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6BG1T-BE2

SHOP MANUAL
6BG1, 6BG1T ENGINE

APPLICABLE MACHINE MODEL


FD100/115/135/150E/160E-6
FD150/180/200Z-5
FD150/180/200Z-6
F4EC/5EC/6EC-1

SERIAL No.
5001 and up
2001 and up
2301 and up
1001 and up

No. 3-4, 2 Chome, Akasaka, Minato-ku, Tokyo, Japan

BE

2003 KOMATSU FORKLIFT


All Right Reserved
Printed in Japan 06-03(03)

00-1

CONTENTS
No. of page

GENERAL INFORMATION ..................................................................1-1

ENGINE ASSEMBLY ...........................................................................2-1

LUBRICATING SYSTEM .....................................................................3-1

COOLING SYSTEM .............................................................................4-1

FUEL SYSTEM ....................................................................................5-1

AIR COMPRESSOR ............................................................................6-1

FLYWHEEL, P.T.O. ..............................................................................7-1

TROUBLESHOOTING .........................................................................8-1

SPECIAL TOOLS.................................................................................9-1

10

REPAIR SERVICE STANDARD ........................................................10-1

00-1

SAFETY
FOREWORD

FOREWORD
This workshop manual is designed to use for the repair and adjusting procedures on Model 6BG1 and 6BG1T
industrial engines.
This manual provides service men with a guide on maintaining the best conditions of the engines.
Komatsu Forklift Co. LTD reserves the right to make changes concerning numerical values due to the design
change at any time without prior notice.

00-2

SAFETY

SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe machine operation. The service
and repair techniques recommended by Komatsu and described in this manual are both
effective and safe. Some of these techniques require the use of tools specially designed by
Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous
situation arises or may possibly arise, first consider safety, and take the necessary actions to
deal with the situation.

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which
are fixed to the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting
parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.

6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there
is no dirt or oil on the floor. Smoke only in the
areas provided for smoking. Never smoke while
working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park
the machine on hard, level ground, and block
the wheels or tracks to prevent the machine
from moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from
falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.

00-3

SAFETY

HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the Disassembly
and Assembly section, every part weighing
25 kg or more is indicated clearly with the
symbol
4

Slinging near the edge of the hook may


cause the rope to slip off the hook during
hoisting, and a serious accident can result.
Hooks have maximum strength at the middle
portion.

1. If a part cannot be smoothly removed from the


machine by hoisting, the following checks should
be made:
Check for removal of all bolts fastening the
part to the relative parts.
Check for existence of another part causing
interference with the part to be removed.
2. WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter (mm)
10
11.2
12.5
14
16
18
20
22.4
30
40
50
60

Allowable load (tons)


1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0

a The allowable load value is estimated to be


one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of
the hook.

00-4

3) Do not sling a heavy load with one rope


alone, but sling with two or more ropes
symmetrically wound on to the load.

k Slinging with one rope may cause


turning of the load during hoisting,
untwisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a
dangerous accident.

4) Do not sling a heavy load with ropes forming


a wide hanging angle from the hook.
When hoisting a load with two or more
ropes, the force subjected to each rope will
increase with the hanging angles. The table
below shows the variation of allowable load
kg when hoisting is made with two ropes,
each of which is allowed to sling up to 1,000
kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to
2,000 kg of total weight can be suspended.
This weight becomes 1,000 kg when two
ropes make a 120 hanging angle. On the
other hand, two ropes are subjected to an
excessive force as large as 4,000 kg if they
sling a 2,000 kg load at a lifting angle of
150.

GENERAL INFORMATION

1 GENERAL INFORMATION
Page
General precautions for repairing engine ...................................................................................................... 1- 2
How to read repair manual ............................................................................................................................ 1- 4
Sketch drawing .............................................................................................................................................. 1- 6
Main specifications ......................................................................................................................................... 1-11
Tightening torque specifications .................................................................................................................... 1-12
Angular tightening method ............................................................................................................................. 1-14
Tightening torque of main parts .................................................................................................................... 1-15
Parts which need packings ............................................................................................................................ 1-21
Inspection and maintenance .......................................................................................................................... 1-22
Recommended lubricants .............................................................................................................................. 1-26

1-1

GENERAL INFORMATION

GENERAL PRECAUTIONS FOR REPAIRING ENGINE


When servicing an engine, take the following precautions to "prevent damage to the engine" and "secure the
performance and reliability of the engine.
1. When servicing the engine "mounted on the machine", disconnect the cables from the battery terminals to
protect the wiring harnesses from a burn caused by a short circuit.
2. When "lifting up" or "supporting" the engine, do not apply a jack, etc. to the oil pan.
If the jack is applied so, the oil pan and oil pump may be damaged since the clearance between the oil pan
and strainer is narrow.
3. If the air duct or air cleaner is removed, "cover the intake opening" to "prevent foreign matter from entering"
the cylinders.
If the foreign matter enters, it may damage the cylinders seriously.
4. Handle the oil and antifreeze carefully, since they can "stain the painted surfaces".
5. Use the specified "ISUZU special tools" effectively.
6. Use "ISUZU genuine parts".
7. Do not reuse the gaskets, oil seals, and lock washers as a rule.
Remove all the used "gasket sealant" from the sealing faces.
8. Arrange the removed parts "by the groups" to perform the work securely.
9. Before inspecting and assembling the parts, clean them carefully. Check each oil hole for "clogging" with
compressed air.
Wipe the rubber parts lightly with cloths, taking care not to damage their sealing faces.

1-2

GENERAL INFORMATION
10. Arrange the valves, bearings, pistons, piston rings, connecting rods, bearing caps, etc. by putting "numbered
tags" to them according to the "cylinder Nos." (The cylinders are number 1, 2, 3, and 4 from the crank
pulley side.)

11. When installing the rotary parts and sliding parts, apply "engine oil" or "grease" to them.
12. Observe the "tightening torque" of the bolts and nuts.
13. After completing inspection and maintenance, perform the "final inspection" to make sure that the work has
been performed correctly.

1-3

GENERAL INFORMATION

HOW TO READ REPAIR MANUAL


1. Find out each item in "General contents".
2. In each chapter, "Disassembly", "Inspection and maintenance", and "Assembly" sections are arranged in
this order.
3. Work such as removal of each part from a unit, etc. is not explained, but important work such as
"adjustment method", "tightening torque", etc. is mainly explained.
4. In the chapter of each inspection and maintenance work which starts with the disassembly drawing of the
objective component, the component parts and the inspection procedure are shown.

Main component parts


A number in parenthesis ( ) shows the sequence of Disassembly, Inspection maintenance, Reassembly.

1-4

GENERAL INFORMATION
5. The following is the symbols identifying the type of the inspection maintenance operation.

6. Definition of terms
"Nominal size" ....... A standard value for manufacture.
"Standard" .............. A standard value for maintenance (inspection, adjustment, assembly, and installation).
"Limit" ........ A maximum value or a minimum value which an inspected part must not exceed or fall below.
If the inspected part exceeds the maximum value or falls below the minimum value, it must be
replaced or repaired.
7. Explanation of abbreviations
"IN" ...................... Intake (Intake air)
"EX" .................... Exhaust (Exhaust gas)
"STD" .................. Standard
"O/S" ................... Oversize
"" ...................... Diameter

"rpm" ................... Revolutions per minute


"A" ....................... Ampere (Current)
"V" ....................... Volt (Voltage)
"z" ...................... Ohm (Resistance)

8. Application of "SI (International System of Units)"


The international system of units was applied to unify the "metric system" and various units used in many
countries (Japanese conventional system, foot-pound system, etc.) and avoid "troubles with the units"
(conversion with computers, etc.)

1-5

GENERAL INFORMATION

SKETCH DRAWING
Model BB-6BG1T

1-6

GENERAL INFORMATION

1-7

GENERAL INFORMATION
Model A-6BG1

1-8

GENERAL INFORMATION

1-9

GENERAL INFORMATION

MAIN SPECIFICATIONS
Engine name
Item

Unit

Type

BB-6BG1T
(with turbocharger)

AA-6BG1

4-stroke, water-cooled, overhead valve, in-line

Type of combustion chamber

Direct injection

Number of cylinders - Bore x Stroke


Displacement

mm

6 105 x 125

6.494

Compression ratio

18.0

Overall length x Overall width x Overall height * mm


Weight of engine

Intake valve opening angle


(before top dead center)
Intake valve closing angle
(before bottom dead center)
Exhaust valve opening angle
(before bottom dead center)
Exhaust valve closing angle
(before top dead center)

kg

1204 x 762 x 961

1143 x 672 x 797

484

458

19

47

57

15

Valve clearance (Intake)

mm

0.4 (When cold)

Valve clearance (Exhaust)

mm

0.4 (When cold)

Fuel injection timing (before top dead center)*

8
Clockwise when seen from fan side

Rotation direction

Centrifugal all-speed control

Governor

Forced-feed circulating water, pre-pressure cooling

Cooling method
*

Quantity of cooling water (in only engine)

mm

600, 7 vanes, pull type 500, 6 vanes, pull type

Made of plastics

12.0

Excluding water
in radiator

Forced lubrication

Lubrication method
Quantity of lubricating oil (in oil pan)

Max. 21.5 Min. 17.5

Max. 13 Min. 10

Generator output

Starting motor output

24V, 40A

24V, 25A

Model RHG6, IHI

Cartridge type

Oil filter

Cartridge type

Fuel oil

Diesel fuel

Oil cooler
Recommended battery capacity

Generator and regulator


are made in 1 unit.

24V, 4.5kW

Fuel filter

Lubricating oil

Prepared by
manufacturer

Element type

Type of air cleaner

Turbocharger

Dry weight

153624

Firing order

Cooling fan

Remarks

API classification, Class CD


(ISUZU specified oil)

API classification, Class CD


or CC

Installed

Prepared by
manufacturer

(Note) Items marked with *: Depend on the machine equipped with the engine.

1-11

GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS


Standard bolts
Apply the tightening torque in the following table, unless otherwise specified.
(Nm {kgfm})
Indication
at boom head

Nominal
thread size
(Diameter x Pitch)
M6 X 1.0

3.9 7.8 {0.4 0.8}

4.9 9.8 {0.5 1.0}

M8 X 1.25

7.8 17.7 {0.8 1.8}

11.8 22.6 {1.2 2.3}

16.7 30.4 {1.7 3.1}

M10 X 1.25

20.6 34.3 {2.1 3.5}

27.5 46.1 {2.8 4.7}

37.3 62.8 {3.8 6.4}

*M10 X 1.5

19.6 33.4 {2.0 3.4}

27.5 46.1 {2.8 4.7}

37.3 62.8 {3.8 6.4}

M12 X 1.25

49.1 73.6 {5.0 7.5}

60.8 91.2 {6.2 9.3}

75.5 114.0 {7.7 11.6}

*M12 X 1.75

45.1 68.7 {4.6 7.0}

56.9 84.4 {5.8 8.6}

71.6 107.0 {7.3 10.9}

M14 X 1.5

76.5 115.0 {7.8 11.7}

93.2 139.0 {9.5 14.2}

114.0 171.0 {11.6 17.4}

*M14 X 2.0

71.6 107.0 {7.3 10.9}

88.3 131.0 {9.0 13.4}

107.0 160.0 {10.9 16.3}

M16 X 1.5

104.0 157.0 {10.6 16.0}

135.0 204.0 {13.8 20.8}

160.0 240.0 {16.3 24.5}

*M16 X 2.0

100.0 149.0 {10.2 15.2}

129.0 194.0 {13.2 19.8}

153.0 230.0 {15.6 23.4}

M18 X 1.5

151.0 226.0 {15.4 23.0}

195.0 293.0 {19.9 29.9}

230.0 345.0 {23.4 35.2}

*M18 X 2.5

151.0 226.0 {15.4 23.0}

196.0 294.0 {20.0 30.0}

231.0 346.0 {23.6 35.3}

M20 X 1.5

206.0 310.0 {21.0 31.6}

270.0 405.0 {27.5 41.3}

317.0 476.0 {32.3 48.5}

*M20 X 2.5

190.0 286.0 {19.4 29.2}

249.0 375.0 {25.4 38.2}

293.0 440.0 {29.9 44.9}

M22 X 1.5

251.0 414.0 {25.6 42.2}

363.0 544.0 {37.0 55.5}

425.0 637.0 {43.3 64.9}

*M22 X 2.5

218.0 328.0 {22.2 33.4}

338.0 507.0 {34.5 51.7}

394.0 592.0 {40.2 60.4}

M24 X 2.0

359.0 540.0 {36.6 55.0}

431.0 711.0 {43.9 72.5}

554.0 831.0 {56.5 84.7}

*M24 X 3.0

338.0 507.0 {34.5 51.7}

406.0 608.0 {41.4 62.0}

521.0 782.0 {53.1 79.7}

Use the bolts marked with * for "female screws" of soft materials such as "cast iron".

1-12

GENERAL INFORMATION

Hexagon head bolts with flanges


Apply the tightening torque in the following table, unless otherwise specified.
(Nm {kgfm})
Indication
at boom head

Nominal
thread size
(Diameter x Pitch)
M6 X 1.0

4.6 8.5 {0.5 0.9}

6.6 12.2 {0.6 1.2}

M8 X 1.25

10.5 19.6 {1.1 2.0}

15.3 28.4 {1.6 2.9}

18.1 33.6 {2.1 3.4}

M10 X 1.25

23.1 38.5 {2.4 3.9}

35.4 58.9 {3.6 6.1}

42.3 70.5 {4.3 7.2}

*M10 X 1.5

22.3 37.2 {2.3 3.8}

34.5 57.5 {3.5 5.8}

40.1 66.9 {4.1 6.8}

M12 X 1.25

54.9 82.3 {5.6 8.4}

77.7 117.0 {7.9 11.9}

85.0 128.0 {8.7 13.0}

*M12 X 1.75

51.0 76.5 {5.2 7.8}

71.4 107.0 {7.3 10.9}

79.5 119.0 {8.1 12.2}

M14 X 1.5

83.0 125.0 {8.5 12.7}

115.0 172.0 {11.7 17.6}

123.0 185.0 {12.6 18.9}

*M14 X 2.0

77.2 116.0 {7.9 11.8}

108.0 162.0 {11.1 16.6}

116.0 173.0 {11.8 17.7}

M16 X 1.5

116.0 173.0 {11.8 17.7}

171.0 257.0 {17.4 26.2}

177.0 265.0 {18.0 27.1}

*M16 X 2.0

109.0 164.0 {11.2 16.7}

163.0 244.0 {16.6 24.9}

169.0 253.0 {17.2 25.8}

Use the bolts marked with * for "female screws" of soft materials such as "cast iron".

1-13

GENERAL INFORMATION

ANGULAR TIGHTENING METHOD


A method to tighten bolts and nuts to specified torque is generally used, but the axial tension to the specified
torque by this method dispereses widely. Therefore, the bolts may break at the upper limit value if the required
minimum axial tension should e maintained. Conversely, less dispersed axial tension may be obtained by
tightening bolts while measuring the elongation of the bolts. But this method is impractiocable in the actual
work. The pitch of the screw thread is considered to be as corresponding to the elogation of the bolts, of which
number of turns is controlled in the angular method. Accordingly, the dispersion of the axial tension can be
diminished by tightening to the plastic limit.
TIGHTENING METHOD
(1) Apply molybdenum disulfide grease to the threaded portion and setting faces of the bolts.
(2) Tighten all the bolts to the specified torque.
(3) Mark the place corresponding to one end of the bolt as shown in the figure below, and tighten to the
specified angle. Be sure to check by the marking that tightening has been made to the specified angle.
Neglect of this checking may lead to another tightening by the angular method and may cause breakage of
the bolts.
(NOTE)
Q Tighten bolts in the specified order.
Q Do not overtighten when the angular method is used.

Draw a line across the center of the bolt (A B


... bolt side) (C D ... part side) and a line in the
direction of the specified tightening angle from
the center of the bolt (E F) on the face of each
part to be clamped.

1-14

Use a socket wrench to tighten the bolt to the


point where the line on the bolt (A B) is aligned
with the point of the specified angle (line of the
face of the part E F).

GENERAL INFORMATION

TIGHTENING TORQUE OF MAIN PARTS


Cylinder head, cylinder head cover, and manifold
(Nm {kgfm})

1-15

GENERAL INFORMATION
Cylinder body, oil pan, and oil pump
(Nm {kgfm})

1-16

GENERAL INFORMATION
Crankshaft, piston, flywheel, and flywheel housing
(Nm {kgfm})

1-17

GENERAL INFORMATION
Camshaft and timing gear parts
(Nm {kgfm})

1-18

GENERAL INFORMATION
Water pump, fan, generator, starting motor, etc
(Nm {kgfm})

1-19

GENERAL INFORMATION
Injection pipe and turbocharger
(Nm {kgfm})

1-20

GENERAL INFORMATION

PARTS WHICH NEED PACKINGS


(Nm {kgfm})

1-21

GENERAL INFORMATION

INSPECTION AND MAINTENANCE


Cylinder head bolts
Tighten the cylinder head bolts in the order shown at
left.
(Nm {kgfm})
Tightening
torque

69 {7.0} o Loosen all o 88 {9.0}


O
90 120

Apply "molybdenum disulfide" to the "seat" and


"thread portion" of each bolt.
Use shorter bolts (6 pieces) on the nozzle side.
Do not use the head bolts more than 2 times.

Bring the No. 1 or No. 6 cylinder piston to the


compression top dead center.
Rotate the crankshaft forward and match the "T.D.C
line" of the pulley damper to the "pointer".
At this time, check that there are "clearances"
respectively between valves and rocker arms on both
intake side and exhaust side of the No. 1 or No. 6
cylinder.
(When a cylinder piston is at the compression top
dead center, there are "clearances" respectively
between valves and rocker arms on both intake side
and exhaust side.)
Adjusting the valve clearances
Adjust the valve clearances of the cylinder, the piston
of which is at the compression top dead center.
Insert a feeler gauge in the clearance between the
intake valve and rocker arm and adjust the clearance
with the adjustment screw. Adjust the clearance of
the exhaust valve similarly.
Valve clearance

Both intake and exhaust valves:


0.4 mm (When cold)

When starting the adjustment with the No. 1 cylinder,


adjust the valve clearances of the cylinders marked
with "Q". When starting the adjustment with the No.
6 cylinder, adjust the valve clearances of the cylinders
marked with "q".
1

Cylinder No.

Valve arrangement

IN

EX

IN

When No. 1 cylinder piston is at


compression top dead center
When No. 6 cylinder piston is at
compression top dead center

1-22

3
EX

IN

4
EX

IN

5
EX

IN

6
EX

IN

EX

Q
q

GENERAL INFORMATION
Fuel injection timing (1)
Match the "T.D.C mark" (top dead center mark) of
the crank pulley to the "pointer".

When the "pointer" is matched to the "T.D.C mark",


if the plate stamp line of the injection pump is matched
to the pointer of the timing gear case cover, the
injection pump is installed normally.

Fuel injection timing (2)


1. Remove the No. 1 injection pipe and the No. 1
delivery holder of the injection pump.
Pull out the delivery valve and spring and tighten
only the holder to (39 - 44 Nm {4 - 4.5 kgfm}).
2. Rotate the crank pulley counterclockwise about
30 from the "T.D.C" mark.
3. Operating the feed pump with the hand, rotate
the crank pulley clockwise slowly, and the
discharge rate of the fuel from the No. 1 delivery
holder of the injection pump is reduced gradually
to zero.
4. When discharge of the fuel stops (at the injecting
timing), check the mark of the crank pulley
indicated by the pointer tip.
5. Clean and reinstall the removed delivery valve
and spring and tighten the delivery holder to the
"specified torque".
If you do not observe the tightening torque of (39
- 44 Nm {4.0 - 4.5 kgfm}), the engine may hunt
and have some troubles.
6. When removing and installing the delivery valve
and spring, take extreme care that dirt will not
enter.
Injection
timing

6BG1T

8 or 10

6BG1

If deviation is larger than 2, adjust.

Note: The proper injection timing depends on the


machine equipped with the engine.

1-23

GENERAL INFORMATION
Adjusting the injection timing
In the case of the flange mount type, loosen the
mounting nuts (4 pieces) of the injection pump
housing and pump bracket with the special tool and
change the installed angle of the injection pump to
adjust the injection timing. The injection timing
adjusted when the engine was assembled is indicated
by the stamped "match marks" at the joint of the
injection pump housing and bracket.
Special tool: Injection pump wrench
9-8511-3703-0

In the case of the center mount type, loosen the


coupling bolt on the front face of the timer and match
the timer stamp line to the pump body stamp line as
shown in the figure.

Measuring the compression pressure


Remove each glow plug and injection pipe from the
cylinder head. Then, rotate the starting motor and
measure the compression pressure in each cylinder
with a "pressure gauge".
Be sure to measure the compression pressure in all
the cylinders. (Measure each cylinder at least twice.)
(MPa {kgf/cm2})
Compression pressure
(at 200 rpm)

Standard

Limit

3.0 {31}

2.5 {26}

Special tool: Compression gauge adapter


5-85317-001-0
1. Before measuring the compression pressure,
warm up the engine (until the coolant temperature
rises above 70C).
2. Take care that foreign matter will not enter the
cylinders.
3. The difference in the compression pressure
between the cylinders must be less than 294
kPa {3 kgf/cm2}. If it exceeds this limit, inspect
the engine.
4. The compression pressure varies with the
altitude.

1-24

GENERAL INFORMATION
Injection nozzle
Check the condition and pressure of injection, and
then adjust them if necessary.
(MPa {kgf/cm2})
Fuel injection pressure

18.1 {185}

Note: When the nozzle holder is new, the injection


pressure is set about 980 kPa {10kgf/cm2}
higher than the above value, considering aging.
When adjusting, however, observe the above
value.

Using the nozzle tester, adjust the injection pressure


with the adjustment screw.

Bleeding the air


You can bleed the air from the fuel circuit by simply
operating the feed pump with the hand, but that takes
you much time. Accordingly, bleed the air according
to the following procedure.
Loosen the joint bolt of the fuel filter outlet and operate
the feed pump, and the filter is filled with fuel.
Then, operate the feed pump until the "air" is bled
and "hissing sound" is heard.

Fan belt
(mm)
Belt deflection

Approx. 7 10

Loosen the generator mounting bolts and press the


belt as shown in the figure at left, and then adjust
the belt deflection to the specified value.

1-25

GENERAL INFORMATION

RECOMMENDED LUBRICANTS
ENGINE TYPE AND GRADE
Enging type

Recommended lubricants (API Service Cassification)

With turbocharger

CD Grade

Without turbocharger

CC or CD Grade

ENGINE OIL VISCOSITY CHART


THE RELATIONSHIP BETWEEN ENGINE OIL VISCOSITY AND AMBIENT TEMPERATURE
(Single grade)
SAE 40, 50

SAE 20, 20W

SAE 10W

(Ambient
30C
Temperature) (22F)

15C
(0F)

SAE 30

0C
(32F)

15C
(60F)

25C
(80F)

30C
(90F)

(Multi- grade)
SAE 10W-30

SAE 15W-40, 20W-40, 20W-50

Start-up, operability, oil consumption, the wear of sliding portions and seizure of the engine may be affected
by engine oil viscosity. Select the proper oil according to the temperature referring to the above table.

1-26

ENGINE ASSEMBLY

2 ENGINE ASSEMBLY
Page
General view of engine .................................................................................................................................. 2- 2
Disassembly ................................................................................................................................................... 2- 3
Main component parts ............................................................................................................................. 2- 3
Disassembly procedure (1) ..................................................................................................................... 2- 4
Disassembly procedure (2) ..................................................................................................................... 2- 5
Disassembly procedure (3) ..................................................................................................................... 2- 6
Engine oil and coolant ............................................................................................................................. 2- 7
Exterior parts ........................................................................................................................................... 2- 7
Rocker arm shaft assembly .................................................................................................................... 2-11
Cylinder head assembly .......................................................................................................................... 2-11
Cylinder body parts ................................................................................................................................. 2-13
Timing train parts, camshaft, and tappet ................................................................................................ 2-15
Piston and connecting rod assembly ...................................................................................................... 2-18
Crankshaft assembly ............................................................................................................................... 2-19
Inspection and replacement .......................................................................................................................... 2-20
Cylinder body ........................................................................................................................................... 2-20
Cylinder head .......................................................................................................................................... 2-22
Valve, valve guide, valve guide insert ..................................................................................................... 2-23
Rocker arm shaft assembly parts ........................................................................................................... 2-25
Camshaft, tappet, idle gear, and shaft ................................................................................................... 2-26
Piston, piston pin, piston ring .................................................................................................................. 2-30
Connecting rod, connecting rod bearing ................................................................................................. 2-32
Crankshaft, crankshaft bearing ............................................................................................................... 2-34
Reassembly ................................................................................................................................................... 2-37
Cylinder head assembly .......................................................................................................................... 2-37
Rocker arm shaft assembly .................................................................................................................... 2-39
Piston and connecting rod assembly ...................................................................................................... 2-40
Component parts ..................................................................................................................................... 2-42
Crank shaft assembly .............................................................................................................................. 2-43
Cylinder body parts ................................................................................................................................. 2-44
Piston and connecting rod ...................................................................................................................... 2-46
Timing gear, tappet, and oil pump .......................................................................................................... 2-47
Rear oil seal, housing, oil pan, and oil cooler ........................................................................................ 2-49
Fuel injection pump and gear case cover .............................................................................................. 2-50
Relationship between flywheel, crank pulley, and cylinder head ........................................................... 2-51
Exterior parts ........................................................................................................................................... 2-53

2-1

ENGINE ASSEMBLY

GENERAL VIEW OF ENGINE

2-2

ENGINE ASSEMBLY

DISASSEMBLY
MAIN COMPONENT PARTS

2-3

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (1)

2-4

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (2)

2-5

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (3)

2-6

ENGINE ASSEMBLY

ENGINE OIL AND COOLANT


Engine oil
Loosen the drain plug of the oil pan and drain the
engine oil.
Note: Be sure to collect the oil of first 0.1 L (100 cc)
for inspection.

Coolant
Loosen the drain valve of the cylinder body and drain
the coolant remaining in the engine.
Note: If water leaks through the water pump, collect
first 0.1 L (100 cc) of it for inspection.

EXTERIOR PARTS
Cooling fan
Remove the cooling fan.
Take care not to break or damage the removed fan.

Intake duct
Remove the duct between the turbocharger and
intake manifold.
Note: Take care that foreign matter will not enter
the turbocharger and intake manifold.

Fuel piping and nozzle holder


Remove the leak-off pipe, fuel pipe, injection pipe,
and nozzle holder.
Note: Take measures to prevent foreign matter from
entering the nozzle holder, injection pump, fuel
filter, etc., since foreign matter can cause a
trouble.

2-7

ENGINE ASSEMBLY
Lubrication piping
Remove the lubricating oil pipe of the injection pump,
oil pipe of the oil filter, and oil feed pipe of the
turbocharger (Remove the return pipe later).
Note: Cover the oil feed opening of the turbocharger
with an adhesive tape to prevent foreign matter
from entering the turbocharger. When
reassembling, remove the tape and clean.

Turbocharger
1. Remove the turbocharger and return oil pipe
together.
2. Remove the return pipe from the turbocharger.
Note: Take care that foreign matter will not enter
the intake opening, exhaust opening, and
return oil port of the turbocharger.

Generator
Remove the adjustment plate of the generator, and
then remove the generator and fan belt.

Starting motor
Remove the starting motor mounting nuts, and then
remove the starting motor and ground cable from the
flywheel housing.

Glow plug
Remove the glow plug connector, and then remove
the glow plug from the cylinder head.

2-8

ENGINE ASSEMBLY
Oil filter
Loosen each cartridge, and then remove the oil filter
assembly. (Replace the cartridges.)
Note: Take care that foreign matter and dirt will not
enter the oil filter fitting parts of the cylinder
body.

Fuel injection pump


Remove the fuel injection pump and bracket together
from the timing gear case.

Oil cooler
Remove the oil cooler from the cylinder body by
lightly hitting around it with a wooden hammer, etc.

2-9

ENGINE ASSEMBLY
Water pump and fan pulley
Loosen the bypass hose band and remove the pump
mounting bolts and water pump.

Cylinder head cover


Remove the cylinder head cover mounting bolts and
cylinder head cover.
Air breather and tappet chamber cover
Remove the air breather and tappet chamber cover.
Oil pump pinion gear
Remove the mounting bolts of the cylinder body hole
cover (pinion gear), and then remove the cover and
pinion gear shaft of the oil pump.

2-10

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY

Rocker arm bracket


Loosen the mounting bolts evenly from both ends
and remove the rocker arm brackets.

CYLINDER HEAD ASSEMBLY


Cylinder head
Loosen the cylinder head bolts in the numerical order
shown in the figure.

2-11

ENGINE ASSEMBLY

Before disassembling the valve mechanism, remove


the nozzle holder assembly and glow plug.
Remove the intake manifold and exhaust manifold
together (including the gasket).

Valve
Valve and valve spring
Special tool: Valve spring replacer
1-85235-006-0
Compress the valve spring and remove the split collar,
spring seat, valve spring, and valve.

2-12

ENGINE ASSEMBLY

CYLINDER BODY PARTS


Crank pulley
1. Remove the claw nut and washer of the crank
pulley with torque wrench (637 Nm and up {65
kgfm and up}).
Note: When loosening the claw nut, install a long
bolt to the flywheel to stop the flywheel.

2. Using the taper bushing puller, pull out the taper


bushing and remove the crank pulley.
Special tool: Taper bushing puller
9-8521-0122-0

Oil pan
Remove the mounting bolts and oil pan.
Oil pump and oil pipe
Remove the oil pump and oil pipe together from the
cylinder body.
At this time, remove the drive gear shaft coupling,
too.

2-13

ENGINE ASSEMBLY
Flywheel
1. Lock the crankshaft and remove the mounting
bolts.
2. Remove the flywheel, hitting it lightly with a plastic
hammer.
Note: Do not damage the ring gear.
Timing gear case cover
1. Loosen the bolts (7 pieces) of the timing gear
case cover and remove the injection pump. Then,
remove the other bolts and gear case cover.
Note: Remove the rear bracket of the injection pump
in advance.
2. Install the claw nut of the crank pulley temporarily
to rotate the crankshaft.

Piston and connecting rod


Rotate the crankshaft to bring the piston to the top
dead center.
Then, remove the bearing cap and push the
connecting rod from the lower end with the grip of a
hammer, etc. to push out the piston and connecting
rod toward the top of the cylinder body.
Note: Take care not to damage the oil jet.

2-14

ENGINE ASSEMBLY

TIMING TRAIN PARTS, CAMSHAFT, AND TAPPET

Backlash of gears
Before removing each gear, measure its backlash.
(mm)
Standard

Limit

0.10 0.17

0.3

2-15

ENGINE ASSEMBLY
Clearance of idle gear in axial direction
(mm)
Standard

Limit

0.128 0.185

0.2

Clearance of crankshaft in axial direction


Before removing the crankshaft, measure its
clearance.
Measure the clearance at No. 4 bearing cap.
(mm)
Standard

Limit

0.15 0.33

0.4

Camshaft assembly
Remove the thrust plate mounting bolts through the
hole of the cam gear and pull out the camshaft slowly.

Gear case
Remove the timing gear case from the cylinder body.
Rear oil seal
Remove the flywheel housing.
Using the special tool, remove the oil seal.
Special tool: Rear oil seal remover
5-8840-2360-0

2-16

ENGINE ASSEMBLY
Flywheel housing
Remove the flywheel housing from the cylinder body.

Idle gear shaft


Utilize the seal plug concave of the oil gallery to
remove the shaft with a screwdriver.

Crankshaft bearing and crankshaft


Loosen the mounting bolts in the order shown in the
figure.
Remove the cap, hitting it lightly with a copper
hammer.
Then, remove the crankshaft.

Camshaft bearing
Remove the flywheel and the flywheel housing, and
pull out the plate plug, and then remove the bearings
successively from the rear of the cylinder body using
a puller.
Special tool: Bearing puller
9-8523-1818-0

2-17

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY

Piston ring
Use a replacer to remove the piston ring.
Special tool: Piston ring replacer
1-8522-1025-0

Piston pin
Remove the snap ring. Put a holding-up rod to the
piston pin and tap it out with a hammer.

2-18

ENGINE ASSEMBLY

CRANKSHAFT ASSEMBLY

Crankshaft gear
Use a puller to remove the crankshaft gear.
Special tools: Puller; Crankshaft gear
9-8521-0141-0

2-19

ENGINE ASSEMBLY

INSPECTION AND REPLACEMENT


Make the necessary adjustments, and part replacement if excessive wear, damages or other defects are
discovered during the inspection.

CYLINDER BODY
Cylinder body
Inspect the cylinder body for wear, breakage, water
leakage, etc.
Water leakage: Water pressure test 490kpa {5 kg/cm2}
(for 3 min.)
2. Inspect the cylinder body for damage with defect
detector material, etc.

Cylinder body top warpage


Use a rule and a feeler gauge to measure the four
sides and the two diagonals.
(mm)
Standard

Limit

0.05 or less

0.2

Repair procedure
Grinding with surface
grinder

The maximum grinding must not exceed 0.3 mm.

Cylinder liner bore


(mm)
Standard

Limit

Repair procedure

105.0

105.2

Replacement

Measure the maximum wear portion at 20 mm above


the upper face of the liner
Note: Since the inside of the liner is plated with
special chromium, it cannot be finished by
boring or honing. Accordingly, if the liner has
a seizure mark or a flaw or the measured
value exceeds the service limit, replace the
liner.

2-20

ENGINE ASSEMBLY
Setting of grade part Nos. of pistons, cylinder
liners, and liner sets
Part Nos. are set for each grade of the spare pistons,
cylinder liners, and liner sets supplied in and after
August 1997. Accordingly, when repairing these
parts, observe the following points.
1. Repair standard
Judge the repair standard of these parts by the
repair standard values in this repair manual as
before.
2. Grade part Nos. (Replacement of new and
current part Nos.)
3. How to order parts
Select a proper grade of each part in the new
and current part Nos. table and place an order
by the corresponding new part No.
Selecting the liner
The combinations of the liners and cylinder bores
are as follows. The interference between each liner
and cylinder must be 0.001 - 0.0019 mm.
(mm)
Liner inside Cylinder body
diameter
bore

105

Liner
Liner outside
grade No. diameter

107.001 107.010

107.001 107.010

107.011 107.020

107.011 107.020

107.021 107.030

107.021 107.030

The grade stamps are made on the outside and


inside of each new liner, but they are defaced once
the liner is used.

Cylinder liner projection


Standard: 0.03 0.10 mm
Check that the difference in the projection height
between any two adjacent cylinders is not exceeding
0.03 mm.

Removing the cylinder liner


Special tools: Remover; Cylinder liner
9 8523 1169 0
9 8523 1004 0 (Angle)

2-21

ENGINE ASSEMBLY
Installing cylinder liner
Carefully wipe away oil from the cylinder liner and
body and install the liner with special tools.
Use the bench press to apply initial pressure of 500
kg for press-fitting the liner and apply final pressure
of 2500 kg for press-fitting and fully seating the liner.
Special tools: Setting tool; Cylinder liner
5 85221 018 0

CYLINDER HEAD
Cylinder head
Remove carbon residues which are sticking on the
bottom face of the head carfully not to damage the
valve seat face and inspect wear, damage and the
like.
Water leakage: Water pressure test 490 kpa {5 kg/
cm2} (for 3 min)
Perform a magnetic particle inspection and a red
check, as necessary.

Lower face warpage


Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals.

(mm)
Standard

Limit

0.05
or less

0.20

Repair procedure
Grinding with surface
grinder

The maximum grinding must not exceed 0.3 mm.

2-22

ENGINE ASSEMBLY

VALVE, VALVE GUIDE, VALVE GUIDE INSERT


Valve guide
Check the wear of the inner face. If the measured
values exceed the specified clearance, the valve and
the valve guide must be replaced as a set.
Measure at the position of 10mm above the upper
face of the guide.
(mm)
Valve Stem
Clearance

Standard

Limit

Inlet Valve Side

0.39 0.068

0.20

Inlet Valve Side

0.064 0.096

0.25

Removing the valve guide


Special tools: Replace and Installer, Valve guide
1-85220-001-0

Valve contact width and valve depression


(1) Contact width check (A)
(2) Depression Check (B)
(mm)

Depression
(B)

Contact
width (A)

Intake

Standard

Limit

1.0

2.5

Exhaust
Intake

1.5

2.0

Repair
procedure

Correct
or replace
the valve
and insert

Exhaust

Valve seat insert


Put a smooth patch on the insert surface not to
damage the surface and use a bench press to apply
pressure of [9,807 14,710N] 1,000 1,500kg for
press-fitting.
Notes on removing the valve seat insert.
(1) Red-heat (700 800) two diagonal points of the
inside of the valve seat insert with a gas burner.
(2) Allow the valve seat insert to cool for 3 5
minutes.
Then tap the insert out. Take care not to damage
the cylinder head.

2-23

ENGINE ASSEMBLY
Valve stem diameter
Correct slightly stepped wear with an oil stone.
(mm)
Standard

Limit

Repair Procedure

9.00

8.88

Replacement

Intake
Exhaust

Valve thickness
(mm)
Standard

Limit

Repair Procedure

1.5

1.0

Replacement

Intake
Exhaust

Valve spring force (Tension)


Use a spring tester to measure the spring tension at
specified setting.
Without valve rotator: When compressed by 44.5 mm
(N {kgf})
Distinction

Standard

Limit

Repair
procedure

Blue

142 {14.5}

127 {13.0}

Replacement

With valve rotator: When compressed by 40 mm


(N {kgf})
Distinction

Standard

Limit

Repair
procedure

Pink

142 {14.5}

127 {13.0}

Replacement

Valve spring free length (A)


Without valve rotator

(mm)

Distinction

Standard

Limit

Repair
procedure

Blue

60.6

58.0

Replacement

With valve rotator

(mm)

Distinction

Standard

Limit

Repair
procedure

Pink

55.0

53.0

Replacement

Valve spring squareness (B)

2-24

(mm)

Standard

Limit

Repair procedure

1.9 or less

2.7

Replacement

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY PARTS


Bracket
Rocker arm
Rocker arm shaft
Check for wear, breakage and the like.
Check for the clogged oil hole of the bracket (fron
side).

Rocker arm shaft


Use a micrometer to measure the shaft outer
diameter at 6 places.
Rocker arm shaft diameter.
(mm)
Normal Size

Limit

Repair procedure

19.00

18.85

Replacement

Measuring the bushing bore and inspecting the


clearance limit.
Clearance between the bushing and the rocker arm
shaft.
(mm)
Standard

Limit

Repair procedure

0.01 0.05

0.2

Replacement

Check the rocker arm contact surface with the valve


stem end, and replace the rocker arm if there is
stepped or streaked surface.
Measureing the rocker arm shaft warpage
Support both ends of the shaft with V blocks and
measure the run-out at the center with a dial gauge.
(Warpage is 1/2 of the run-out.)
Warpage of the rocker arm shaft.
(mm)
Standard

Limit

Repair procedure

0.2 or less

0.3

Replacement

If warpaage is slight, the shaft may be re-used after


correcting by the press (to be corrected during cold
processing).

2-25

ENGINE ASSEMBLY
Push rod bend
If the both ends of a push rod are worn or damaged
remarkably, replace that push rod.
(mm)
Limit

0.3

CAMSHAFT, TAPPET, IDLE GEAR, AND SHAFT


Inspecting the camshaft
Inspect the journals, cams, and oil pump drive gear
for wear and breakage, and replace the camshaft if
there is any abnormality.

Axial clearance between thrust plate and camshaft


journal end
Before removing the camshaft gear, move the thrust
plate to the gear side and measure the "clearance"
between the thrust plate and camshaft journal end.
If the measured value exceeds the limit, replace the
thrust plate.
Clearance between journal end and thrust plate
(mm)
Standard

Limit

0.050 0.114

0.2

Removing and installing the camshaft gear and


thrust plate
1. Removal procedure
(1) Grip the camshaft assembly in a vise and
remove the gear clamping bolt.
(2) Using the gear puller or a press, remove the
camshaft gear and thrust plate together.
2. Installation procedure
(1) Install the thrust plate and camshaft gear to
the camshaft. When installing the gear, set
the stamp of match mark "B" on this side.
(2) Apply engine oil to the camshaft gear bolt.
(N.m {kgf.m})
Tightening torque

2-26

142 172 {14.5 17.5}

ENGINE ASSEMBLY
Camshaft runout
Inspect the camshaft for bend.
Measure the runout and divide it by 2 (to obtain the
bend).
(mm)
Limit

Repair procedure

0.12

Replacement

Cam lobe height (Lift)


Using a micrometer, measure the cam lobe height
(lift). If the measured value is less than the limit,
replace the camshaft.
(mm)
Standard

Limit

Repair procedure

7.71

7.21

Replacement

Clearance at camshaft journal


1. Using a micrometer, measure the outside
diameter of the camshaft journal. If the measured
value is less than the limit, replace the camshaft.
Camshaft journal outside diameter

(mm)

Standard

Limit

55.94 55.97

55.6

Uneven camshaft journal wear


Limit

(mm)
0.05

2. Using a bore gauge, measure the inside diameter


of the camshaft bearing and calculate the
difference between it and the outside diameter
of the journal. If the measured value exceeds
the limit, replace the bearing of camshaft.
Clearance at camshaft journal

(mm)

Standard

Limit

0.03 0.09

0.15

2-27

ENGINE ASSEMBLY
Replacing the camshaft bearing
1. Removal procedure
(1) Remove the sealing cup of the cylinder body.
(2) Using the camshaft bearing puller, remove
the bearing.
Special tool: Camshaft bearing puller
9-8523-1818-0

2. Installation procedure
(1) Match the oil hole of the bearing to that of
the cylinder body.
(2) Using the bearing replacer, install the bearing.
Special tool: Camshaft bearing installer
9-8523-1818-0

Inspecting the tappet contact face


Inspect the tappets for wear, damage and any
abnormality. Replace the pitted or cracked tappet.

Tappet outside diameter


Measure the outside diameter of the tappet.
(mm)

2-28

Nominal size

Limit

Repair procedure

28

27.92

Replacement

ENGINE ASSEMBLY
Clearance between tappet and cylinder body
Using a bore gauge, measure the inside diameter of
the tappet inserting hole of the cylinder body and
calculate the difference between it and outside
diameter of the tappet.
(mm)
Standard

Limit

Repair procedure

0.020 0.054

0.1

Replacement

Inspecting the idle gear and shaft


Visual inspection
1. If the sliding surfaces of the idle gear shaft and
the inside wall of the idle gear bushing are worn
or damaged remarkably, replace the shaft or gear.
2. If there is a stepped surface on the idle gear or
thrust collar, replace the gear or thrust collar.

Idle gear shaft outside diameter


Using a micrometer, measure the outside diameter
of the shaft. If the measured value is less than the
limit, replace the idle gear shaft.
Shaft outside diameter

(mm)

Nominal size

Limit

Repair procedure

45

44.9

Replacement

Clearance between idle gear bushing and shaft


Using a dial gauge, measure the inside diameter of
the bushing and calculate the difference between it
and outside diameter of the shaft. If the measured
value exceeds the limit, replace the idle gear.
(mm)
Standard

Limit

Repair procedure

0.025 0.085

0.2

Replacement

2-29

ENGINE ASSEMBLY

PISTON, PISTON PIN, PISTON RING


Selecting the grade
The pistons and liners are classified into the grades
of "A", "B", "C", and "D" when shipped. The service
parts are classified into the grades of "AX" and "CX",
however.
1. Use service pistons of grade AX for liners of
grade A or B.
2. Use service pistons of grade CX for liners of
grade C or D.
Note: The grades of the liner and piston of each
spare liner kit are selected properly.
Cylinder liner and piston clearance
(mm)
Standard
Cylinder liner inside diameter

105.021 105.060

Piston outside diameter

104.945 104.984

Clearance between cylinder


liner and piston (for service)

0.051 0.085

Service piston outside diameter


(mm)
Grade
Piston outside
diameter

AX

CX

104.959
104.975
104.974
104.990

Liner and piston combination (for service)

2-30

Cylinder inside
diameter grade

Piston grade

Combination

AX

AX

OK

CX

CX

OK

AX

CX

NG

CX

AX

NG

ENGINE ASSEMBLY
Piston pin wear
Piston pin outside diameter

(mm)

Nominal size

Limit

Repair procedure

35

34.95

Replacement

Piston pin hole and piston pin clearance


Standard

(mm)

0.010 0.018

Piston ring gap


Insert and push the piston ring horizontally in the
cylinder bore using an inverted piston.
(mm)
Standard

Limit

Repair procedure

1.5

Replacement

1st pressure ring 0.35 0.50


2nd pressure ring 0.60 0.75
3rd pressure ring 0.60 0.75
Oil ring

0.30 0.50

Piston ring groove and piston ring clearance


Measure at several points around the piston.
(mm)

1st pressure ring

Standard

Limit

2nd pressure ring 0.07 0.11 0.15

Repair procedure

Replacement

3rd pressure ring 0.05 0.09 0.15


Oil ring

0.030 0.070 0.15

2-31

ENGINE ASSEMBLY
Piston ring tension
(N {kgf})
Standard
20.4
1st pressure ring {2.08
14.1
2nd pressure ring {1.44
14.1
3rd pressure ring {1.46
36.3
Oil ring
{3.7

30.6
3.12}
21.2
2.16}
21.2
2.16}
55.9
5.7}

Limit Repair procedure


9.8
{1.0}
4.9
{0.5}
4.9
{0.5}
31
{3.2}

Replacement

CONNECTING ROD, CONNECTING ROD BEARING


Connecting rod torsion, parallelism
(mm)
Torsion
(in 100 mm)
Parallelism
(in 100 mm)

Standard

Limit

0.05 or less

0.2

0.05 or less

0.2

Repair procedure
Repair or
replacement

Connecting rod small end bushing and piston pin


clearance
(mm)

2-32

Standard

Limit

Repair procedure

0.012 0.025

0.05

Replacement

ENGINE ASSEMBLY
Replacing the bushing
Use a proper rod and a bench press.
Inside diameter finish after press fitting the bushing.
(mm)
Standard

( 35) + 0.025 0.017

Bearing tension
Check if the tension of the bearing is sufficient. The
back face must be fit closely.

Wear of connecting rod bearing


Bearing and crank pin clearance
Measure the inside diameter of the bearing and
calculate the clearance.
(mm)
Standard

Limit

Repair procedure

0.030 0.073

0.1

Replacement

Note: Tighten the bearing cap to 39 N.m {4.0 kgf.m}


and further tighten by 60 - 90, and then
measure the inside diameter and calculate the
clearance.
Connecting rod axial cleranace
Install the connecting rod to the crankshaft and
measure the clearance with a feeler gauge.
(mm)
Standard

Limit

Repair procedure

0.17 0.30

0.35

Replacement

2-33

ENGINE ASSEMBLY

CRANKSHAFT, CRANKSHAFT BEARING


Inspecting the crankshaft
Check the whole crankshaft visually. If there are
slight streaks on the sliding surfaces, remove them
with an oilstone. If there are deep streaks, replace
the crankshaft.
Check the crankshaft for cracking by a red check or
a magnetic particle inspection. In addition, check
that the tufftride layers are left on the journals and
pins.
Note: Since the journals and pins are finished with
TUFFTRIDE method, they cannot be polished.
Accordingly, undersize bearings are not
prepared.
Tufftriding Inspection
The crankshafts are finished with TUFFTRIDE
method.
Tufftrided areas: Journals, Pins
1. Judgment
Apply a solution of ammonium cuprous chloride
(5 10% solution dissolved in distilled water) on
the test area excluding the periphery of the
crankshaft pin and the journal oil port. If no
discoloration appears (hte color of copper), the
crankshaft may be re-used. If discoloration
appears, the crankshaft must be replaced.
2. Inspection method
(1) Clean the crankshaft carefully and degrease
it perfectly. Do not check the range of about
10 mm around the oil hole.
(2) Drop the inspection solution from a pipette
or a glass rod onto the surface to be checked.
At this time, keep the surface to be checked
horizontally to prevent the solution from
flowing down.
* Inspection solution .... 5 - 10% distilled
water solution of
ammonium cuprous
chloride
(Judgment)
(1) Re-usable
No discoloration is recognized after 30 40
seconds.
(2) Unusable (No tufftride layer remaining)
After 30 40 seconds, the light blue color
changes to clear and the solution dropped
area becomes the color of copper.
Note: 1) Since the inspection solution is very
corrosive, wipe it off immediately after
finishing the inspection, and then clean
the inspected surface with water, steam,
etc.
2) Never put the inspection solution to the
eyes, hands, or clothes. If it enters the
eyes, wash it away with much water, and
then consult a doctor.

2-34

(mm)

ENGINE ASSEMBLY
Journal, pin outside diameter
(mm)
Portion

Nominal size

Standard

Journal

80

79.919 79.939
No. 4 journal is
79.905 79.925

Pin

64

63.924 63.944

Note: Regrinding is not allowed for the crankshaft


as it is tufftrided.
(mm)
Uneven wear

Limit: 0.05

Runout of crankshaft
Apply a dial gauge to No. 4 journal, turn the shaft
slowly, and read the gauge.
(mm)
Standard

Limit

Repair procedure

0.05 or less

0.4

Replacement

Wear of crankshaft bearing


Journal and bearing clearance
Measure the inside diameter of the bearing and
calculate the clearance.
(mm)
Standard

Limit

Repair procedure

0.025 0.084
No. 4 journal is
0.039 0.098.

0.11

Bearing
replacement

Note: Tighten the bearing cap to 235 N.m {24 kgf.m}.


Crankshaft bearing tension
Check that the bearing has sufficient tension. If the
tension is insufficient, replace the bearing.

2-35

ENGINE ASSEMBLY
Removing the crankshaft gear
Using the puller, remove the crankshaft gear.
Special tool: crankshaft gear, puller
9-8521-0141-0

Gear case cover


Using the special tool, press fit the oil seal.
Special tool: Front oil seal setting tool
9-8522-0034-0

Removing and installing the ring gear


1. Strike with a hammer and chisel to remove.

2. Heat the ring gear with a gas burner to install.

2-36

ENGINE ASSEMBLY

REASSEMBLY
CYLINDER HEAD ASSEMBLY

Valve seal
When press fitting the valve seal, apply engine oil to
the periphery of the valve guide.
Special tool: Valve seal setting tool
1-85221-005-0
Note: Press fit the seal securely until it reaches the
cylinder head top. When press fitting the seal,
take care not to damage its lip. After press
fitting, check that the spring has not come off.

2-37

ENGINE ASSEMBLY
Valve
Valve spring
Lubricate valve stems with engine oil when inserting
the valve.
Install the valve spring with the shorter pitch side
(painted side) down.

Spring seat, split collar


Use a tool (replacer) to push the spring into position.
Special tool: Valve spring; Replacer
1-85235-006-0

Intake manifold
Tightening torque: 2.1 3.1 kg.m
{20.6 30.4 N.m}

Exhaust manifold
Tightening torque: 2.6 3.2 kg.m
{25.5 31.4 N.m}
Install the gasket with the TOP mark facing up to
the engine and to you.

2-38

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY

Brackets (Rear and inner)


Warm the brackets in hot water and install them to
the rocker arm shaft as shown in the figure.

Bracket (Front)
Warm the bracket in hot water.
Coat the O-ring with oil and fit it to the bracket.
Install the bracket to the rocker arm shaft with the Oring side ahead.

2-39

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY

Reassembling piston, connecting rod


Install the connecting rod to the piston with the notch
of the piston head and the direction of the connecting
rod as illustrated. Then secure the piston pin with a
snap ring. Finally, check that the piston moves
smoothly.

Piston pin
Insert the piston pin manually without heating the
piston.

2-40

ENGINE ASSEMBLY
Install the expander ring
Engage the abutting faces of the expander ring closely
and insert into the groove of the piston.

Piston ring
Install the top ring with its marking facing up. Install
the second ring with its undercut facing down. The
oil ring has no facing mark. Then, lubricate the
periphery of the rings with oil and rotate the rings.
Check that the piston rings rotate smoothly without
any catching.
1-8522-1025-0

2-41

ENGINE ASSEMBLY

COMPONENT PARTS

2-42

ENGINE ASSEMBLY

CRANK SHAFT ASSEMBLY

Crankshaft gear
Install the crankshaft gear to the crankshaft with the
chamfered side of the key facing the front. Use the
setting tool to install the crankshaft gear with the
gear timing set mark facing outside.
Special tools: Crankshaft gear setting tool
9-8522-0033-0

2-43

ENGINE ASSEMBLY

CYLINDER BODY PARTS


Installing the camshaft bearing
1. Match the oil holes of the bearing to those of the
cylinder body.
2. Using the bearing installer, install the camshaft
bearing.
Special tool: Camshaft bearing installer
9-8523-1818-0

Piston oil jet


Install oil jet , matching its dowel pin to the pin
hole of the cylinder body, and tighten check valve .
(N.m {kgf.m})
Tightening torque

16 25 {1.6 2.6}

Note: Take care not to deform or damage the oil jet


nozzle.

Crankshaft bearings
Since the lower bearing (on the bearing cap side)
does not have an oil groove or an oil hole, take care
not to mistake it for the upper bearing.
Note: If the lower and upper bearings are installed
reversely, the crankshaft bearing will be seized.
Take care.

Thrust bearings
Apply sufficient amount of engine oil to the inside of
the crankshaft bearing and place the crankshaft
slowly. Apply oil to both sides of the thrust bearings
and push them into both sides of No. 4 journal with
the hand, setting the oil groove sides out (on the
crankshaft side).

2-44

ENGINE ASSEMBLY

Bearing caps (1)


Apply engine oil to the journal of the crankshaft.
Install the bearing caps in the numerical order with
their "arrows" on the front side of the engine.

Bearing caps (2)


Apply engine oil to the threads and seats of the
bolts. Tighten each bolt in 2 - 3 times and tighten all
the bolts from the central one (No. 4) to both ends in
order. After tightening each bolt, check that you can
turn the crankshaft lightly with the hand.
(N.m {kgf.m})
Tightening torque

16 25 {1.6 2.6}

2-45

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD


Installing the piston ring
Before inserting each piston in the cylinder, set the
piston ring as shown in the figure at left. (The
abutment joint must not be at a right angle to the
piston pin.)

Installing the piston


Apply engine oil to the inside of the cylinder and the
side of the piston. Direct the cut (front mark) of the
piston head toward the front side of the cylinder
body. Using the setting tool, push in the piston with
the grip of a hammer until it reaches the crank pin.
Special tool: Piston setting tool
9-8522-1173-0

Note 1: When pushing in the piston, turn the


crankshaft, as necessary, so that the large
end of the connecting rod will not interfere
with the crank pin.
Note 2: Take care not to bend or damage the oil jet
with the large end of the connecting rod.

Connecting rod and cap


Apply engine oil to the bearing and crank pin and
install the connecting rod cap, matching the stamp of
connecting rod cap to that of the connecting rod.
Apply molybdenum disulfide to the threads and seats
of the bolts before tightening them. At this time,
check that the stamps are on the camshaft side.
(N.m {kgf.m})
Tightening torque

39 {4.0} o 60 90

Note: After tightening the bolts, check that you can


turn the crankshaft lightly.

2-46

ENGINE ASSEMBLY

TIMING GEAR, TAPPET, AND OIL PUMP


Idle gear shaft
1. Direct the oil hole of the shaft toward the
camshaft.
2. Match the bolt hole of the shaft to the screw hole
of the cylinder body.
3. Using the thrust collar bolt as a guide, drive the
shaft with a plastic hammer, etc.

Timing gear case


Match the gear case to the dowel pin, install it and
gasket together and tighten the bolts alternately and
evenly.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

Idle gear
1. Apply engine oil to the inside of the idle gear.
2. Match mark "A" of the idle gear to that of the
crankshaft gear and install the idle gear to the
idle gear shaft.
3. Install the idle gear with the chamfered side of
the thrust collar out.
(N.m {kgf.m})
Tightening torque

44 64 {4.5 6.5}

Camshaft assembly
1. Apply engine oil to the camshaft journals and
install the camshaft to the cylinder body.
Note: Install the camshaft carefully so that its lift will
not damage the camshaft bearing.

2-47

ENGINE ASSEMBLY
2. When installing the camshaft, match mark "B" of
the idle gear to that of the crankshaft gear.
3. Check that the camshaft is installed perfectly
and tighten the thrust plate.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

Tappet
Coat each tappet with engine oil and install it to the
cylinder body.

Oil pump assembly


Fill the oil pump with engine oil and install it.

Oil pump assembly and coupling


1. Apply "engine oil containing molybdenum
disulfide" to the serrated parts of the coupling
and the tooth surfaces of the oil pump drive
gear.

2. After installing the oil pump, install the oil pipe


and tighten the bolts in the order shown in the
figure.
(N.m {kgf.m})
Tightening
torque

2-48

Oil pump bolt

42 62 {4.3 6.3}

Oil pipe bolt

21 30 {2.1 3.1}

ENGINE ASSEMBLY

REAR OIL SEAL, HOUSING, OIL PAN, AND OIL COOLER


Flywheel housing
Apply gasket sealant and install the flywheel housing,
taking care not to damage the oil seal, and then
tighten the bolts in the numerical order shown in the
figure.
(N.m {kgf.m})
Tightening
torque

Bolt (M8 x 1.25)

21 30 {2.1 3.1}

Bolt (M14 x 1.5) 147 167 {15.0 17.0}

Note: A part of the back side of the flywheel housing


stops oil from oozing through the oil gallery
plug of the cylinder body. Apply gasket sealant
to that part, too.

Rear oil seal (Axial type)


Install the adapter to the rear part of the crankshaft
with the 2 bolts. Insert the oil seal around the adapter
and press fit it with the sleeve and check the installed
dimension.
Standard dimension: 11.6 0.3 mm
Special tool: Rear oil seal setting tool
5-8840-9025-0

Oil pan
Install the oil pan and gasket together to the cylinder
body and tighten the bolts alternately and evenly.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

Note: Wipe off oil and grease from the gasket fitting
surface of the cylinder body, and then install
the gasket to the correct position of the cylinder
body.

Oil cooler
Apply gasket sealant to the packing and stick it to
the body case and tighten the bolts in the numerical
order shown in the figure.
(N.m {kgf.m})
Tightening torque

14 24 {1.4 2.4}

2-49

ENGINE ASSEMBLY
Oil relief valve
Apply engine oil to the threads of the oil relief valve
and tighten it, check that the gasket is not shifted.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

Oil pump pinion gear, collar, and hole cover


1. When installing the pinion gear, apply "engine oil
containing molybdenum disulfide" to the part
indicated with the arrow.
2. Fit the gasket to the hole cover groove securely
and install them to the cylinder body.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

FUEL INJECTION PUMP AND GEAR CASE COVER


Installing the injection pump and gear case cover
Match the "match marks" of the injection pump and
install the gear case cover.
Before installing the injection pump and case cover,
fit the packing to the gear case.
If a little Three bond is applied to the surface of the
packing, the packing will not come off.
Note: Match the "gear match marks" A, B, and C
securely.
(N.m {kgf.m})
Tightening torque

2-50

21 30 {2.1 3.1}

ENGINE ASSEMBLY

RELATIONSHIP BETWEEN FLYWHEEL, CRANK PULLEY, AND CYLINDER HEAD


Flywheel
Install the flywheel, matching it to the dowel pin of
the crankshaft, and insert the bolts through the
washers. Tighten the bolts in the diagonal order.
(N.m {kgf.m})
Tightening torque

196 240 {20.0 24.5}

Apply engine oil.

Crank pulley
(N.m {kgf.m})
Tightening torque

539 637 {55.0 65.0}

1. Match the crankshaft gear key to the key way at


the crank pulley end.
2. Apply "molybdenum disulfide" to the washer
contact surface of the taper bushing and install
it.
Then, apply "molybdenum disulfide" to all the
threads and seat of the nut and tighten it with the
chamfered side ahead.
Cylinder head gasket
Clean the top of the cylinder body. Fit the cylinder
head basket to the cylinder body with the "stamp"
(FRONT TOP) up and on the front side.

Cylinder head
Clean the underside of the cylinder head and place it
slowly on the gasket.
Apply "molybdenum disulfide" to the seat and threads
of the head bolts and tighten them spirally, starting
with the central one, as shown in the figure.
Use the 6 shorter bolts on the nozzle side.
Do not use the head bolts more than 2 times.
Tightening torque of head bolt
(N.m {kgf.m})
Tightening
Loosen
69 {7.0} o
o 88 {9.0} o 90 120
torque
all bolts

2-51

ENGINE ASSEMBLY
Push rod
Insert each push rod and hit it lightly with a plastic
hammer to bring the tappet in contact with the cam
surface of the camshaft.

Rocker arm shaft assembly


Put the adjustment bolts of the rocker arms in the
hollows of the push rods and tighten them evenly,
starting with the central one.
Note: Since the bolt of the front bracket is used as
an oil passage, do not replace it with another
one.
(N.m {kgf.m)
Tightening torque

25 35 {2.6 3.6}

Adjusting the valve clearance

Tappet chamber cover


Apply "gasket sealant" (TB1207B) to the tappet
chamber cover and install it to the tappet chamber of
the cylinder block.
(N.m {kgf.m})
Tightening torque

2-52

21 30 {2.1 3.1}

ENGINE ASSEMBLY

EXTERIOR PARTS

The Nos. in ( ) indicate the assembly order.

2-53

ENGINE ASSEMBLY
Nozzle holder
(N.m {kgf.m})
Tightening torque

17 21 {1.7 2.1}

Glow plug
Connector
(N.m {kgf.m})
Tightening torque (Glow plug)

20 25 {2.0 2.5}

Fuel piping
1. Install the injection pipe and secure it with the
clip.
(N.m {kgf.m})
Tightening torque

29 {3.0}

2. Install the fuel pipe and secure it with the clip.


(N.m {kgf.m})
Tightening torque

20 25 {2.0 2.5}

3. Install the leak-off pipe.


(N.m {kgf.m})
Tightening torque

10 15 {1.0 1.5}

Note: Be sure to use packing for each eyebolt. If


dirt enters the pipes or injection pump, it can
cause a trouble.

2-54

ENGINE ASSEMBLY
Turbocharger
Fit the gasket with the folded side up and install the
turbocharger.
At this time apply seizure prevention compound to
the mounting nuts.
Since heat-resistant nuts are used, do not replace
them with other ones.
(N.m {kgf.m})
Tightening torque

52 {5.3}

Oil pipe: Turbocharger


Fit the O-ring to the oil feed pipe and install the oil
pipe.
(N.m {kgf.m})
Turbocharger Cylinder body
side
side
Tightening
torque

Oil feed pipe

25 {2.6}

21 {2.1}

Return pipe

37 {3.8}

21 {2.1}

Note: Before installing the pipe, supply engine oil


through the oil inlet of the turbocharger.

Water pump
(N.m {kgf.m})
Tightening torque

42 62 {4.3 6.3}

Fan pulley
Fan belt
Fan

2-55

ENGINE ASSEMBLY
Generator
For adjustment of the fan belt tension, see the section
of the fan belt (page 1-25).

Starting motor
(N.m {kgf.m})
Tightening torque

75 91 {7.6 9.3}

Note: Secure the ground cable and starting motor


together.

2-56

LUBRICATING SYSTEM

3 LUBRICATING SYSTEM
Page
Lubricating oil circulation system diagram ...................................................................................................... 3-2
Oil pump .......................................................................................................................................................... 3-3
Disassembly .............................................................................................................................................. 3-3
Inspecting .................................................................................................................................................. 3-4
Assembly ................................................................................................................................................... 3-6
Oil relief valve .................................................................................................................................................. 3-8
Removing and installing the oil relief valve .............................................................................................. 3-8
Inspecting .................................................................................................................................................. 3-8

3-1

LUBRICATING SYSTEM

LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM

3-2

LUBRICATING SYSTEM

OIL PUMP
DISASSEMBLY

Disassembly procedure
1. Oil pump body
2. Drive shaft and gear
3. Driven gear
4. Split pin and spring seat
5. Relief valve spring
6. Relief valve
7. Oil pump cover

3-3

LUBRICATING SYSTEM

INSPECTING
Clearance between gear and inside wall
Using a feeler gauge, measure the clearance between
the gear and cover inside wall.
If the clearance between the gear and cover inside
wall exceeds the limit, replace the gear or cover
assembly.
Clearance between gear and cover inside wall
(mm)
Standard

Limit

0.075 0.150

0.2

Clearance between gear side and cover top


Using a feeler gauge and a square, measure the
clearance between the gear side and cover top.
If the clearance between the gear side and cover top
exceeds the limit, replace the gear or cover assembly.
Clearance between gear side and cover top
(mm)
Standard

Limit

0.040 0.094

0.15

Clearance between drive shaft and pump body


Measure the outside diameter of the drive shaft and
the inside diameter of the pump body, and then
calculate the clearance.
1. Using a micrometer, measure the outside
diameter of the drive shaft.
Outside diameter of drive shaft
(mm)
Nominal size

Limit

16

15.9

2. Using a dial gauge, measure the inside diameter


of the pump body.
If the clearance between the drive shaft and pump
body exceeds the limit, replace the oil pump
assembly.
Clearance between drive shaft and pump body
(mm)

3-4

Standard

Limit

0.032 0.070

0.15

LUBRICATING SYSTEM
Clearance between driven gear shaft and gear
1. Using a micrometer, measure the outside
diameter of the drive gear shaft.
Outside diameter of driven gear shaft
(mm)
Standard

Limit

15.956 15.974

15.9

2. Using caliper calibrator, measure the inside


diameter of the driven gear.
If the clearance between the driven gear shaft
and gear exceeds the limit, replace the gear or
cover assembly.
Clearance between driven gear shaft and gear
(mm)
Standard

Limit

0.045 0.078

0.15

Relief valve and spring


Check the relief valve and spring visually. If they are
damaged, replace them.

3-5

LUBRICATING SYSTEM

ASSEMBLY

Assembly procedure
1. Oil pump cover
2. Relief valve
3. Relief valve spring
4. Split in and spring seat
5. Driven gear
6. Drive shaft and gear
7. Oil pump body

3-6

LUBRICATING SYSTEM
Driven gear
Drive shaft and gear
1. Apply engine oil to the driven gear and shaft.
2. Apply engine oil to the drive shaft and gear and
install them to the pump body.
3. Install the pump cover to the pump body and
secure them with the bolts.
(N.m {kgf.m})
Tightening torque

10 16 {1.0 1.6}

3-7

LUBRICATING SYSTEM

OIL RELIEF VALVE


REMOVING AND INSTALLING THE OIL RELIEF VALVE
Removal procedure
1. Remove the injection pump.
2. Remove the oil relief valve.
Installation procedure
1. Install the oil relief valve.
2. Install the injection pump.
(N.m {kgf.m})
Tightening torque

21 30 {2.1 3.1}

INSPECTING
Relief valve and spring
Press the relief valve with a screwdriver, etc. to check
for fixing. If it is fixed, replace it.
Breathe into the relief valve to check for air leakage.
If air leaks through the relief valve, replace the relief
valve.

3-8

COOLING SYSTEM

4 COOLING SYSTEM
Page
Cooling water circulating system ..................................................................................................................... 4-2
Water pump ..................................................................................................................................................... 4-3
Component parts ....................................................................................................................................... 4-3
Disassembly .............................................................................................................................................. 4-4
Assembly ................................................................................................................................................... 4-6
Inspecting .................................................................................................................................................. 4-8
Thermostat ....................................................................................................................................................... 4-9
Inspecting and replacing ........................................................................................................................... 4-9

4-1

COOLING SYSTEM

COOLING WATER CIRCULATING SYSTEM

4-2

COOLING SYSTEM

WATER PUMP
COMPONENT PARTS

1.
2.
3.
4.
5.
6.
7.
8.
9.

Cover
Packing
Screw
Seal unit
Impeller
Shaft
Ball bearing: Rear
Ball bearing: Front
Snap ring (Clip)

10.
11.
12.
13.
14.
15.
16.

Snap ring
Fan center
Spacer
Dust cover
Spacer (Washer)
Seal: Secondary (Oil seal)
Pump body

4-3

COOLING SYSTEM

DISASSEMBLY
Rear cover
Remove the rear cover and packing.

Fan center
Remove the fan center.

Snap ring
Remove the dust cover and the snap ring on the fan
center side.

Impeller
Using the special tool (remover), pull out the impeller.
Special tool: Water pump impeller remover
9-8521-0097-0
Note: Never pull out the impeller by giving impacts
with a hammer, etc.

4-4

COOLING SYSTEM
Shaft and bearing
Using a press, push out the shaft and bearing
together from the impeller side.

Bearing and spacer


Using a press, remove the bearing and spacer
(including the washer) from the shaft.

Oil seal and seal unit


Remove the oil seal from the impeller side and
remove the seal unit from the center side.

4-5

COOLING SYSTEM

ASSEMBLY
Note: Since the fan center and impeller are press fitted to the shaft, they are loosened if they are
removed and installed repeatedly.
Accordingly, if they have been removed 2 times or their press fitting load is less than 5.9 kN
{600 kgf}, replace the water pump assembly.
Oil seal
Apply bearing grease (NIHON KOYU, HILEX NO. 3
GREASE) to the lip of the oil seal. Then, using a
press, install the oil seal to the pump body.
Note: Do not reuse the oil seal. Install the new oil
seal by using the jig.

Rear bearing
Install the washer to the shaft, and then press fit the
rear bearing to the shaft with the seal side toward
the impeller.
Note: Hold the inner race or both inner race and
outer race of the bearing.

Shaft
Press fit the shaft to the pump body.
At this time, press the outer race of the bearing with
the special tool (setting tool).
Special tool: Water pump bearing setting tool
9-8522-1140-0
Press fit the shaft until the bearing reaches the pump
body. Before press fitting, fill the space between the
inner race and outer race of the bearing with bearing
grease (NIHON KOYU, HILEX NO. 3 GREASE).
Note: The bearing may be reused only when it has
little play and rotates smoothly.

4-6

COOLING SYSTEM
Spacer
Install the spacer to the shaft and supply sufficient
bearing grease to the spaces between the bearing
and body and shaft.
(g)
Quantity of grease

Approx. 28

Front bearing
Press fit the front bearing.
Direct the seal side toward the center. Hold both of
the shaft and pump body so that the shaft will not go
through down and the bearing will not be broken and
press fit the bearing until it reaches the spacer.
Use the jig to push the inner race and outer race
simultaneously.
Dust cover
Install the slip ring and dust cover.

Fan center
Press fit the fan center. Hold only the shaft so that it
will not go through and the bearing will not be broken
and press fit the fan center until it reaches the dust
cover.

Seal unit
Install the seal unit to the pump body.
Note: Fix the pump body and press fit the seal unit
with the jig. Do not reuse the seal unit.

4-7

COOLING SYSTEM
Floating seat (Seal unit)
Press fit the floating seal side of the seal unit to the
impeller.
Note: Limit leaning of the floating seal to 0.1 mm.

Impeller
While press fitting the impeller, adjust the clearance
between it and the pump body to the standard range.
At this time, put a liner to the shaft on the fan center
side so that the snap ring will not be broken.
Clearance between impeller and body
(mm)
Standard

0.3 1.0

Cover
Install the packing and cover with the screws.

INSPECTING
Turn the pump with the hand and check that it rotates
smoothly.

4-8

COOLING SYSTEM

THERMOSTAT
INSPECTING AND REPLACING

Inspecting the outside


Check the outside of the thermostat for wear,
damage, deformation, etc. If there is any abnormality,
replace the thermostat.
Inspecting the function
Opening temperature

82 2 C

Valve lift

Min. 10 mm (At 95C)

If there is any abnormality, replace the thermostat.

4-9

FUEL SYSTEM

5 FUEL SYSTEM
Page
Fuel circulation system diagram ...................................................................................................................... 5-2
Nozzle holder assembly ................................................................................................................................... 5-3
Nozzle assembly .............................................................................................................................................. 5-3

5-1

FUEL SYSTEM

FUEL CIRCULATION SYSTEM DIAGRAM

5-2

FUEL SYSTEM

NOZZLE HOLDER ASSEMBLY

NOZZLE ASSEMBLY
Inspection and replacement
Put the removed nozzle into clean light oil and
separate the needle valve from the nozzle body to
clean them. Check to see if the valve moves lightly
through the needle body. If the valve does not move
smoothly, remedy or replace the defective part.

Adjustment
Refer to INSPECTION AND MAINTENANCE for
the injection pressure adjustments and spray
conditions.
(Page 1 - 25)

5-3

AIR COMPRESSOR

6 AIR COMPRESSOR
Page
Outline .............................................................................................................................................................. 6-2
Sectional view ............................................................................................................................................ 6-2
Disassembly ..................................................................................................................................................... 6-3
Inspecting and repairing .................................................................................................................................. 6-4
Assembly .......................................................................................................................................................... 6-6

6-1

AIR COMPRESSOR

OUTLINE
SECTIONAL VIEW

Main specifications
Piston ring
Delivery
Bore x Stroke
Max. speed
Revolution ratio (to crankshaft)
Weight

6-2

mm
rpm
kg

3-piece unit
0.155 L/rev {155 cc/rev.}
70 X 40
1,650
0.5
7.0

AIR COMPRESSOR

DISASSEMBLY

Disassembly procedure
1. Cylinder head and gasket
e2. Cylinder body
3. Piston
4. Bearing cover

5. Bearing
6. Connecting rod
7. Crankshaft

Important work
2. Cylinder body
1) Remove the cylinder mounting bolts.
2) Lightly hitting the cylinder, remove it from the
crankcase.

6-3

AIR COMPRESSOR

INSPECTING AND REPAIRING


If a damaged or abnormal part is found during inspection, repair or replace it.
Cylinder
Using a cylinder gauge, measure uneven wear of the
inside of the cylinder at the piston skirt.
Uneven wear of inside of cylinder
(mm)
Standard

Limit

0 0.03

0.2

Cylinder and piston


1. Measure the inside diameter of the cylinder and
the outside diameter of the piston and calculate
the clearance.
Clearance between cylinder and piston
(mm)
Standard

Limit

0.10 0.30

1.0

Note: Measure the outside diameter of the piston at


the skirt at a right angle to the piston pin.

2. Measure the clearance between the oil ring


groove and oil ring and the closed gap of the
piston.
Clearance between ring groove and ring
(mm)
Standard

Limit

0.025 0.050

0.15

Closed gap of piston ring

6-4

(mm)

Standard

Limit

0.10 0.30

1.0

AIR COMPRESSOR
Piston pin and connecting rod
1. Measure the clearance between the piston pin
and piston pin hole.
Clearance between piston pin and piston pin hole
(mm)
Standard

Limit

0.002 0.023

0.04

2. Measure the clearance between the piston pin


and the small end of the connecting rod.
Clearance between piston pin and small end of
connecting rod
(mm)
Standard

Limit

0.002 0.026

0.1

Crankpin and connecting rod


Measure the clearance between the crankpin and
the large end of the connecting rod.
Clearance between crankpin and large end
connecting rod
(mm)
Standard

Limit

0.02 0.06

0.15

6-5

AIR COMPRESSOR

ASSEMBLY

Disassembly procedure
e1. Crankshaft and bearing
e2. Connecting rod
3. Bearing
e4. Bearing cover

6-6

5. Piston
e6. Cylinder body
e7. Cylinder head and gasket

AIR COMPRESSOR
Important work
1. Crankshaft, bearing, and spacer
Using a copper hammer, install the bearing and
spacer to the crankshaft.

2. Connecting rod
(1) Apply engine oil to the bearing.
(2) Install the connecting rod and bearing cap.
(3) Tighten the connecting rod bearing cap bolts
to the specified torque.
Bearing cap bolt
(N.m {kgf.m})
Tightening torque

23 26 {2.3 2.7}

4. Bearing cover
Install the bearing cover to the crankcase and
tighten the mounting bolts to the specified torque.
Bearing cover mounting bolt
(N.m {kgf.m})
Tightening torque

5.9 {0.6}

5. Piston pin snap ring


Using the snap ring priers, install the snap ring.

6-7

AIR COMPRESSOR
5. Piston rings
(1) Using the piston ring replacer, install the
piston rings.
(2) Direct the abutment joints of the piston rings
as shown in the figure.
Front mark
No. 1 compression ring
No. 2 compression ring
Oil ring with expander (Upper)
Oil ring with expander (Upper)
Oil ring (Upper) rail
(3) Apply engine oil to the surfaces.

7. Cylinder body
(1) Apply engine oil to the O-ring and install it to
the cylinder body.
Take care not to twist the O-ring.
(2) Install the cylinder body to the crankcase
and tighten the mounting bolts to the specified
torque.
Cylinder body bolt
(N.m {kgf.m})
Tightening torque

27 31 {2.8 3.2}

8. Cylinder head
(1) Install cylinder head
and tighten the
mounting bolts to the specified torque.
(2) Tighten unloader valve
to the specified
torque.
Tightening torque of mounting bolt and valve
(N.m {kgf.m})

6-8

Cylinder head bolt

27 31 {2.8 3.2}

Unloader valve

44 54 {4.5 5.5}

FLYWHEEL P.T.O.

7 FLYWHEEL, P.T.O.
Page
Component parts ............................................................................................................................................. 7-2
Disassembly ..................................................................................................................................................... 7-3
Inspection and measurement .......................................................................................................................... 7-6
Assembly .......................................................................................................................................................... 7-9

7-1

FLYWHEEL P.T.O.

COMPONENT PARTS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

7-2

Bearing case
Packing
Oil seal
P.T.O. gear
P.T.O. shaft
Bearing
Nut
Lock washer
P.T.O. flange
Packing
Oil thrower
Washer
Nut
Split pin
Spacer
Shim
Idle gear
Bearing
Outer spacer
Inner spacer

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

Cover
Packing
Spindle
Bolt
Nut
Lock washer
Bolt
Spring washer
Plain washer
Bolt
Spring washer
Plain washer
Clip; Oil pipe
Bolt
Nut
Spring washer
Spacer

FLYWHEEL P.T.O.

DISASSEMBLY
The following disassembly and assembly drawings show Model DH100 engine. The shapes of some parts of
other models are different from those in these drawings.
Removing the P.T.O. gear assembly
1. Remove the P.T.O. gear assembly from the
flywheel housing.
Remove the oil pipe for lubrication of the P.T.O.
gear in advance.

2. Removing the flywheel


Remove the flywheel.

3. Removing the idle gear


1) Remove the idle gear cover.

2) Raise the lock washer claw and remove the


fixing nut of the idle gear.
(Width across flats: 65 mm)

7-3

FLYWHEEL P.T.O.
Disassembling the P.T.O. gear assembly
1. Removing the flange mounting nut
Grip the P.T.O. fixing nut in a vise and remove
the split pin and flange mounting nut. Then,
remove the flange, bearing (outer), bearing case,
etc.

2. Removing the P.T.O. gear fixing nut


Raise the lock washer claw and loosen the nut.

3. Removing the bearing (inner)


Using a press, pull out the bearing.

Disassembly of idle gear


The spindle, bearing, idle gear, etc. are removed by
removing the idle gear in the above step.

3) Remove the spindle fixing bolt.

7-4

FLYWHEEL P.T.O.
4) Insert a proper rod in the 17 hole from
which the bolt was removed and move it up,
down, to the right, and to the left to remove
the spindle.
At this time, the tapered roller bearing (outer)
is removed, too.

5) Put your hand in the hole from which the


P.T.O. gear was removed and take out the
idle gear and tapered roller bearing (inner).

4. Removing the crankshaft gear


1) Remove the oil seal retainer and oil thrower
from the crankshaft.

2) Insert a proper rod in the hole of the


crankshaft gear and move it up, down, to the
right, and to the left to remove the gear.

7-5

FLYWHEEL P.T.O.

INSPECTION AND MEASUREMENT


Measuring the backlash of each gear
Insert and flatten fuses between the crankshaft gear
and idle gear and between the idle gear and P.T.O.
gear, and then measure their thickness, or measure
the backlash between the gears with a dial gauge.
If the backlash of each gear is exceeds the limit or
the tooth surface of that gear is damaged extremely,
replace that gear.
(mm)
Inspection item

Assembly standard

Limit

Backlash of each gear

0.10

0.2

Inspecting and replacing the bearing


1. Inspecting
Visually inspect the bearings of the idle gear and
P.T.O. gear. If there are pitting marks or bruises
on their rollers or inside of their outer races,
replace them.
2. Replacement procedure
Use a press to remove and install the inner race
of each bearing. The outer race can be removed
and installed by hitting it lightly with a brass rod,
however. For selection of the bearing shim
inserted when the bearing is installed, see
"SELECTING THE P.T.O. GEAR BEARING
SHIM".
Selecting the idle gear bearing spacer
1. Place the idler gear and bearing assembly,
excluding the spacer, on a surface plate and
measure (t1) of the bearing inner race top with a
dial gauge.

2. Select and install a proper spacer and measure


(t2) of the bearing inner race top similarly to step 1.

7-6

FLYWHEEL P.T.O.
3. Select one from 23 spacers prepared at intervals
of 0.07 mm so that t1 - t2 will be 0 - 0.07 mm.
Bearing spacer
(mm)
Part No.
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9

38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226

022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
041
042
043
044

Thickness

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

9.28
9.21
9.14
9.07
9.00
8.93
8.86
8.79
8.72
8.65
8.58
8.51
8.44
8.37
8.30
8.23
8.16
8.09
8.02
7.95
7.88
7.81
7.74

Note: After the above adjustment, tighten the fixing


nut of the idle gear to about 147 N.m {15
kgf.m} and check that you can turn the gear
lightly with the hand.

7-7

FLYWHEEL P.T.O.
Selecting P.T.O. gear bearing shim
Similarly to "Selecting the idle gear bearing spacer"
explained above, select the P.T.O. gear bearing shim.
Select 3 shims, however, so that t2 - t2 will be 0.01
- 0.07 mm.
Bearing shims

(mm)
Part No.

9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9

7-8

41229
41229
41229
41229
41229
41229
41229
41229
41229
41229
41229
38226
38226
38226
38226
38226
38226
38226

324
325
326
327
328
329
330
331
332
333
334
045
046
047
048
049
050
051

Thickness

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

3.50
3.51
3.52
3.53
3.54
3.55
3.56
3.57
3.58
3.59
3.60
17.95
18.20
18.45
18.70
18.95
19.20
19.45

FLYWHEEL P.T.O.

ASSEMBLY
Assembling the P.T.O. gear
1. Install the P.T.O. gear and lock washer to the
P.T.O. shaft and tighten the nut.
(N.m {kgf.m})
Tightening torque

294 {30.0}

Install the gear with the more projected boss on


the nut side. Do not lock at this time but lock
after installing all the parts.
Note: When tightening the nut, fit the flange to the
spline for convenience.

2. Press fit the bearing to the shaft with a press.


Apply engine oil to the inner and outer races of
the bearing.
Special tool: P.T.O. bearing setting tool
9-8524-1702-0

3. Install the bearing spacers and shims selected in


the previous section to the shaft, and then install
the O-ring and bearing case, bearing, and oil
thrower.
Next, apply engine oil between the lips of the oil
seal and apply "SHINETSU KAGAKU, (KE42)
SILICONE RUBBER" to the bearing case, and
then press fit the oil seal.

4. Install the flange and washer to the shaft with


the specified tightening torque, and then check
that you can turn the bearing cage lightly with
the hand.
(N.m {kgf.m})
Tightening torque

294 392 {30.0 40.0}

7-9

FLYWHEEL P.T.O.
Installing the flywheel to the P.T.O.
1. Assembling the crankshaft gear
1) Match the dowel pin at the rear end of the
crankshaft to the dowel pin hole of the
crankshaft gear and drive the crankshaft gear
with a copper hammer.

2) Install the oil seal to the crankshaft gear.

2. Assembling the idle gear


1) Install the bearing outer race to the idle gear.
Insert the idle gear and inner bearing together
in the P.T.O. gear mounting hole and install
the bearing and spindle assembly through
the idle gear mounting hole (shown in the
figure at right), and then tighten the spindle
fixing bolt.
(N.m {kgf.m})
Tightening torque

157 177 {16.0 18.0}

2) Tighten the nut to about 147 N.m {15 kgf.m}


and bend the claw of the lock washer.
3) Fit the O-ring to the idle gear cover and
install them to the flywheel housing.

7-10

FLYWHEEL P.T.O.
3. Installing the P.T.O. gear
Install the P.T.O. gear assembly assembled in
the previous section to the flywheel.
4. Installing the flywheel
Apply engine oil to the flywheel and install it.
(N.m {kgf.m})
Tightening torque

196 240 {20.0 24.5}

7-11

TROUBLESHOOTING

8 TROUBLESHOOTING
Page
Engine fails to start ........................................................................................................................................ 8- 2
Engine fails to run smoothly .......................................................................................................................... 8- 3
Engine lacks power ....................................................................................................................................... 8- 4
Engine knocks ............................................................................................................................................... 8- 6
Smoky exhaust .............................................................................................................................................. 8- 7
Excessive oil consumption ............................................................................................................................ 8- 8
Excessive fuel consumption .......................................................................................................................... 8- 9
Low oil pressure ............................................................................................................................................ 8-10
Run-down battery ........................................................................................................................................... 8-11
Engine does not start .................................................................................................................................... 8-12

8-1

TROUBLESHOOTING

ENGINE FAILS TO START

8-2

TROUBLESHOOTING

ENGINE FAILS TO RUN SMOOTHLY

8-3

TROUBLESHOOTING

ENGINE LACKS POWER

8-4

TROUBLESHOOTING

8-5

TROUBLESHOOTING

ENGINE KNOCKS

8-6

TROUBLESHOOTING

SMOKY EXHAUST

8-7

TROUBLESHOOTING

EXCESSIVE OIL CONSUMPTION

8-8

TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

8-9

TROUBLESHOOTING

LOW OIL PRESSURE

8-10

TROUBLESHOOTING

RUN-DOWN BATTERY

8-11

TROUBLESHOOTING

ENGINE DOES NOT START

Engine does not start

Crankshaft does not revolve

Crankshaft revolves

Check if starting motor


revolves
Revolving speed is low

Revolving speed is normal

Check battery charge level


and check battery terminals
for disconnection and
corrosion

Check engine unit

OK
Check battery charge level
and check battery terminals
for disconnection and
corrosion

Check meshing condition of


pinion and ring gear

OK
Same as *1
Charge or replace battery
Repair battery terminals

OK

Check operating sound of


electromagnetic switch

Check key switch


Check connecting condition
Check and repair wiring to
electromagnetic switch of
starting motor
Repair or replace
electromagnetic switch

Check roller clutch of pinion,


and replace if necessary

Engine oil viscosity is


abnormal.

Check meshing spring for


fatigue and sliding
condition of pinion.
If pinion ring gear end is
worn, replace it.
Repair pinion cap.

Viscosity is improper
(Replace engine oil)

OK

Replace starting motor

OK

Check revolution of starting


motor unit
(Connect to terminal M)
Check inside of engine

OK

Replace starting motor


(brush holder or armature)

8-12

OK

There is defective contact in


electromagnetic switch of
starting motor (Replace
electromagnetic switch)

OK

Starting motor is defective


(Repair starting motor)

SPECIAL TOOLS

9 SPECIAL TOOLS
Page
Special tool list ................................................................................................................................................. 9-2

9-1

SPECIAL TOOLS

SPECIAL TOOL LIST


No.

Outside view

Part No.

Part name

Page

9 8511 3703 0

Injection pump wrench

1-24

5 85317 001 0

Compression gauge adapter

1-24

Valve spring replacer

2-12

1 85235 006 0
Removing and installing split collar

2-38

Tapered bushing puller


4

9 8521 0122 0

2-13
Removing tapered bushing of crank pulley
Camshaft bearing puller and installer

Removing and installing camshaft bearing

2-17
2-28
2-44

Piston ring replacer

2-18

Removing and installing piston ring

2-41

Crankshaft gear puller

2-19

Removing crankshaft gear

2-36

9 8523 1818 0

1 8522 1025 0

9 8521 0141 0

9 8523 1169 0

Cylinder liner remover

5 8523 1004 0

Angle

Removing
cylinder
liner

2-22

Cylinder liner setting tool


9

5 8522 1018 0

2-22
Installing cylinder liner
Valve guide replacer

11

1 85220 001 0

2-23
Removing and installing valve guide

9-2

SPECIAL TOOLS

No.

Outside view

Part No.

Part name

Page

Front oil seal setting tool


11

9 8522 0034 0

2-26
Installing oil seal to timing gear case cover
Valve seal setting tool

12

1 85221 005 0

2-37
Installing valve seal
Crankshaft gear setting tool

13

9 8522 0033 0

2-43
Installing camshaft bearing
Piston setting tool

14

9 8522 1173 0

2-46
Installing piston to cylinder liner

15

5 8840 2360 0

Rear oil seal remover

2-17

16

5 8840 9025 0

Rear oil seal setting tool

2-49

9-3

REPAIR SERVICE STANDARD

10 REPAIR SERVICE STANDARD


Page
General .......................................................................................................................................................... 10-2
Repair service standard ................................................................................................................................. 10-4

10-1

REPAIR SERVICE STANDARD

GENERAL
1. This standard table is applicable to KOMATSU FORKLIFT diesel engine model 6BG1 and 6BG1T.
2. Repair Service Standard includes the Checking Item, Nominal Size, Assembly Standard, Limit, and Repair
Method.
1) Nominal Size specifies the values to be referred to in manufacturing of new engines.
2) Assembly Standard specifies the target values that apply to reconditioned engines and may somewhat
differ from those values of newly assembled engines.
3) Limit specifies the values beyond which any worn parts should not be used continually, but repaired or
replaced.
4) Repair Method gives the points of repair work.
5) Unless otherwise specified, all dimensions are in mm.
3. Definition
1) Wear means a difference between the size of non-worn part (or nominal size if no part remains
without wear) and the size of most worn down part.
2) Uneven wear means a difference between a maximum wear and a minimum wear.
4. When reconditioning an engine as a whole is entrusted to you, first check the engine by bench test or
another suitable means to asscertain which part needs repairing, and proceed to an overhaul of the
restricted, minimum necessary portion of the engine. When reconditioning a part of the engine is requested,
carry out repair work of that part according to this repair service standard.

10-2

Part name

Cylinder block

Engine

10-4

Proper time
for
engine overhaul

Group

Hydraulic test (3 min)

Flatness of cylinder block top


surface

Projection of liner from cylinder

0.05 or less

490 {5}

KPa
{kgf/cm2}

0.2

105.2

200 %

100 %

105

140 %

2.5 {26}

Limit

100 %

0.03 0.10

3.0 {31}

Nominal size Assembly standard

mm

mm

mm

L/h

Oil consumption,

Wear of liner inside


wall at position A A

L/h

MPa
{kg/cm2}

Cylinder compression pressure,

Fuel consumption,

Unit

Checking item

REPAIR SERVICE STANDARD

It water leak is found, repair or


replace.

Use surface grinder for


correction.

Adequate projection is
indispensable

If uneven step-wear is found in


upper portion, repair or replace
with normal size of liner.

Overhaul the engine.

Repair method

Maximum allowable grinding


depth 0.3.

Difference in projection
between adjacent liners shall
not exceed 0.03. (0.0012)

0.001 0.019

(Reference)
Interface of liner to cylinder:

When measurement on new


engine is assumed 100 %

Water temperature: 70 85C


Speed: Approx. 200 240 rpm
(Varies with altitude)

Remarks

REPAIR SERVICE STANDARD

Engine

Main moving parts

Part name

Cylinder head

Piston

Group

Clean bolt seat and threads


and apply molybdenum
disulfide.
After tightening by angular
method, never retighten.
Do not use bolt more than 2
times.

69 (7.0)
O
(Loosen all)
O
88 (9.0)
O
90 120

Wear of pin

Clearance between piston pin


and pin hole

Piston and cylinder clearance


measured at the position 82
mm below top surface

mm

mm

mm

Nm
Cylinder head bolt tightening
torque,
(angular method) {kgfm}

35

If water leak is found, repair or


replace.

490 {5}

KPa
{kgf/cm2}

Hydraulic test (3 min),

0.05 or less

0.005 0.018

Clearance at major
axis 0.047 0.085

34.95

0.05

0.4

Replace piston.

It undue knock is mode,


replace piston or piston pin.

Correct.

Correct with ginder.

mm

0.2

Flatness of manifold fitting surface

0.05 or less

mm

Warpage (flatness) of underside


(mounting face) of cylinder head

Part Nos. of pistons have been


set by grades since August
1997. For details, see page
56.

Tighten to 69 Nm {7.0 kgfm},


then loosen. Next, tighten to
88 Nm {9.0 kgfm}.
Next tighten by 90 120.

Maximum allowable grinding


depth: 0.3
Never allow piston to strike
valves.

After correction, lap contact


surface satisfactorily.

Correct with valve seat cutter.

2.0

1.5

mm

Valve seat angle: 45

Remarks

Replace valve seat insert.

Repair method

Width of contact to valve seat

Limit

2.5

Nominal size Assembly standard

1.0

Unit

mm

Checking item

REPAIR SERVICE STANDARD

10-5

Part name

Piston rings

Group

10-6

N {kgf}

mm
0.05 0.09

0.03 0.07

Oil ring

0.07 0.11

2nd pressure
ring

3rd pressure
ring

0.15

0.15

0.15

31 {3.2}

36.3 55.9
{3.7 5.7}

1st pressure
ring

Oil ring

4.9 {0.5}

14.1 21.2
{1.44 2.16}

14.1 21.2
{1.44 2.16}

2nd pressure
ring

3rd pressure
ring

4.9 {0.5}

20.4 30.6
{2.08 3.12}

1st pressure
ring

N
{kgf}

9.8 {1.0}

0.30 0.50

Oil ring

1.5
0.60 0.75

mm

Limit

3rd pressure
ring

Direction of abutment joint

Clearance between
piston ring groove
and ring

Tension

Closed gap of piston


ring

0.60 0.75

No. 2
compression

Nominal size Assembly standard


0.35 0.50

Unit

No. 1
compression

Checking item

Remarks

Set rings at intervals of 120.

Replace ring or piston.

Replace.

Replace.

Install rings to piston with ring


marks up. If they are installed
in reverse, oil consumption is
increased. There is no
difference between both sides
of oil ring, however.

Measure with expander


installed (including tension of
coil expander of about 5.9 N
{0.6 kgf}).

When measuring, compress


ring to standard closed gap.

Standard inside diameter of


Replace. In the case of
engine overhaul, replace all gauge: 105
piston rings.

Repair method

REPAIR SERVICE STANDARD

Main moving parts

Part name

Connecting rod

Group

192

Repair method

39 o 60 90
{4.0}

mm

Nm
{kgfm}

Rod bore allgnment between big end


and small end (for mm in distance)

Difference in weight between pistonand-rod assemblies,

Bearing cap bolt tightening torque


(angular method,)

20 or less

mm

Connecting rod twist between big end


and small end (for 100 mm in distance)

0.05 or less

0.05 or less

mm

Distance between large-end center and


small-end center

0.17 0.30

mm

Play in axial direction between


connecting rod and crank pin

Connecting rod brg under sizes

0.2

0.2

0.35

0.05

Coat bolts with molibuden


disulphide grease.

Repair or replace.

Repair or replace.

Repair or replace.

Clearance between piston pin


and pin hole

Replace bushing or pin.

0.012 0.025

Clearance between small-end bushin


and piston pin
mm

Replace if poorly contacted


or scratched.

0.030 0.073

Contact of connecting rod brg to crank


pin

mm
Replace bearing.

0.1

Limit

Clearance between connecting rod brg


and crank pin

1.5

Nominal size Assembly standard

Use bearing having projection


and elasticity. Take care of
fitness of back side.

mm

Unit

Elasticity of connecting rod bearing

Forward-backward play of small end


against piston boss (on one side)

Checking item

For reference purpose

Do not polish crankshaft,


regardless of installation of
turbocharger (Undersize
crankshaft is not prepared).

Clearance must be adequate


enough to allow big end to
be swung lightly.

Take care of accuracy of


crankpin.

4.9kN {500kgf}
Projection: 0.043 0.068

For reference purpose

Remarks

REPAIR SERVICE STANDARD

10-7

Main moving parts

Part name

Crankshaft

Group

10-8
mm

Journal and pin finish accuracy


(Both taper and cylindroid)

mm

Crankshaft runout

Nm
{kgfm}

Journal brg cap bolt tightening


tourque,

Wear of crankshaft rear oil seal

g-cm

Crankshaft balance

Ring gear

mm

Crankshaft play in axial direction

Journal bearing undersizes

Clearance between journal and


bearing
mm

64

mm

Wear of pins

Journal bearings

80

mm

Wear of journals

80
64

mm

Uneven wear of journals and pins

0.4

0.05 or less

226 245
{23.0 25.0}

36 or less

0.4

0.11

0.05

Limit

0.15 0.33

No.4
0.039 0.098
Other than # 4
0.025 0.084

Both taper and


cylindroid 0.007

63.924 63.944

79.919 79.939
* No.4 journal
79.905 79.925

Nominal size Assembly standard

Unit

Checking item

(Reference value)
At both ends.

Measure on No.4 brg thrust


surface.

If turbocharger is installed, do
not polish.

Remarks

Replace if oil leaks.

Prevent oil seal from getting


out of place. (Oil satisfactorily).

Brg cap joint surfaces shall be


Apply engine oil to bolts before
free from scratches and foreign
tightening.
particles.

Check for dynamic balance.

Chamfer to remove burrs if any.


Replace if chipped excessively.

Replace.

Replace thrust bearing.

Do not undersize bearing.

Replace bearing.

Bearings must fit tightly into


bearing cap and cylinder block.

Replace.

Repair method

REPAIR SERVICE STANDARD

Main moving parts

Main moving parts

Valve-train mechanism

Part name

Camshaft

Timing gear

Group

mm
mm

Clearance between journal and bearing

Wear of journal

mm

mm

mm
mm

Interference of crankshaft gear to


crankshaft

Interference of camshaft gear to


camshaft

Clearance between idle gear


bushing and shaft

Uneven wear of idlegear shaft


mm

mm

Timing gear backlash

Idle gear play in axial direction

mm

Camshaft play in axial direction

Oil pump drive gear

mm

mm

Uneven wear of journal

Cam lobe height


AB

Unit

Checking item

45

56

0.128 0.185

0.025 0.085

0.021 or less

0.021 or less

0.10 0.17

0.050 0.114

0.2

44.9

0.2

0.3

0.2

7.21

55.6

55.94 55.97

7.71

0.15

0.05

Limit

0.03 0.09

Nominal size Assembly standard

Replace thrust collar.

Replace gear shaft.

Replace bushing or shaft.

Replace gear.

Replace thrust plate.

If damaged excessively,
replace camshaft.

Replace camshaft.

Replace camshaft.

Replace bearing.

Repair or replace camshaft.

Repair method

Clearance not exceeding 0.021


is also allowed.

Clearance not exceeding 0.016


is also allowed.

Correct slightly uneven stepwear on cam.

Remarks

REPAIR SERVICE STANDARD

10-9

10-10

Part name
mm
mm
mm
mm
mm

mm

mm

mm

Wear of intake valve stem

Wear of exhaust valve stem

Clearance between intake valve stem


and valve guide

Clearance between exhaust valve stem


and valve guide

Interference of valve guide to cylinder


head

Valve margin

Height of valve guide


above cylinder head

Valve stem oil seal lip

Squareness

Free height
Blue

Pink

mm

mm

Tension
N {kgf}
(When installed and compressed)

Unit

Checking item

Valve spring

Valves

Group

8.5

14.1

1.5

1.9 or less

2.7

58.0

53.0
55.0
60.6

127 {13.0}

8.8

1.0

0.25

0.20

8.88

8.88

Limit

142 {14.5}

0.024

0.064 0.096

0.039 0.068

Nominal size Assembly standard

Replace valve spring.

Replace oil seal.

Replace valve.

Replace valve or valve


guide.

Replace valve.

Repair method

Take care not to scratch lip.

Reference value

Coat valve guide with oil.

Replace valve when valve seat


has been worn down.

Remarks

REPAIR SERVICE STANDARD

Valve-train mechanism

Valve-train mechanism

Intake system

Part name

Valve

Tappet

Air creaner

Group

Air cleaner element

Tappet-to-cam contact surface

mm

Tappet-to-cam contact surface

28

mm

Clearance between tappet and


cylinder block
0.020 0.054

mm

27.92

0.1

0.3

(Reference)
Length of push rod: 301 mm

Remarks

This part is prepared by


manufacturer.

If worn or deformed excessively, Remove slight scratches with


replace.
oil stone.

Replace tappet.

Replace tappet.

Replace.

Replace.

Bend of push rod

18.85

mm

Wear or rocker arm shaft

19

Replace bushing or shaft.

0.2

Adjust.

Repair method

mm
0.01 0.05

Limit

Clearance between rocker arm


shaft and bushing

0.4

Nominal size Assembly standard

At arm tip and stem end.

mm

Unit

Contact of valve stem to rocker arm

Valve clearance; IN and Ex. (cold)

Checking item

REPAIR SERVICE STANDARD

10-11

Lubricating system

Oil
pressure

Part name

mm

mm

mm

Clearance between drive shaft and


pump body

Clearance between drive shaft and


bushing

Diameter of drive shaft and bushing

Oil-cooler relief valve cracking pressure,


KPa
kPa{kg/cm2} {kgf/cm2}

Oil pump

KPa
{kgf/cm2}

mm

Axial-direction clearance between pump


cover and gear

Oil gallery

L/min

Delivery flow,
(1650 rpm, SAE #30, delivery pressure
392 KPa {4 kg/cm2}, oil temp 50C)

Relief valve cracking


pressure,

mm

KPa
{kgf/cm2}

Unit

Clearance between pump cover wall and


gear tooth tip

Lubricating oil pressure

Checking item

Oil filter element clogging and damage

Oil pump and relief valve

Oil filter

10-12

Oil cooler

Group

16

196 {2.0}

785 {8}

441 {4.5}

0.045 0.078

0.032 0.070

0.040 0.094

53.3

0.075 0.150

Nominal size Assembly standard

15.9

0.15

0.15

0.15

0.2

Limit

Replace.

Replace shaft.

Replace bushing.

Replace gear or cover.

Replace bushing, gear or


body.

Repair method

Replacement interval of
cartridge: 500 hours

Reference value

Remarks

REPAIR SERVICE STANDARD

Part name

Water pump

Group

mm

mm

Thermostat full-open temp.


(Under atmospheric pressure)

Interference of fan center to bearing


shaft

Interference of bearing shaft to impeller

mm

Thermostat cracking temp.


(Under atmospheric pressure)

Clearance between pulley and fan


center

mm

mm

L/min

mm

Unit

Deflection of
fan belt

Clearance between pump impeller and


pump body

Delivery flow,
(3720 rpm, normal water temp, total lift
13.5 mm)

Play of water pump ball brg.


(Radial direction)

Checking item
#6204 V

0.14 or less

Replace pump ASM.

Replace pump ASM.


0.020 0.060

A temperature at which
thermostat lift is 10 mm or
more.

Adjust.

If impeller contacts pump


body, repair or replace.

Replace pump ASM.

Repair method

Replace pump ASM.

0.2

Limit

0.07 0.11

95

82 2

Approx. 7 10

0.3 1.0

300

0.008 0.01

Nominal size Assembly standard

If malfunctioning, replace
thermostat.

(Reference)
10 kg/belt (22 lb) [98 N]

Remarks

REPAIR SERVICE STANDARD

10-13

Cooling system

Fuel system

Part name

Piping, ets.

Fuel feed pump

Injection pump

10-14

Wear of delivery valve

Air tightness,
[Air pressure: 196 kPa {2.0 kgf/cm2}]

Oil feed flow:


pump speed 1,000 rpm
15 seconds
Suction head 1 m
Discharge head 0.3 m

Sucking capacity:
Hand pumping speed 60 100 st./min;
head 1 m; pipe ID 8 mm x length 2 m

cc

Air bubbles leaking


from push rod shall
be as small as a
millet grain and
shall not exceed
30 cc./min.

405 or more

Sucking to be
completed by
within 25 times
of pumping.

Limit

Repair method

300
or less

Check valve piston and seat


surface for damage. Replace
valve assembly if lengthwise
scroes are in piston, if seat
surface is dented remarkably
and lacking in luster, or if
valve fails to return to original
state when, after wetted with
clean diesel fuel, it is
compressed lightly, while
valve seat bottom is plugged
with a finger, and then the
finger is released.

If leak exceeding specification


is found, repair or replace.

Repair or replace.

120 times
or more Repair or replace.

Replace.

Nominal size Assembly standard

Fuel filter element for clogging and


damage.

Unit

Repair or replace.

Checking item

Fuel pipe, injection pipe, and nozzle


holder for clogging, cracks, loose joint,
and defective packings

Delivery valve

Group

Cartridge type

Remarks

REPAIR SERVICE STANDARD

Part name

Injection pump

Group

Nominal size Assembly standard

Limit

Repair method

Remarks

Adjustment condition

Adjustment of injection rate

Standard

Lever

Rack
Lever

14

89 1.5

9 1.3
150 5

1,075

450
100

10.3

7.5

Rack limit

Remarks

Fixing method

Variance
(%)

Average injection rate


(mm3/stroke)

Pump speed
(rpm)

Rack position
(mm)

40 5

Fuel temperature

Adjustment point

JIS No. 2 diesel fuel

mm

Test fuel

6 x 2.0 x 600

157 {1.6}

MPa {kgf/cm2}

Fuel feed pressure


mm

17.2 {175}

MPa {kgf/cm2}

Cracking pressure of nozzle

Pipe
Outside diameter x Inside diameter x Length

105780 8140

Clockwise when seen from drive side

115603 3280

Nozzle holder assembly No.

Unit

105780 0000

Part No. of pump

Nozzle No.

Turning direction

Adjustment item

The following are examples of adjustment values of the injection rate. For the adjustment values of each injection pump, see the data supplied by ZEXEL.

Checking item

REPAIR SERVICE STANDARD

10-15

Fuel equipment

Part name

Injection pump

Group

10-16
Nominal size Assembly standard

Examples of the governor performance curves are shown below.

Checking item

Limit

Remarks

Max. 13
Max. 16
Max. 20

1350
1230

Notch limit
1450

Speed at which governor


starts working
(min-1)

Target notch: 9

Remarks

Note) When changing the speed at which this governor starts


working, observe the following.
Interference limit of flyweight and swivel lever

Repair method

REPAIR SERVICE STANDARD

Fuel equipment

Fuel equipment

Electrical system

Part name

Injection nozzle

Charge
indicator

[12 V, 50 A, MITSUBISHI 1-81200-530-1]

Wiring

AC generator

Limit

Repair method

0.06 or less

0.1

Rated output current: 27 V


(5000min-1)

Loose bearing

50

Replace bearing.

Replace rotor.

Correct.

Loose connection, disconnection, and


broken covering

Bent shaft

If abnormality is found at
ordinary engine speeds,
correct electrical system.

mm

(1) Relatively large drops must not be


scattered, when checked with naked
eyes.
(2) Any drop must not be scattered sideway. Replace defective nozzle.
(3) Spray must not be dispersed from each
injection nozzle.

Lighting of warning lamp

Spray and injection


(Adjust cracking pressure of needle
valve to 19.1 MPa {195 kgf/cm2}.)

5.0 sec. or more

Replace.

Nominal size Assembly standard

Oiltightness of needle valve stem: sec


(Apply initial pressure of 29 MPa
{300 kgf/cm2} to nozzle and
measure time spent to lower
pressure from 24.5 MPa {250 kgf/
cm2} to 19.6 MPa {200 kgf/cm2}.)

Unit
If fuel leaks through seat,
repair or replace.

Checking item

Oiltightness of needle valve seat


(at 7.8 MPa {80 kgf/cm2})

Rotor

Performance

Group

Rotor must be rotated


smoothly by hand without
causing abnormal sound or
quiver.

Oil to be used: Diesel fuel


Viscosity (Redwood): 37
40 sec at 120 C

Remarks

REPAIR SERVICE STANDARD

10-17

Preheating
system

Starting motor

Electrical system

Part name

[24 V, 4.5KW, HITACHI 1-81100-342-0]

10-18

Battery

Group

mm

mm

mm

mm

min-1

Hear side
(Armature)

Front side
(Armature)

Pinion shaft
(Shaft)

No-load
characteristics
(Max. 24 V,
100 A)

mm

Outer
diameter

Depth of
undercut

Cloudy electrolyte

Battery plates, separators, cells

Battery terminal

mm

Unit

Resistance of
series coil

Resistance of
shaft coil

Control resistor and glow plug.

Performance

Ball bearing

Commulator

Magnetic switch

Brush length

Loose fitting

Checking item

16

3,500

Replace if disconnection or
short-circuit is found.

6905D

Correct.

Replace armature.

Replace.

16 (Outside
diameter of
bearing)

0.2

Repair method
Correct.

6001D

0.5 0.8

36.5

10

Limit

28 (Outside
diameter of
bearing)

37

0.187 (At 20C)

1.31 (At 20C)

18

Nominal size Assembly standard

This part is prepared by


manufacturer.
As per instructions of
manufacturer.

Pinion must operate smoothly


and must not make abnormal
sound.

If bearing does not revolve


smoothly or makes abnormal
sound, replace it.

If deviation from standard


resistance is remarkable,
replace switch.

Remarks

REPAIR SERVICE STANDARD

Part name

Battery

Group

Electrical equipment

Completion inspection

290 (3) or less

290 590
{3 6}
85 or more

110 or less

KPa
{kgf/cm2}

KPa
{kgf/cm2}
%

Difference in compression pressure


between cylinders,
(Water temp.: 70 85 C, Approx. 200
min-1)

Lubricating oil pressure

Output inspection

Fuel consumption inspection

3.0 {31}

Nominal size Assembly standard

MPa
{kgf/cm2}

Unit

Compression pressure of cylinder,


(Water temperature: 70 85 C,
Approx. 200 min-1)

"Running-in" operation of engine

Electrolyte level

Terminal voltage

Capacity (20-hour rate)

Specific gravity of electrolyte (at 20C


after charged)

Checking item

Perform for at least 30 minutes.

Repair method

200
{2.0}

Adjust.

Correct.

2.5 {26} Correct.

Limit

Set value of new engine as


100.

Before engine warms up.

Before engine warms up.

This part is prepared by


manufacturer.

Remarks

REPAIR SERVICE STANDARD

10-19

6BG1T-BE2

6BG1T-BE2

SHOP MANUAL
6BG1, 6BG1T ENGINE

APPLICABLE MACHINE MODEL


FD100/115/135/150E/160E-6
FD150/180/200Z-5
FD150/180/200Z-6
F4EC/5EC/6EC-1

SERIAL No.
5001 and up
2001 and up
2301 and up
1001 and up

No. 3-4, 2 Chome, Akasaka, Minato-ku, Tokyo, Japan

BE

2003 KOMATSU FORKLIFT


All Right Reserved
Printed in Japan 06-03(03)

00-1