Table Of Contents - Mitsubishi K3M Maintenance Manual

Table of Contents

Contents5
General Information7
Description8
Engine Model And Engine Number8
Engine Model Designation8
Engine Model And Total Displacement8
Sectional Views Of Engine9
Longitudinal Sectional View Of K3 Engine9
Longitudinal Sectional View Of K4 Engine10
Cross Section Of K3/4 Engines11
Governor System Of K3/4 Engines12
Engine Performance Curves13
Engines For Agricultural Machines13
Engines For Industrial Use And For Export14
Specifications15
Maintenance17
Engine Oil And Oil Filter17
Engine Oil Level Check17
Oil Replacement Period17
Oil Filter18
Engine Oil Replacement18
Oil Filter Replacement18
Cylinder Head Bolt Re-Tightening19
Valve Clearance Adjustment19
Tdc Of Compression Stroke19
Fan Belt Adjustment20
Fuel Injection Timing Adjustment20
Fuel Injection Timing Inspection By Removing The Delivery Valve20
Fuel System Air Bleeding21
Injection Pump And Adjusting Shims21
Air Bleeding From Fuel Filter21
Air Bleeding From Injection Pump21
Fuel Filter Replacement22
Air Bleeding Of Injection Pump With Hand Pump22
Idle Speed Adjustment23
Idle Speed Adjusting Screws23
Adjusting Damper Spring23
Nozzle Inspection24
Compression Pressure Test25
Compression Pressure Measurement25
Troubleshooting26
Hard Starting27
Knocking28
Overheat29
Excessive Black Smoke30
Irregular Idling31
Poor Performance32
Engine Proper Contents33
Special Tools36
Rocker Arm And Rocket Shaft37
Components37
Removal And Installation38
Rocker Arm Installation Direction38
Removing Rocker Shaft Assembly38
Inspection39
Inlet And Exhaust Mani Fold40
Manifold Inspection40
Valve And Valve Spring41
Removing Valve Spring42
Valve And Valve Spring Inspection43
Valve Refacing43
Cylinder Head45
Removing Inspection Pipe46
Cylinder Head Bolt Loosening Sequence46
Cylinder Head Inspection47
Valve Guide Replacement48
Valve Seat Refacing48
Valve Guide Pressing Height48
Valve Head Depth48
Cylinder Head Bolt Tightening Sequence49
Cylinder Head Gasket Selection50
Identification Number Of Head Gasket50
Measuring Position Of Piston Protruding50
Gear Case Assembly51
Tie Rod Removing52
Gear Case Assembly Removing52
Gear Case Inspection53
Timing Gear54
Idle Gear Removing55
Camshaft Removing55
Timing Gear Inspection55
Timing Gear Assembly56
Camshaft Valve And Pump57
Valve Camshft Removal58
Installing Pump Camshaft60
Piston And Connecting Rod61
Removing Piston And Connecting Rod Assembly61
Piston Ring Gap62
Measuring Piston Ring-To-Groove Clearance63
Measuring Semi-Keystone Piston Ring-To-Groove Clearance63
Measuring Rod Big End Bearing63
Connecting Rod Small End Bush Replacement64
Removing The Piston Pin64
Installation Direction Of Piston And Connecting Rod65
Piston Ring Installation Position65
Piston Ring Gap Position65
Installing Connecting Rod Cap66
Crankshaft And Flywheel67
Crankshaft And Flywheel Inspection68
Crankshaft Wear Inspection69
Grounding Crankshaft To Undersize69
Measuring Crankshaft Journal Od69
Crankshaft Oil Clearance Inspection70
Crankshaft Rear Oil Seal Replacement70
Measuring Bearing Id70
Inspecting Main Bearing70
Installing Crankshaft71
Cylinder Block Assembly72
Honing Cylinders74
Cylinder Liner Replacement75
Measring Locations And Directions For Block Bore75
Protrusion Of Liner75
Camshaft Front Bush Replacement76
Pressing-In Of Idle Gear Shaft76
Driving Camshaft Bush Out76
Pressing-In Of Camshaft Bush76
Lubrication Contents77
General78
Oil Pump And Oil Filter79
Fuel System Contents81
Fuel Injection Pump86
Inspection On The Engine86
Removing Injection Pump86
Injection Pump Disassembly87
Removing Delivery Valve87
Removing Tappet And Tappet Roller87
Control Rack And Pinions89
Plunger Installation Direction89
Tightening Delivery Holder89
Injection Nozzle90
Nozzle Injection Test93
Installing Nozzle Holder93
Installing Injection Pipe94
Fuel Filter95
Precautions For Disassembly/Assembly96
Fuel Pump97
Governor System Contents99
Installing Governor Shaft102
Cooling System Contents103
Fan And Fan Belt106
Fan Belt Inspection106
Fan Inspection106
Water Pump107
Installing Fan107
Thermostat Installation108
Thermostat Inspection108
Water Temperature Gauge Unit109
Thermo Switch Inspection109
Thermo Unit Inspection109
Air Cleaner111
Electrical System Contents113
Wiring Diagram116
Operating Combination Of Key-Off Stop System116
Key Switch Connection Of Key-Off Stop System116
Standard Type117
Key-Off Stop Type118
Starter119
Starter Assembly Inspection120
Pinion Gap120
No-Load Test120
Magnetic Switch121
Attraction Test121
Holding Test121
Return Test121
Removing Center Bracket122
Removing Reduction Gear122
Inspection After Disassembly123
Magnetic Switch Inspection123
Armature Inspection124
Brush Holder124
Short-Circuit Test Of Armature Coil124
Field Coil Inspection124
Pinion Shaft End Play Adjustment125
Adjusting Thrust Gap125
Alternator126
Built-In Ic Regulator Type127
Inspection On Engine128
Inspection Of Alternator Separate From Regulator128
Charging Performance Inspection128
Diode Inspection129
Alternator Terminals129
Regulating Voltage Inspection130
Output Inspection130
Output Test Connection130
Removing Alternator131
Disassembling Stator131
Stator Coil Inspection134
Continuity Test Of Field Coil134
Insulation Test Of Field Coil134
Continuity Test Of Stator Coil134
Alternator Assembly135
Lifting Of Brushes135
Inserting Spacer135
Regulator136
No-Load Regulating Voltage Inspection136
Pilot Lamp Voltage Inspection136
Glow Plug137
Glow Plug Inspection137
Key-Off Stop System138
Control Timer Specification138
Wire Identification Color138
Solenoid For Key-Off Stop138
Solenoid Installation139
Glow Timer Specifications140
Auto-Glow Timer System Wiring140
Glow Relay Specifications141
Maintenance Contents143
Periodic Service Chart144
Specifications And Service Standard145
Tightening Torque155
Tightening Torque And Sealant156
Reference Contents159
Comparison Between Swirl Chamber Type And Direct Injectio160
Speed Adjusting Table161
Fast Idle Speed161
Slow Idle Speed161
Fuel Injection Timing Table162
Fuel Injection Rate Table163
Turborcharger167
Precautions168
Definition Of Terms168
Table Of Contents169
Disassembly172
Removal Of Actuator173
Removal Of Turbine Housing173
Removal Of Compressor Cover173
Removal Of Compressor Wheel174
Removal Of Snap Ring174
Removal Of Insert, Oil Deflector And Others175
Removal Of Shaft And Turbine Wheel And Bearing175
Removal Of Snap Rings And Bearing176
Cleaning And Inspection177
Reassembling Sequence180
Installation Of Shaft And Turbine Wheel And Bearings181
Installation Of Thrust Bearing182
Installation Of O-Ring182
Reassembly Of Insert Subassembly183
Installation Of Snap Ring183
Measurement Of Clearanc Between Turbine Wheel And Turbine Housing184
Installation Of Compressor Wheel184
Measurement Of Axial Play Of Shaft And Turbine Wheel184
Measurement Of Clearance Between Turbine Back Plate And Turbine Wheel185
Installation Of Compressor Cover185
Installation Of Turbine Housing186
Installation Of Coupling Assembly186
Installation Of Actuator186
Maintenance Standards189