 7 .1 Inspection Intake Air Heater 1) Removal and Installation [Refer to Group 15 Intake and Exhaust] (2) Inspection Air heater #� IG F L Starter switch (6D22, 6D22-TI HEAT A N E 844018 START (1) Regulated Voltage of Voltage Regulator...
  • Page 316 • ENGINE ELECTRICAL - SERVICE PROCEDURES (b) On-vehicle inspection Check the solenoid relay according to the following flowcharts and determine whether it is good or not on the basis of the terminal voltage, etc. measured in the individual states. • The terminal symbols denote those of the sole­...
  • Page 317 • ENGINE ELECTRICAL - SERVICE PROCEDURES (3) Thermo Switch Connect the pipes as shown above, close the cocks A and B, and start the engine. After the oil pressure has risen, fully open the cock A to lead the oil pressure to the oil pressure switch.
  • Page 319 ENGINE ELECTRICAL - SERVICE PROCEDURES (b) On-vehicle inspection Check the soleno id relay according to the following flowchart and determine whether it is good or not on the basis of the terminal voltage, etc. measured in the individual states. • Terminal symbols denote those of the solenoid relay.
  • Page 320 • ENGINE ELECTRICAL - SERVICE PROCEDURES Perform measurements with engine running. /� / Measure' Solenoid relay Engine does not stop Measure voltage ;' � - �..,.- voltage at S defective with water temperature �: terminal. high and oil pressure low. -��...
  • Page 321 ENGINE ELECTRICAL - SERVICE PROCEDURES (3) Thermo Switch (4) Oil Pressure Switch Engine oil pressure gauge Testing oil pressure gauge Item Operating ° 93 to 97 temperature ON-OFF ° Cock A difference reservoir Oil pressure NV ... Nominal Value switch Cock B Tem p erature- �...

  • Page 322: Troubleshooting

    ENGINE ELECTRICAL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable Ref. group Remerly r.aus1� ·- ballery l Defective Starter will Replace or charge or lnw capacily not start. Defective wiring Defective Correct starter wiring • Defective starter relay wiring Defective magnetic switch wiring Defective heater relay wiring •...
  • Page 323 ENGINE ELECTRICAL - TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Charger lamp does Replace Defective regulator not come on when engine is stopped (starter switch ONl. Premature loss of Defective alternator (see "Battery is normal but is Replace battery electroyte. overdischarged"...
  • Page 324 CLUTCH CONTENTS CLUTCH PROPER ....... 1. GENERAL ........2. SPECIFICATIONS •••.•••.•••••••••••.•••••• 5.2.1 Disassembly and Inspec- 3. SERVICE STANDARDS .••...••.•..tion ......... SERVICE STANDARD TABLE ••••. 5.2.2 Reassembly and Adjust- 3.2 TIGHTENING TORQUE TABLE •.• ment ........11 4. SPECIAL TOOL •••.•••.•.••..•..••.•••••••••. BEARING CASE ......

  • Page 325: General

    CLUTCH - GENERAL 1. GENERAL Strap plate Release lever support Clutch disc Pressure plate E0754A The clutch is a dry single disc type which transmits is performed, the pressure spring force causes the and disconnects engine power through the clutch pressure plate to press the clutch disc against the shift shaft.

  • Page 326: Specifications

    CLUTCH - SPECIFICATIONS, SERVICE STANDARDS 2. SPECIFICATIONS Clutch [Option] Item Specification ·------+-- - - -------- - - --� - - - - - - - -- - - -- - 16022 1 Clutch 16022-T, TCI Type Dry single disc coil spring type Dry single disc coil spring type Model C10W41 or C12W43...

  • Page 327: Special Tool

    CLUTCH - SPECIAL TOOL 4. SPECIAL TOOL Unit:mm Part No. Tool name Shape 03726-21000 Clutch alignment arbor Alignment of clutch disc at installation E0012B Clutch installer MH061331 Removal and installation of clutch cover E0007A Clutch lever aligner MH061330 Adjustment of release lever height 37 ±...

  • Page 329: Service Procedures

    CLUTCH - SERVICE PROCEDURES NOTE: (d) Adjustment after installation of clutch 1. Before installing the clutch, check and and bearing case clean the flywheel and repair or replace a s necessary. 2. Tighten bolts evenly, in the diagonal order. 3. After installation, be sure to remove the set bolt.

  • Page 330: Clutch Proper

    CLUTCH - SERVICE PROCEDURES CLUTCH PROPER 5.2.1 Disassembly and Inspection r--- - ----1 Clcarc1nce of hub spl111e 111rn11H1 d1rcct1on Depth to rivet head NV 2.2 to 2.8 NV O 06 to O 195 0 47 � Flatness 0.6 or less --------- Lateral runout 1.2 or less J r···------------...
  • Page 331 CLUTCH - SERVICE PROCEDURES Disassembly and Inspection Procedure (2) Inspection of Clutch Disc (1) Removal of Clutch Cover (a) Facing w ear ----� Strap bolt Depth to rivet head or cup head Assembled Stopper bolt thickness (4 places) E0860A E0694A (a) Compress the pressure spring with the stopper Measure the assembly thickness of facing and the bolts and, at the same time, remove the strap bolts,...
  • Page 332 CLUTCH - SERVICE PROCEDURES (c) Clutch disc runout (3) Inspection of Pressure Plate (a) Measurement of thickness E0696A Pressure plate E0438A Using the runout tester, measure the clutch disc runout. If tlie measurement exceeds specification, Measure the pressure plate thickness and, if it is correct or replace the clutch disc.
  • Page 333 CLUTCH - SERVICE PROCEDURES (c) Strap bolt fitting hole I.D. (5) Inspection of Pressure Spring Strap bolt hole Squareness Pressure spring E0440A E0487A Measure . the 1.0. or strap bolt fitting hole in the Measure the free length, squareness, and installed pressure plate and, if the limit is exceeded, replace.
  • Page 334 CLUTCH - SERVICE PROCEDURES 5.2.2 Reassembly and Adjustment <Assembly sequence> --,1 1 -9-10- a.�7-6-,5-4-,3-2--·1 15 - For parts with an encircled number, refer to Reassembly Procedure E0754B that follows. Reassembly Procedure (2) To install the clutch cover, align the alignment marks and, using the special tool, Clutch Installer, (1) Whenever the pressure plate friction surface is temporarily tighten the stopper bolts.

  • Page 335: Bearing Case

    CLUTCH - SERVICE PROCEDURES Clutch Lever Aligner MH061330 Stopper bolt E0860A (3) With the pressure spring compressed by the (4) After installing the clutch, check the clutch cover stopper bolts, install the strap bolt, support nut, and and release lever for height using the special tool, Clutch Lever Aligner.
  • Page 337 CLUTCH - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Clutch drags Defective clutch proper when (Disassemble and check clutch assembly) disengaged Damaged or poorly lubricated pilot bearing Replace or lubricate Damaged release bearing Replace • Uneven height of release lever or its damage Adjust height replace...
  • Page 338 CLUTCH - TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Clutch is Worn. damaged, poorly lubricated pilot heari119 Replace or lubricate noisy when Worn, disengaged damaged, poorly lubricated release bearing Defective clutch disc • Worn clutch disc splines Replace Clutch disc torsion spring losing prorer tension or broken...
  • Page 340 SPECIAL EQUIPMENT CONTENTS 1. GENERAL •••.••••••••••..••.••••••.••••••••.••• 5. SERVICE PROCEDURES ....2 SPECIFICATIONS •••••.•••••••.••••••.•.•.• AIR COMPRESSOR ..... 3. SERVICE STANDARDS •••••••••••••..• 5.1 .1 Removal and Installation •••••.• SERVICE STANDARD TABLE ••..• 5.1 .2 Disassembly ••••••••..••••••••••.•..11 TIGHTENING TORQUE TABLE ... 5.1.3 Inspection and Correction ..••.

  • Page 341: General

    • SPECIAL EQUIPMENT - GENERAL 1. GENERAL ( 1) Air Compressor [2-cylinder Air Compressor] [1-cylinder Air Compressor) To air tank To air tank From oil cooler ,� I 84809A 84810A - - - - � - - - - --- - - - - - --- - - - - - - - - - - - -...
  • Page 342 SPECIAL EQUIPMENT - GENERAL From Sna p rmq jHP ss11 re Cylinder head quidc Delivery valve Unloader volve To air tank holder ------ sprinn 0-ring Suction valve spring spring Delivery valve Delivery valve seat B4812A A suction valve, delivery valve, and unloader valve are provided in the cylinder head of the air compres­...

  • Page 343: Specifications

    SPECIAL EQUIPMENT - GENERAL, SPECIFICATIONS (2)Pressure Governor Cornpressed air Adjusting spring from pressure To air compressor unloader Low pressure valve Valve body· Diaphragm Filter From air tank B4080A The pressure governor controls compressor opera­ tion to keep the air tank pressure within specified limits.

  • Page 344: Service Standards

    SPECIAL EQUIPMENT - SERVICE STANDARS 3. SERVICE STANDARDS SERVICE ST AN DARO TABLE (1) 1-cylinder Air Compressor Unit:m m Limit Descriptmn Nominal value Correction and !Basic diameter! remarks Installed load/ 3.5 N (0.36 kgtl/5 4.4 N (0.45 kgfl/5 Replace. Suction valve spring installed length (0.46 kgfl/9.5...

  • Page 345: Tightening Torque Table

    SPECIAL EQUIPMENT - SERVICE STANDARDS (3) Pressure Governor Unit: kPa (kg!/cm Description Limit Correction and Nominal value ! Basic diameter! remarks MC802148 +3.4 (+0.35) High pressure valve opening pressure Adjust or replace 72 (7.3) -0.5 (-0.05) 3.4 ( MC802150 0.35) 78 (8.0) + --0.5 (-0.05) Low pressure valve opening pressure...

  • Page 346: Special Tool

    SPECIAL EQUIPMENT - SPECIAL TOOL 4. SPECIAL TOOL Air Compressor Unit: mm Tool name Part No. Shape . - W � � - � , Suction valve tool MH0612G3 Removal and installation of suction valve holder B5241A Piston ring tool MH060014 Removal and installation of air compressor piston ring...
  • Page 347 SPECIAL EQUIPMENT - SERVICE PROCEDURES 5. SERVICE PROCEDURES AIR COMPRESSOR 5.1.1 Removal and Installation [2-cylinder type) [1-cylinder type) Water outlet pipe 2 Air outlet pipe 3 Unloader pipe A 4 Unloader pipe B (2-cylinder type only) 5 Water inlet pipe 6 Air suction hose (1-cylinder type) Air suction pipe (2-cylinder type) 7 Oil pipe...
  • Page 348 SPECIAL EQUIPMENT - SERVICE PROCEDU RES Installation of Air Compressor (2) Insert the bolt (M10 x 1.5 about 100 mm long) from the rear end of the flywheel housing to support the air compressor. U sing the bolt as a guide, insert the air compressor into the mounting hole of the flywheel housing.
  • Page 349 SPECIAL EQUIPMENT - SERVICE PROCEDURES (4) Installation of Tachometer Sensor (b) Adjusting type (a) Non-adjustable type Clearance Flywheel housing 0.5 to 1.5 mm Sealant to be applied to threaded portion (THREEBOND 1211) Hexagonal portion Sensor plate 24 to 35 Nm (2.4 to 3.6 kgfm) Tachometer sensor Lock nut 24 to 35 Nm...
  • Page 351 SPECIAL EQUIPMENT - SERVICE PROCEDURES (2-cylinder Type I Cracks. scratch Cracks. wear of bushing, clogged oil hole Damage of circle, wear Cracks, wear :�28 Damage of circle. wear � _ � 2 7 Wear. damage Crankshaft end play Limit <Disassembly sequence> Sensor plate spring Delivery valve...
  • Page 352 • SPECIAL EQUIPMENT - SERVICE PROCEDURES Disassembly Procedure D9259A D9257A (2) Using Piston Ring Tool (special tool), remove the compression ring and oil ring from the piston. (1) Using Suction Valve Tool (special tool), remove NOTE: the suction valve holder from the bottom surface of When a piston ring is removed, do not the cylinder head and remove the suction valve widen the open ends of the piston ring...
  • Page 353 SPECIAL EQUIPMENT - SERVICE PROCEDURES 5.1.3 Inspection and Correction (1-cylinder Type] Tension Load/ i nstalled length NV 4.5 N (0.46 kgfl/ 9 .5 3.6 N (0.37 kgfl/ 9 .5 Tension Load/ i nstalled length NV 4.4 N (0.45 kgf)/ 5 3.5 N (0.36 kgtl/ 5 Clearance Piston ring groove to...
  • Page 355 SPECIAL EQUIPMENT - SERVICE PROCEDURES (1) Piston and Cylinder Liner (a) Measure the clearance between the piston ring groove and compression ring. If the clearance is over the limit, replace the compression ring or piston. NOTE: Measure the clearance all around the pis­ ton.
  • Page 356 SPECIAL EQUIPMENT - SERVICE PROCEDURES (c) Measure the crankshaft journal outside diameter [Crankshah[ and bearing inside diameter and calculate the clear­ Mr.asuring Measuring position ance. If the clearance is over the limit, replace parts. direction End play !Connecting rod bearing! 09268A Measuring Measuring direction...
  • Page 357 SPECIAL EQUIPMENT SERVICE PROCEDURES (5) Unloader Valve Assembly If the unloader valve in unloader valve assembly is badly worn, replace the unloader valve assembly. Snap ring � Unloader valve-----1 Valve spring ------� Valve guide D9272A 61-18...

  • Page 358: Service Procedures

    • SPECIAL EQUIPMENT - SERVICE PROCEDU RES 5.1.4 Reassembly (1-cylinder Type] 9 8 to 115 Nm ( 1 0 to 12 kgfm) to 115 Nm to 115 Nm ( 1 0 to 12 kgfm) (10 to 12 kgfm) � � "-- Apply 0.2 to 0.3 cc of...
  • Page 359 SPECIAL EQUIPMENT - SERVICE PROCEDURES [2-cylinder Type] Apply 0.2 to 0.3 cc THREEBOND Lock Paint 13238 to three threads 98 to 115 Nm (10 to 12 kgfm) 98 to 115 Nm (10 to 12 kgfm) :tT��������19 15 to 20 Nm (1.5 to 2.0 kgfm) Apply engine oil to lips 215 Nm...
  • Page 360 SPECIAL EQUIPMENT - SERVICE PROCEDURES Reassembly Procedure Face side with letters ( 1) Assembly of Connecting Rod stamped lip '<. 1_ s t com pression - -��� � - •. rtng LC� 2nd, 3rd compression ring <2- Oil ring Connecting cylinder>...
  • Page 361 SPECIAL EQUIPMENT - SERVICE PROCEDURES (4) Installation of Injection Pump Gear Punch at three places. "U" mark, except the head gasket surface 83251A 83262A Stake the cylinder head at three places shown over the suction valve holder. Install the injection pump gear, sensor plate, and nut as instructed in the figure.

  • Page 362: Reassembly And Adjustment (2·Spring Nozzle)

    SPECIAL EQUIPMENT - SERVICE PROCEDURES 5.2.2 Reassembly and Adjustment Unit: kPa (kgf/cm') Part no. Nominal value High pressure valve Low pressure valve opening pressure opening pressure MC802148 t-3.4 ( 10.351 +0.5 (-t-0.051 72 (7_3) 63 (6 41 -0.5 (-0 05) -3.4 (-0.35) MC802150 f 3.4 ( +0.35)
  • Page 363 Notes: for 6D22 parts call: Phone: 269 673 2313 or email: wwparts@gmail.com...

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