ENGINE
SERVICE
QUICK REFERENCE INDEX
MANUAL
�:2:,0ISASSEMBLY JUDGMENT , ".. ?·ir;� '-,:::--.::it��1t
,·<!,
MODEL
FD6 & FD6T
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FOREWORD
This service manual covers repair procedure of the
,';\
:i T FD6 and FD6T diesel engines. In order for the engine
!I: (: :);� displ.ays 100% performance at all times, and to ex
,:;!I '<, pand the life of each part, daily inspection and
!, servicing must, of course, be performed according to
a pl.an, but proper overhaul and repair in accordance
"1uJ
with the maintenance standards is also vital.
Keep this manual in the shop for everyone en
gaging in servicing of the engine.
Nissan Diesel reserves the right to make changes
for improvement at any time without notice.
Accordingly, some of the descriptions contained in
this manual may not be applicable to your particular
vehicle.
EF1-002
RIGHT
However, the unit of horsepower uses
F ranee horsepower.
ABBREVIATION
In this manual, the following abbrevia
REAR tions are used.
FRONT
O.D.......... Outside Diameter
I.D. ......... Inside Diameter
O.S.......... Over Size
U.S. ......... Under Size
B.T.D.C....... Before Top Dead
CA-052
Center
A.B.D.C........After Bottom
Dead Center
B.B.D.C. ...... Before Bottom
Dead Center
A.T.D.C....... After Top Dead
Center
P.T.O. . ...... Power Take Off
ENGINE SPECIFICATIONS
Type
Model FD6
Diesel
I FD6T
Compression ring 2
Number of piston rings
Oil ring 1
°
Open 15 B.T.D.C.
Intake valve timing
°
Clostd 47 A.B.D.C.
°
Open 53 B.B.D.C.
Exhaust valve timing
°
Closed 9 A.T.D.C.
Intake 0.4
Valve clearance [mm]
Exhaust 0.4
Ignition system Compression ignition
Q.
Type Bosch A type
I
E
::,
Eu Q. Plunger diameter [mm] 9.0 8.5
C
>- O ·
"' ·;; Cam lift [mm! 8.0
:s
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Governor Centrifugal
u.. Timer Centrifugal
C
.i
Nozzle holder Flange type
u .!
.!t ,.,,. Number of injection nozzle 4
C "'
·-
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0
- C
::,
Ii, Injection pressure [kg/cm2 J · 200 2201
GENERAL 1-3
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External dimensions
(Length x Width x Height}
- 210x 220x 215
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C:
Counterclockwise as
Direction of rotation - viewed from the exhaust
turbine side
Air volume [kg/min] - 20
Compression ratio - 3.0
Type Forced circulation
E Oil pump Gear pump
�.,,
>-
"' Fullflow Paper element
lOO
C: Oil filter
"'
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By-pass Paper element
·.:::
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:::, Lubrication oil capacity [Q] 15
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'I Oil cooler Water cooled flat tube type
1
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Type Forced circulation
E
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Corrugated fin
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Cooling water capacity (only for the engine)[Q] 10
[ I
if,:1q 0 Water pump Centrifugal
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Thermostat Wax pellet type
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Type AC , diode-rectified
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"' .s.,, Output [V-A] 24 - 80, 24 - 25 or 24 - 40 24 - 15 or 24 - 25
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�E Output [V-kW] 24 - 3.5, 24 - 4. 5, 24 · 5.0 24 - 4.5 or 24 · 3.5
V,
1-4 GENERAL
Petroleum
Brand SAE Viscosity
Maker Recommended class-CC engine oils
CALTEX RPM DELO300 (MIL-L-2104B or MIL-L46152)
I OIL
1 20W/20, 30, 40 ow,
CALTEX (.__-------------+------�--I
I CALTEX RPM DELO400 lSW/40, 20W/20, Petroleum
;,tY
Brand SAE Viscosity
I
Maker
i OIL l0W,30,40
I SUPER 1000 S-3 MOTOR AGIP AGIP F.1 DIESEL GAMMA l0W,20W/20,30,40
VALVO
I OIL OR ALL FLEET l0W, 20W, 30,40
LINE
I MOTOR OIL VALVO·
LINE
HD SUPER HPO MOTOR
OIL
10W,20W,30,40
Petroleum Brand
Maker FUEL
CALTEX MARFAK MULTIPURPOSE NO. 2
CALTEX
The Nissan Diesel engine is designed to produce power by
CALTEX MARFAK ALL PURPOSE NO. 2 using light oil as fuel. Do not use any fuel except light oil;
TEXACO MARFAK MULTIPURPOSE NO. 2 otherwise, engine trouble will result.
TEXACO • The light oil should have a cetane number greater than 45,
TEXACO MARFAK ALL PURPOSE NO. 2
specific gravity of 0.81 to 0.85, boiling point ranging from
°
ESSO MULTIPURPOSE GREASE 180 to 380 C, sulfer content of less than 0.5%, and should
ESSO
ESSO RONEX MP prove neutral in a chemical reaction test. It should be clean,
possess the proper viscosity, and contain no water or sediment.
MOBIL MOBIL GREASE MP
,,i
,,
I
2. DISASSEMBLY JUDGMENT
EF1-002
REDUCTION IN COMPRESSION
a
period as reference. If the FC value
1.0 kg/cm 2
Repair limit
drops below 60% of the reference Min. 0.5 kg/cm 2
PRESSURE value, the engine should be over At 1,500 rpm
The compression pressure of the en hauled.
Maintenance standard
gine lowers as the cylinder liner, 3.2 to 4.4 kg/cm 2
piston, piston rings and valves become DETERIORATION IN ENGINE Repair limit
worn. If compression pressure drops to OIL CONSUMPTION (OC) Min. 2.0 kg/cm 2
the repair limit, the engine must be
The OC value changes according to
overhauled.
various factors including operating
Compression pressure (Warm engine conditions of vehicle, quality of
and engine rpm: 180 to 220) engine oil, etc. However, if the OC
Maintenance standard value drops below 40% of its initial
More than 30 kg/cm 2 value during the new car period, it can
Repair limit be regarded as a sign that engine over
Less than 25.0 kg/cm 2 haul is required. Before making the
Iii' Difference between cylinders final decision to overhaul, it is also
:;; Maintenance standard necessary to check compression pres
/ii
i:: Less than 4.0 kg/cm 2
ii! sure, blow-by gas pressure and other
u:
. I
2-2 DISASSEMBLY JUDGMENT
TROUBLESHOOTING TESTS
MEASURING COMPRESSION Compression pressure (Warm engine Examples of trouble
PRESSURE and engine rpm: 180 to 220) Trouble symptoms that are attributa
The measureme11t value of the com Maintenance standard ble to incorrect compression pressure
pression pressure is important in deter More than 30.0 kg/cm2 are: low engine output, deteriorated
mining the time that engine overhaul is Repair limit oil consumption, deteriorated fuel
needed. It is therefore necessary to Less than 25.0 kg/cm2 consumption, emission of white smoke
periodically measure and record engine Difference between cylinders
during high speed travelling, difficulty
compression pressure. Maintenance standard
in starting, irregular engine operation,
Max. 4.0 kg/cm2
diesel knock, overheating, etc. If
compression pressure drops below the
repair limit, the cause must be ex
amined, and the engine overhauled.
, ,,,,
( ,.;,
..
Low compression...L------------��-----------;..J'--------------
pressure
MEASURING BLOW-BY GAS Trouble symptom measured, and then a decision should
PRESSURE Trouble symptoms that are attributa be made whether the engine requires
ble to excessive blow-by gas pressure overhauling.
Measurement of blow-by gas pressure
like measurement of compression are: low engine output, deterioration
pressure provides an important in in oil or fuel consumption, emission of
formation, in deciding whether or not white smoke during high speed travell
an engine should be overhauled. ing, difficulty in starting, irregular
engine operation, diesel knock, over
Blow-by gas pressure (Warm engine
heating, oil leakage from air breather
at maximum rpm under no load)
or other areas, etc. If the blow-by gas
Maintenance standard
pressure exceeds the service standard,
Max. 12 mmAq
compression pressure should also be
'iii/
Extensive scuffing Half-opened exhaust shutter
Clogged or crushed muffler or pipe
Malfunction of injection
pump
....
mal water flow in the radiator.
2) Slight water temperature differ
ences are caused by foreign matter ENGINE OIL SPOT TEST
such as mud and insects accumu The engine oil spot test is performed IUO
lated on the radiator core fin, to evaluate the condition of the engine
obstructing smooth flow of air oil, thereby judging whether or not the
through the fins. engine oil requires changing. V 1.18
Trouble symptom
If the acidity of cooling water is ex
cessively high, engine overheating or
reduction in the quantity of cooling
water may result.
DISASSEMBLY JUDGEMENT 2- 7
DIAGNOSIS GUIDE
The diagnosis guide is a table which HOW TO USE THE GUIDE section through the dot mark
can be used for seeking out the cause 1) Open the page of the guide corre "•". If there are more than one
of trouble without disassembling the sponding to the trouble symptom applicable "Cause of trouble"
engine on the basis of the symptoms complained of by the user. items, the item having the largest
of the problem and the result of 2) Check all of the points listed in the number of dot marks should be
checks performed in the shop. page. regarded as the central cause of
3) If there is any applicable item in the trouble.
the checking points, the cause of • The "cause" items having no dot
the trouble may be assumed in the mark can be regarded as not
following manner. being the cause of the trouble.
• Each item in the "Symptoms Note
and checking points" section If more than one cause is assumed,
corresponds to one or more repair operation should begin with the
items in the "Cause of trouble" simplest operation.
2-8 DISASSEMBLY JUDGEMENT
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(Check by connecting and disconnecting the clutch)
DISASSEMBLY JUDGMENT 2-9
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Incorrect adjustment of lirik or rod
Fuel leakage from injection pipe
Uneven injection quantity
E Malfunction of governor
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Improper fuel quality
Improper adjustment of in-
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Clogged fuel filter element
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Improper fuel spray from
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LL. Improper injection timing
Malfunction of delivery
valve
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Malfunction of injection
pump
Faulty boost compensator
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Half-opened exhaust shutter
Turbocharger malfunctio
control linkage .
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stop wire
2- 12 DISASSEMBLY JUDGMENT
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Improper fuel spray from nozzle
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Faulty boost compensator
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Uneven injection quantity
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s
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Clogged or crushed exhaust pipe or muffler+--+-------<---+---
Gas leakage from head gasket
-4�-------------4t----•
Gas leakage from cylinder head nozzle tube,1--....,_
, _____
EF1-002
This chapter covers engine disassembly and reassembly, Refer to the chapter
4 "Engine proper" when inspecting the cylinder block, piston, crankshaft,
etc.
' . . .
'·,:,.,;,;.,) /i,,', '
ENGINE DISASSEMBLY AND REASSEMBLY 3-1
DISASSEMBLING ENGINE
Before disassembling the engine, be 5) Remove the turbo adapter bracket,
sure to completely drain engine oil and turbo adapter support and turbo
cooling water. adapter.
EF3-006
EF3·011
EF3-002
EF3-008
EF3-004 4) Remove the water manifold. 8) Remove the vacuum pipe and hose.
3-2 ENGINE DISASSEMBLY AND REASSEMBLY
12) Remove the oil coller water inlet 3) Remove the cooling fan and spacer.
pipe.
EF3-017
EF3-100
FRONT SIDE OF ENGINE
1) Remove the vacuum hose and
vacuum pump lubricating oil hose. 6) Remove the V-belts and fan pulley.
And then remove the generator.
2) Remove the generator adjusting bar 7) Remove the fan pulley bracket.
and bracket.
8) Remove the tension pulley bracket 12) Remove the crank pulley.
and adjusting bracket. Note
If it is difficult to remove the crank
pulley assembly, drive it out by lightly
tapping on the crank shaft end cover
ing it with a brass pad.
EF3-100
EF3-029
EF3-026
EFS-023
6) Remove the injection pump control Note 3) Measure and record the amount of
lever return springs and breather. Be sure to loosen the rocker shaft misalignment between the crank
bracket mounting bolts, starting from shaft and flywheel housing.
the outside and working in.
EF3.033 EF3-037
7) Remove the injection pump lubri 3) Remove the cylinder head mount
cating oil supply tube. And then ing bolts. And then hook a chain or 4) Attach engine stand attachment
remove the injection pump. wire to the engine lifters and re (99554 97001).
move the cylinder head using a
hoist.
Note
Be sure to loosen the cylinder head
mounting bolts, starting from the
outside and working in.
EF3-034
ENGINE PROPER
1) Measure and record the lateral
runout of the clutch disc surface
EF3-035 of the flywheel.
EF3-040
CYLINDER HEAD
1) Remove the rocker cover.
EF3-036
EF3-045
EP3-57
13) Remove the main bearing shell 16) Remove the idler gear shaft.
(lower) and main bearing cap.
17) Loosen the camshaft locating 18) Remove the cam follower.
plate mounting bolt and pull the
camshaft assembly (with camshaft
gear) out to the front.
Note
Set the engine with the oil pan side
facing upward so that the cam fol
lower will not fall out when the cam
shaft is removed.
EF3-049
,,;;:,·,,.
{��)
ND REASSEMBLY
ENGINE DISASSEMBLY fA��=------ 3-7
-
ENGINE REAR P.T.O.
FRONT�
E F3-051
1) Remove the P.T.O. oil tube and 3) Remove the P.T.O. holder and gear 5) Remove the idler gear.
P.T.O. drive shaft cover. assembly.
EF3-052
EF3-054
2) Remove the flywheel housing
cover. And then measure and EF3-056
I
·�
-.........__
i /
---;
EF3-053
EF3-055
ENGINE DISASSEMBLY AND REASSEMBLY 3-9
REASSEMBLING ENGINE
When reassembling the engine, be sure 4) Insert the camshaft and tighten 6) Raise the crankshaft using a hoist
to install new gaskets, packings and 0- the locating plate mounting bolts. or crane and set into the cylinder
ring, and apply engine oil to the sliding Tightening torque block.
surfaces of each component part of 1.3 kgm
the engine.
ENGINE PROPER
1) Install the oil jet (piston cooling
oil jet).
Tightening torque
3.0 to 4.0 kgm
EF3-060
Maintenance standard
0.06 to 0.14 mm
Repair limit 0.40 mm
3) Insert the cam follower into the Thickness -0.005 -0.035 -0.065 0 0
3 3 3 3.2 3.4
cylinder block. (mm) -0.040 -0.070 -0.100 -0.05 -0.05
EFJ-048
EP3-57
EF3-062
3- 10 ENGINE DISASSEMBLY AND REASSEMBLY
8) Install the lower shell to the main 9) Tighten the main bearing cap bolt.
bearing cap and attach the cap to Tightening torque
the block. Be sure to install the 17 to 17.5 kgm
lower thrust washer on each side
of the No. 6 main bearing cap.
ARROW
MARK
EF3-066
EF3-063
CONNECTING ROC. PISTON
EF3-068
Notes 10) Install the upper bearing shell and
1. Apply a coat of engine oil to the bolts to the connecting rod. 2. Do not install the piston ring in
sliding surface of the main bearing such a way that its gap faces the
shells and install them in their Note direction of the piston pin and is in
original positions. Be sure to apply a coat of engine oil to a vertical direction.
2. There is .. mark embossed in the the sliding surface of the bearing shell
main bearing cap as shown in the and re-install in its original position.
figure below. The bearing cap
must be installed with this mark
facing the fan side.
0
-��----
tr '--'--
0
� - I EA4-113
Notes
1. Make sure that the arrow mark
stamped on the top of the piston
faces the front of the engine and
the cylinder number stamped on
the large end of the connecting rod
faces the side with the injection
pump.
EF3-065
EF5-037
ENGINE DISASSEMBLY AND REASSEMBLY 3- 11
'-\;'
' (
'
h . 17
'--
EFS-016
o· ,
'\
18) Align the injection pump gear
� timing mark and idler gear timing
'
mark (B and BB) and install to the
EFS-038
EP3-47 front end plate with O-ring.
Notes
15) Install the idler shaft. When remounting to the engine when
Tightening torque 3.0 to 4.0 kgm only the injection pump has been dis
mounted from the engine, install as
follows:
1. Turn the flywheel in the forward
direction and set the No. 1 piston
to top dead center on the com
pression stroke. (When the No. 1
piston is set to top dead center on
the compression stroke, the exhaust
valve is fully closed and there is
valve rush. Moreover, the 1/6 mark
of the flywheel is matched with the
pointer of the flywheel housing.)
Note
EF3-046 When installing the injection pump,
confirm that the scribed line of the
16) Align the idler gear timing marks injection pump bracket and the
with the crank gear and camshaft scribed line of the front end plate
gear timing marks and insert the are matched.
idler gear onto the idler gear shaft.
Then install the idler gear plate. EF3-073
EF3-072
17) Check the idler gear end play. 19) Confirm that the timing marks
Maintenance standard for each gear coincide when the
0.03 to 0.12 mm injection pump is installed. EF3-074
3- 12 ENGINE DISASSEMBLY AND REASSEMBLY
0
and remove the engine stand and its
0 attachment. Lower the engine onto
EF3-041
the work bench.
27) Install the flywheel assembly.
24) Install the flywheel housing, in· Note
serting the gasket between the If engine rear P.T.O. is equipped, in·
flywheel housing and engine. stall the engine rear P.T.O. before
� Tightening torque installing the flywheel.
0
MS 1.5 to 2.0 kgm Tightening torque
M12 7 to 7.5 kgm 15.0 to 15.5 kgm
EF3-076
Notes
1. If engine rear P.T.O. is equipped,
20) Measure the backlash between any install the idler bracket before
pair of front gear trains to ensure installing the flywheel housing.
2. When installing a new oi seal, drive
that it is within the repair limit.
it into place in the flywheel hous
Maintenance standard ing. Be sure to apply a coat of
0.05 to 0.25 mm engine oil (not grease) to the sealing
Repair limit 0.30 mm lip in advance. Be careful not to
EF3-081
damage or deform the oil seal.
21) Install the timing gear case.
ENGINE DISASSEMBLY AND REASSEMBLY 3-13
J i·
',1ll
EF3-035
6} Tighten the cylinder head bolts
uniformly as described below, using
the cylinder head bolt socket 2) Install the injection pump lubri
wrench (99664 ZS000). At this cating oil supply tube.
time, tighten while being careful
that the ball part of the valve
ER4·121
rocker adjusting bolt and the push
rods don't move out of position.
1. 1st time: Tighten to a torque of
2) Install the cylinder head gasket. 6 kgm.
Note 2. 2nd time: Tighten to a torque of
Install the head gasket assembly with 10 kgm.
the embossed part number facing up 3. 3rd time: Tighten to a torque of
wards. 15 kgm.
4. Finally, check the tightening torque
3) Install the cylinder head. of .the 4 or 6 center bolts.
3- 14 ENGINE DISASSEMBLY AND REASSEMBLY
3) Install the breather with a gasket, 7) Install the fuel spill tube to the
and then install the injection pump nozzle holder with the connector
control lever return springs. bolt through copper two gaskets.
EF3-026
EF3-057
EF3-032
EF3-058
gasket.
Tightening torque 4) Install the tension pulley adjusting
0.8 to 1.0 kgm bolt and bracket.
6) Install the nozzle assembly.
Tightening torque
2.5 to 3.5 kgm
EF3·078
:,
,,
EF3-020
EF3·099
EF3-082
11) Install the generator and V-belts.
2) Install the oil cooler water inlet
pipe (water pump outlet pipe) be
8) Install the fan pulley, fan spacer
tween the oil cooler to water pump
and cooling fan.
through a gasket (water pump side)
and O-ring (oil cooler side).
3) Install the hydraulic pump ad 1 0) Install the water manifold through
justing bar and bracket (if so a gasket.
equipped). Tightening torque 1.5 kgm
EFJ-009
EFJ-008
EFJ-011
EFJ-013
13) Install the water tank, stay and ENGINE REAR P.T.O.
hose. Assembly of the special rear P.T.O.
parts only is described here. Other
operations have been described else
where and are omitted here.
EF3-006
EF3-090
TURBOCHARGER (FD6T ENGINE 4) Install the oil tube and oil drain
ONLY) pipe.
1) Install the turbo adapter support Note
and bracket. And then install the Be sure to insert the O-ring between
turbo adapter through a gasket. oil drain pipe flanges and turbocharger
and cylinder block.
EF3-091
1 Cylinder block
2 Idler gear bracket
3 Idler gear shaft
4 Bearing (inner)
5 Bearing spacer
6 Bearing (outer)
EF3-002 7 Idler mounting bolt
2) Set the turbocharger through a gas 8 Flywheel housing
ket and temporarily tighten the 9 Cover
nuts. Set the turbocharger outlet 5) Install the air intake duct. At the 10 Flywheel
exhaust connector and temporarily same time, connect the earth wire. 11 Idler gear
tighten the nuts.
Notes
1. All nuts are not conventional ones, 1) Assemble the bearing, bearing
but are heat resistant. spacer and idler gear shaft to the
2. When installing the connector, be idler gear, insert from the P.T.O.
careful not to damage the seal ring. cover mounting section of the fly
wheel housing and install to the
idler gear bracket.
EF3-089
2) Tighten the idler gear mounting Installing the P.T.O. gear assembly 2) Make sure that the backlash be
bolt. tween the P.T.O. gear and idler
Tightening torque gear is within maintenance
10 to 11 kgm standards.
Maintenance standard
0.05 to 0.25 mm
Repair limit 0.30 mm
EF3-092
. ·\"'' "'"----�---------
'·,.
./
14 Companion flange
3) Install the flywheel housing cover
J' , ;,;,,� -·
/ //� n -,"'--'\ \--
through a gasket.
4) Install the drive shaft cover through
EFJ-oss 1) Install the P.T.O. holder and P.T.O. a gasket and install the P.T.O. oil
gear assembly through an O-ring. tube.
4) Install the idler gear shaft cover.
EFJ-054 EFJ-052
EF3-093
ADJUSTMENT
o�
�
o Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
EFJ-095
Cylinder No. 1 2 3 4 5 6
Valve arrangement In. Exh. In. Exh. In. Exh. In. Exh. In. Exh. In. Exh.
Valve No. 1 2 3 4 5 6 7 8 9 10 11 12
No. 1 top dead center on
compression stroke
• • • • • •
No. 6 top dead center on
compression stroke
• • • • • •
TEN·
SION
PULLEY
EF13-001 ETl-055
EMl-010
3-20 ENGINE DISASSEMBLY AND REASSEMBLY
EF 13-002
,,,
4. ENGINE PROPER
EFS-041
This chapter describes the method of cleaning and inspecting the cylinder
block, piston, crankshaft, etc., and the method of replacing the cylinder liner,
etc.
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2
REPAIR AND REPLACEMENT ........................ 4- 8
ENGINE PROPER 4-1
CLEANING
Each component part must be cleaned metal plate to scrape off foreign mat 2) Use steam cleaner to clean the lu
of dirty oil, oil sludges, scale, carbon, ter. Perform this preliminary cleaning bricating oil live. In addition, use a
old gasket or adhesives attached to it. before conducting finish cleaning. wire to check for clogging, and
Cleaning methods are: high tempera For those parts composed of a single clean with a cleaning fluid or com
ture steam cleaning, light oil cleaning, kind of material such as copper, cast pressed air. Clean the water cooling
acid or alkaline solution cleaning, iton, and aluminum, alkaline cleaning live in the same manner.
neutral detergent cleaning, triclene fluid may be used. For a metal pro 3) When cleaning rubber parts, use al
solution steam cleaning, and magnas duct composed of two or more than cohol to remove foreign matter.
fluid cleaning. materials, however, such as bearing Never use light oil, lamp oil or any
In cleaning, unexpected crack or dam shell and bushing, cleaning with light other mineral oil. Note that, in
age may often be found out. It is im oil, triclene solvent, steam, or magnas principle, all rubber parts should be
portant, therefore, to take sufficient fluid is recommended, because electro replaced with new ones when over
care during cleaning not to overlook lytic corrosion may occur due to in hauling the engine.
any defect on a part. ionization in these type parts. 4) After cleaning the parts, dry them
Note by using compressed air. When
CLEANING METHOD When handling alkaline fluid, prepare a directing compressed air to a bear
Cleaning can best be done with either boric acid solution so that cleaning ing do not allow the air pressure to
light oil or alkaline cleaning fluid. It is fluid accidentally falling on to the skin cause it to rotate.
important to select the cleaning meth or clothes, or splashed into eyes can be Note
od and fluid best suited to each oc quickly neutralized. Do not use cleaning fluid to clean a
_casion. sealed type bearing it must be cleaned
Light oil features minimal permeabil CLEANING PROCEDURE AND only by wiping.
ity and solubility for matter adhered PRECAUTIONS
to the surface of the parts, and is then 1) Before cleaning cylinder liners and 5) After drying, apply clean engine oil
fore most suitable for cleaning parts pistons (cylinder head and piston to the parts, and keep them free
with sliding surfaces or finely finished rings), use fine emery paper or a from dirt and dust.
surfaces. For other portions, use a wire piece of metal to scrape off carbon
brush, a wooden spatula, or a piece of stuck to these parts.
4-2 ENGINE PROPER
INSPECTION
CYLINDER BLOCK
1) Check each portion of the cylinder
block for damage and cracks. If
faulty, repair or replace the cylin
der block.
2) Inspect each stud bolt for bend and
damage on the threaded portion. If
faulty, replace the stud bolt.
ERS-103
3) Measure and record the inside
diameter of the cylinder liner with
the main bearing cap tightened to
EPS-054 7) Using a water leak test tool
the specified torque. From the
(99561 Z5001) and hydraulic
measured data, obtain the maxi
pump (99570 Z5000), perform a
mum inside diameter, out-of-round
water pressure test on the cylinder
ness (difference between the dimen
block and check for water leakage
sion A and dimension B in the
from the water jacket. If faulty,
figure), and taper (difference be
repair or replace the cylinder block.
tween the dimension D 1 and
dimension D 4 ) of the liner. If the Test conditions
inside diameter exceeds the wear Water pressure
limit, or if the out-of-roundness or 4 to 5 kg/cm2
taper exceeds the maintenance Test time
standard, replace the liner. 5) Measure the flatness of the top sur for 5 to 10 minutes
face of cylinder block. If the
Tightening torque
17.0 to 21.0 kgm measured value exceeds the main 8) Using a cylinder liner tool (99600
Inside diameter tenance standard, repair by grind Z5001 ), remove the cylinder liner.
Wear limit 100.40 mm ing. If the measured value exceeds (Refer to "REPAIR AND RE
Taper and out-of-roundness the wear limit, replace the cylinder PLACEMENT.)
Maintenance standard block. 9) Check the cylinder liner fitted
Less than 0.02 mm Longitudinal direction surface of the cylinder for any sign
Maintenance standard of corrosion or damage. If faulty,
Less than 0.10 mm repair or replace the cylinder block.
Transverse direction 1 O) Measure the inside diameter of the
Maintenance standard liner fitting bore in two directions,
°
Less than 0.02 mm (that is, parallel to and at a 90
Grinding tolerance 0.50 mm angle to the crankshaft) at the
upper and lower portions of the
bore. Keep the main bearing cap
D, tightened to the specified torque
while measuring. Calculate the out
0 of-roundness of the liner fitting
EFS-006 bore, if the value exceeds the main
tenance standard, replace the cylin
der block.
4) Measure the height of the cylinder EFS-042
liner flange portion protruding Tightening torque
above the top surface of the cylin 17.0 to 17.5 kgm
der block. If the measured value is Straight edge Maintenance standard
not within the specified limit, re Less than 0.02 mm
place the cylinder liner or cylinder
block.
Protrusion of cylinder liner flange
above cylinder block
Maintenance standard (Al
0.02 to 0.09 mm
E3 ·1
Cap between adjoining cylinders
6) Measure the inside diameter of the
Maintenance standard
camshaft bushing.
Less than 0.03 mm
ENGINE PROPER 4-3
0
5) Check the oil slinger (rear of block) 9) Measure and record the outside
for damage and deformation. If diameter of the crankshaft pin. If
faulty, repair or replace the oil the outside diameter ouf of round
slinger. ness has reached the repair limit, or
UPPER 'f 6) Using the magnetic flaw detecting if the taper exceeds maintenance
standards, grind the pin to the
method or red check method,
check the whole crankshaft for any undersize, and install the undersize
sign of cracks. If faulty, replace the bearing shell. If the outside dia
crankshaft. meter is smaller than the wear limit
replace the crankshaft.
Note
EFS-005
Outside diameter
When inspecting, special attention
Maintenance standard
MAIN BEARING SHELL should be paid to the journal, crank
61.92 to 61.94 mm
pin and the root of balancer weight.
1) Check the main bearing shell for Repair limit 61.80 mm
damage on the inner and outer sur Wear limit 61.0 mm
7) Measure and record the outside
faces, and for adhesion of kelmet. Out-of-roundness
diameter of the journal. If the
If faulty, repair or replace the main Maintenance standard
measured value has reached the re
bearing shell. Less than 0.01 mm
pair limit, or if the taper exceeds
Note Repair limit 0.02 mm
the maintenance standard, grind the
When replacing, be sure to replace all Taper
journal to the undersize, and install'
the bearing shells as a set. Maintenance standard
the undersize main bearing shell. If
Less than 0.01 mm
the outside diameter is smaller than
2) With the main bearing shells as the wear limit, replace the crank
sembled to the cylinder block, shaft.
measure the inside diameter of
i Outside diameter
main bearing shells, and record the
.,�i Maintenance standard
... measured value. When measuring,
the main bearing cap should be 75.92 to 75.94 mm
tightened with the specified torque. Repair limit 75.82 mm
Wear limit 75.0 mm EPS-6
Tightening torque
Out-of-roundness
17.0 to 21.0 kgm
Maintenance standard
Less than 0.01 mm 1 O) Measure the crankshaft runout
Repair limit 0.02 mm and record the results. If the
Taper measured value exceeds the main
Maintenance standard tenance standard, repair or replace
Less than 0.01 mm the crankshaft.
Maintenance standard
Less than 0.03 mm
EFS-044
CRANKSHAFT
1) Check the journals and crank pins EP5-5
for damage and oil holes for clog
8) Calculate the clearance between the
ging. If faulty, repair or replace the
journal O.D. and main bearing shell
crankshaft. EF5-012
I.D. from the measured values. If
2) Check the crankgear teeth for dam
the clearance has reached the repair
age, wear and cracks. If faulty, re
limit, replace all the main bearing 11) If the measured crankshaft end
pair or replace the crank gear.
shells as a set. If the clearance play during disassembly reaches the
3) Check the oil seal collar for damage
reaches the repair limit even when specified repair limit, replace the
and deformation, or for any sign of
the new main bearing shells are upper and lower thrust washers as
seizure or stepped wear on the oil
used, grind the journal of the crank a unit with a suitable set of thrust
seal contacting surface. If faulty, re
shaft, and install the undersize bear washers so that the end play is
pair or replace the collar.
ing shells. within the maintenance standard.
4) Check the crankshaft for any sign
of seizure or stepped wear on the Maintenance standard Maintenance standard
rear oil seal contacting surface. If 0.05 to 0.12 mm 0.06 to 0.14 mm
faulty, replace the oil seal. Repair limit 0.15 mm Repair limit 0.4 mm
4-4 ENGINE PROPER
Maintenance standard
Size identification Thickness
Remarks Inlet
mark [mm]
48.47 to 48.51 mm (FD6)
A 2.96 -3.00 48.79 to 48.83 mm ( FD6T)
Exhaust
B 2.93 -2.97 48.41 to 48.45 mm
Thrust
Wear limit
washer C 2.90 · 2.94
Inlet
type
0.20 0.5. 3.15-3.20 48.01 mm (FD6)
O.S.: Oversize 48.32 mm (FD6T)
0.40 o.s. 3.35 - 3.40 Exhaust
47.93 mm
CAMSHAFT 1 Nut 5 Locating plate
1) Measure the camshaft end-play. If 2 Lock washer 6 Key
the measured value has reached the 3 Plain washer 7 Camshaft
4 Camshaft gear
repair limit, replace the locating
plate.
Maintenance standard (A) ES-118
5) Measure the outside diameter of the
0.05 to 0.25 mm journal, and record the results. If
Repair limit 0.30 mm the measured value exceeds the 8) Measure the camshaft runout. If
maintenance standard, replace the measured value has reached the
repair limit, repair or replace the
camshaft.
camshaft.
Maintenance standard
Maintenance standard
No. 1 57.33 to 51.35 mm
Less than 0.03 mm
No. 2 57.13 to 57.15 mm
No. 3 56.93 to 56.95 mm Repair limit 0.06 mm
No. 4 56.73 to 56.75 mm
3) Check the surface of each journal 6) Calculate the clearance between the EFS-014
and cam, and the threaded portion journal and camshaft bushing from
and key ways of the camshaft for the measured values. If the clear
damage or any sign of seizure. If ance has reached the repair limit, PISTON AND PISTON RINGS
faulty, repair or replace the cam replace the camshaft bushing. If the
shaft. clearance still reaches the repair
4) Check the whole camshaft for any limit even when the new camshaft
sign of cracks using the magnetic bushing is installed, grind the cam
flow detecting method or red check shaft journal, and install the under
method. If faulty, replace the cam size bushing.
shaft. Maintenance standard
0.02 to 0.11 mm
Repair limit 0.15 mm
CD ® ® ©
2) Check the periphery of each piston
ERS-169
for scuffing. If faulty, repair or re
place the piston. 6) Measure the end gap of each piston
3) Check each piston ring for uneven ring and record the results. If the
wear. If faulty, replace the piston measured value exceeds the wear
ring. limit, replace the piston ring.
4) Measure the outside diameter of the Maintenance standard
piston, and record the results. 0.30 to 0.50 mm ES-125
Measurement should be made at 25 Wear limit 1.5 mm
mm position from the bottom side
of the piston at a right angle to the
piston pin axis. Calculate the clear CONNECTING ROD
ance between the piston O.D. and 1) Check the connecting rod for
cylinder liner I.D. If faulty replace cra·cks and damage. If faulty, re
the piston or cylinder liner. pair or replace the connecting rod.
Outside diameter of piston 2) Inspect the small end bushing for
Maintenance standard damage. If faulty, repair or replace
99.86 to 99.90 mm the small end bushing.
Clearance between piston and 3) Measure the inside diameter of the
cylinder small end bushing and record the
ER5·150
Maintenance standard results. Calculate the clearance
0.10 to 0.17 mm between the small end bushing I.D.
and piston pin O.D. If the calculate
7) Measure the inside diameter of the
value has reached the repair limit,
piston pin bore, and record the re
replace the bushing.
sults.
Maintenance standard
E 0.03 to 0.05 mm
MEASURING E Repair limit 0.10 mm
DIRECTION
EFS-008
=-
1ST
still reaches the repair limit even
when the new bearing shells are in 2ND
w
stalled, grind the crankshaft pin, u /
<{
and install the undersize bearing u.
a: OIL
shells. ::,
U)
a:
Tightening torque w
z
11.5 to 13.0kgm �/
Maintenance standard ...I
<{ EF5-035
0.04 to 0.10mm
Repair limit 0.15 mm
GEAR TRAIN
1) Check each timing gear for damage
and wear on the teeth. If faulty, re
6) If the measured side clearance at pair or replace the gear.
the large end of each connecting
2) If the backlash between timing
rod during disassembly of the en
gears has reached the repair limit,
gine proper is incorrect, replace the
repair or replace the gear.
connecting rod.
Maintenance standard
Maintenance standard
0.06 to 0.16 mm
0.10to 0.30mm
Repair limit 0.30mm
7) Install the connecting rod to the
EP5-17 3) Measure the idler gear assembly
piston, and insert the piston pin.
end play and record the results. If
Note the measured value has reached the
Make sure that the arrow mark stamp repair limit, replace the idler shaft
ed on the top of the piston faces the and plate or idler gear. 1 ,,.
front of the engine and the cylinder
Maintenance standard
number stamped on the large end of
0.03to 0.12 mm
the connecting rod faces the side with Repair limit 0.30 mm
the injection pump.
5) Mount the connecting rod fitted
with the connecting rod cap to the
connecting rod aligner, and insert
ARROW
the piston pin into the small end MARK
bushing. Measure the clearance at
the aligner pin (A) or (B) to check
the bend and twist of the connect EFS-047
ing rod. If the clearance measured
at pin (A) or (B) exceeds the limit, 4) Measure the inside diameter of the
CONNECTING ROC. PISTON
replace the connecting rod. If the idler gear bushing and outside
EF3·068
dimension between pin (A) and pin diameter of the idler gear shaft, and
(B) is other than 250 mm, calculate record the results. Calculate the
the bend or twist by using the. 8) Using a piston ring tool (99630 clearance from the measured values,
following equation: Z5001 ), install the piston rings. and if it exceeds the repair limit, re
Bend or twist Note place the bushing.
200 Be sure the manufacturer's mark faces Maintenance standard
= ----------,,-------
Dimension between pin (A) and (B) upward . 0.02to 0.06 mm
x measured value (mm) Repair limit 0.20mm
Connecting rod bend
Maintenance standard FLYWHEEL
Less than 0.05 mm 1) Check the clutch disc contacting
Connecting rod twist surface for damage. If faulty, repair
Maintenance standard or replace the flywheel.
Less than 0.08 mm 2) Check the ring gear teeth for dam
(When the distance between pins is age, deformation, or excessive wear.
200mm) E F5-022 If faulty, replace the ring gear.
ENGINE PROPER 4-7
3) Check the ball bearing for damage, 3) Check the bolts securing the damp 1 Drive shaft cover 8 Drive shaft
er to the crank pulley for looseness. 2 PTO gear 9 Nut
rotating noise or any signs of PTO plate
3 O-ring 10
seizure. If faulty, replace the ball If faulty, retighten the bolts. 4 PTO holder 11 Ball bearing (inner)
bearing. 5 Snap ring 12 Ball bearing 1outer)
4) If the lateral runout on the clutch ENGINE REAR P.T.O. 6 O-ring 13 Oil hole (idler gear)
disc contacting surface of the fly 7 Oil seal 14 Companion flange
1) Check the companion flange and
wheel measured at the time of dis bearing for cracks or other damage.
assembly reaches the repair limit, 1) Reassemble the oil seal to the
If faulty, repair or replace the com P.T.O. holder.
repair or replace the flywheel. panion flange. 2) Install the drive shaft to the com
Maintenance standard 2) Check the oil seal fitting surface of panion flange.
Less than 0.15 mm companion flange for damage. If 3) Assemble the companion flange of
Repair limit 0.18 mm faulty, repair or replace the com item (2) to the P.T.O. holder of
panion flange. item (1).
5) Measure the dimension A. If it 3) Check the tooth surface of the 4) Assemble the O-ring to the drive
exceeds the wear limit, replace the P.T.O. gear for damage or wear. If shaft and then press fit the ball
flywheel. faulty, repair or replace the P.T.O. bearing (outer). And then lock with
Nominal dimension 21.5 mm gear. the snap rings.
Wear limit 19.5 mm 4) Fit the P.T.O. gear and companion 5) Assemble the P.T.O. gear, aligning
flange onto the drive shaft, and the oil hole of the drive shaft with
check each spline for play. If . the oil hole of the P.T.O. gear.
faulty, replace the P.T.O. gear and/
or companion flange.
5) Check the oil seal lip portion for
EFS-018 damage. If faulty, replace the oil
seal.
1/1�
\
bolt.
4) If the eccentricity between the I
1/
crankshaft and flywheel housing \
measured at the time of disassem
bly is faulty, perform centering, I //
,
_/
ASSEMBLY
EFS·0S0
r
and @ as below. 3 99595 25004
Drive in bushings No. 1 and No. 4 (for No. 2)
using cam bush replacer (1) and@. 4 99595 25005
(for No. 3)
99590 25003
5 99597 25001
(Tool kit cam I 99594 Z5000
(for No. 2 and
bush replacer) (for No. 1)
No. 3)
REMOVE INSTALL
EFS-024
"Tp" or "A"
NO. 4 NO. 3
EFS-051
Note
Press fit with the notched part of the
bushing facing the right side of the
block (as viewed from the rear of the
EFS-053 engine) and confirm that the block oil
Liner installed direction
gallery and the bushing oil hole are
2) After replacing the cylinder liner, aligned.
make sure that the inside diameter
out-of-roundness, taper and flange
projection are all within the main CORRECTION OF CRANKSHAFT 2) Grind the crankshaft pin so that the
tenance standards. 1) Grind the crankshaft journal so that clearance between the undersize
the clearance between the undersize bearing shell I.D. and the crank
Note shaft pin O.D. will be within the
Before measuring these, tighten the bearing shell I.D. and the journal
O.D. will be within the mainten maintenance standard. Be sure to
main bearing cap bolts to the specified remove the balance weight before
torque. ance standard.
grinding the pin.
ENGINE PROPER 4-9
k:,,LLL
Maintenance standard the top.
0.05 to 0.12 mm
Clearance between pin 0.0. and
bearing shell 1.0.
Maintenance standard
0 X X X
EPS-33
0.04 to 0.11 mm
EFS-052
Grinding dimension of
· 2) Measure the inside diameter of the
Size identification mark journal (Ref.) Remarks press-fitted bushing and the outside
[mm] diameter of the piston pin. If the
STD Grinding is not needed clearance between them is less than
the maintenance standard, ream the
0.25 U.S. 75.670-75.690 STD: Standard inside diameter of the bushing.
0.50 U.S. 75.420 - 75.440 U.S.: Undersize Maintenance standard
0.03 to 0.05 mm
0.75 U.S. 75.170-75.190
REPLACEMENT OF IDLER
Grinding dimension of GEAR BUSHING
Size identification mark crank pin (Ref.) Remarks 1) Press the idler gear bushing in until
[mm] its end is flush with the· boss on the
front side of the engine, aligning it
STD Grinding is not needed
with the position of the oil hole.
0.25 U.S. 61.675-61.695 STD: Standard Note
0.50 U.S. 61.425-61.445 U.S.: Undersize When the bushing is flush with the
boss on the front side of the engine,
0.75 U.S. 61.175-61.195 dimension "H" indicated in the figure
below will be 1.5 mm.
REPLACEMENT OF FRONT OIL 3) Press the oil seal onto the timing
SEAL AND COLLAR gear case in the same way.
1) Remove the oil seal and collar by Note
tapping or forcing them. Apply a coat of engine oil to the out
2) Using a oil seal and collar replacer side periphery of the oil seal collar.
<f FRONT
(99718 25002), press the oil seal EPS-38
CORRECTION OF FLYWHEEL
Grind or machine the flywheel so
that the runout of the contacting sur Kobelco Engine Parts
face will be within maintenance email: EngineParts@HeavyEquipmentRestorationParts.com
standards. However, the grinding toler
ance is 2 mm. If dimension A exceeds
Phone: 269 673 1638
the wear limit, replace the flywheel
assembly.·
Flywheel depth (A)
Nominal dimension 21.5 mm
Wear limit 19.5 mm
EFS-018
ET14-070A
CYLINDER HEAD AND
5.
VALVE MECH ANISM
EF6-019
�i
:
i!:":
CYLINDER HEAD AND VAL VE MECHANISM 5-1
DISASSEMBLY
CYLINDER HEAD
II 1 Engine slinger (front)
10 2 Push rod pipe
3 Oil pipe
4 Split collar
5 Upper spring seat
6 Inner valve spring
7 Outer valve spring
8 Valve stem seal
9 Lower spring seat
10 Valve guide
11 Head bolt
12 Cylinder head
13 Head gasket
14 Intake valve insert
20
15 Intake valve
16 Exhaust valve insert
17 Exhaust valve
18 Water jet
19 Water jet
20 Engine slinger (rear)
21 Sleeve
22 O-ring
23 Nozzle tube
1) Measure the distance between the SPLIT COLLAR TOOL ROCKER SHAFT
valve head and the bottom surface
of the cylinder.
Note
Carbon should be removed from the
gasketed surface of the cylinder and
the valve prior to measurement.
ERS-104
NOZZLE TUBE
1) Remove the nozzle sleeve using
2) Remove the split collar using a the nozzle holder wrench (99656
split collar tool (99624 25001). 25501 ).
5-2 CYLINDER HEAD AND VAL VE MECHANISM
CLEANING
1) Wash each part with light oil or
clean with steam, them wash in
water and dry thoroughly.
2) Scrape carbon from each part using
fine emery paper or wire brush.
Note
During cleaning, group all parts ac
cording to valve so that the original
2) Using the nozzle tube remover EFS-014 combination can be reproduced at the
(99655 Z5500}, drive out the time of reassembly.
nozzle tube from the bottom side
of the cylinder head.
INSPECTION
CYLINDER HEAD or not water leaks from the water
jacket. If faulty, repair or replace. . : )
1) If the height of the valve measured
prior to disassembly exceeds the Test of condition
specified maintenance standard, in Water pressure 3 kg/cm 2
spect both the valve and valve insert Test time for 5 minutes
for any abnormalrty. If necessary,
replace faulty part(s).
Maintenance standard
Intake valve
1.32 to 1.84 mm 3) Inspect the bottom surface of the
Exhaust valve cylinder head for any indication of
0.82 to 1.34 mm cracking or other damage. If any
Wear limit abnormality is found, repair or re
Intake valve 2.8 mm place the cylinder head.
Exhaust valve 2.3 mm 4} Check the contacting width of the
valve insert and the contact pattern
2) Measure the flatness of the cylinder with the valve. If faulty, repair or
head, and record the results. If the replace.
measurement exceeds the repair Maintenance standard
limit, grind the cylinder head. If Intake
cylinder head flatness has worn be 2.2 to 2.5 mm
yond the wear limit, it should be Exhaust 6) Inspect the water jacket for accu
replaced. 2.0 to 2.2 mm mulation of water scale and rust. If
Longitudinal direction Repair limit 3.5 mm necessary, clean the cylinder head.
Maintenance standard
Less than 0.05 mm
Repair limit 0.20 mm
Wear limit
0.30 mm (tolerance)
Transverse direction VALVE MECHANISM
Maintenance standard 1) Examine the valve spring for breaks
Less than 0.05 mm or other damage. If fau Ity, replace
Repair limit 0.20 mm the spring.
X X
Wear limit ES-85 2) Measure the squareness of the valve
0.30 mm (tolerance) spring, and record the results. If the
ri=-? >j· ,2 j
c -.-
11 0 0.
-.
0J
r
9 J: q
09-0 0 0 0 '._c 0
11: �
�f
]
5) Using hydraulic pump (99570 limit is exceeded, replace the valve
spring.
1•�00'00��6",..jG f Z5000) and water leak test tool as
1...,�-=,..:.__--c-,.--
(JI�
- ,, : •-:• :....�� ..y�·J
� r'
0
(
'J
O ('•
'9-�
C
·�· ,, -.J, � �.'
.I sembly (99561 Z5002), perform Inner and outer
'J
the water pressure test on the cyl Maintenance standard
EF6-022
inder head, and determine whether Less than 2 mm
CYLINDER HEAD AND VALVE MECHANISM 5-3
3) Examine the valve rocker spring 6) Measure the rocker shaft runout,
and inside spring for breakes or and record the resuIts. If the
other damage. If faulty, replace the measured value exceeds the repair
spring. limit, repair or replace the rocker
4) Measure the free length of the shaft.
inside spring and record the results. Maintenance standard E4·14
ES-88
CYLINDER HEAD AND VAL VE MECHANISM 5-5
CORRECTING CYLINDER HEAD 3) Using valve seat grinder, repair the CHECKING AIR TIGHTNESS
Using a surface grinder, grind the seat surface of the valve insert. OF VALVE
lower surface of the cylinder head. Maintenance standard After completing the lapping opera
° °
The amount of grinding should not Intake· 30 00' to 30 30' tion, conduct an air tightness test to
° °
exceed 0.3 mm. The cylinder head Exhaust 45 00' to 45 30' determine whether air leakage occurs
should be replaced if its height exceeds between the valve and valve insert. If
the specified wear limit. air leakage is noted, again lap the valve
and valve insert.
Nominal dimension (B) 90.0 mm
Wear limit (A) 89.7 mm Note
If the contacting width of the valve
VALVE INSERT ANGLE
and valve insert exceeds the specified
wear limit, correct or replace the valve
EP6-10
insert.
Maintenance standard
° °
Intake 29 30' to 30 00' 2) Using a valve insert replacer (99665
° °
Exhaust 44 30' to 45 00' Z5000), cold-fit the exhaust and
intake valve insert to the cylinder
3) After completing the lapping opera head.
tion, wash the lapping compound
away, and then apply engine oil to
the seating surface, and perform
lapping with oil.
4) After oil lapping, coat the contact
VALVE
ing surface of the valve with read INSERT
lead and repeat lappi� operation
in the same manner as previously VALVE
- GUIDE
done with the grinding compound,
and check the condition of the
valve surface. Repeat lapping until
the valve surface is properly cor
rected. EF6-009
5-6 CYLINDER HEAD AND VALVE MECHANISM
Cold-fitting procedure 2) Using the valve guide replacer REPLACING ROCKER ARM
• Keep the valve insert in dry ice for
(99666 ZS000}, drive the valve BUSHING
guide into place until the lower end 1) Support the rocker arm, place a
more than five minutes. Use of al
cohol will improve the cooling ef of the tool just touches the surface presser having an outer diameter of
fect. of the cylinder head. Also check 23 mm against the bushing, and
the valve guide to see that it is drive the bushing out.
Note perpendicular to the cylinder head.
Do not touch cold valve insert and dry Note
ice directly. Note Mark the bushing gap position on the
Before driving the valve guide into rocker arm prior to removing the bush
• Immerse the cylinder head in hot place, clean it completely and apply a ing.
coat of engine oil to it.
water until its temperature exceeds
°
80 C.
• Take out the valve insert and cylin
der head, and fit the valve insert VALVE
GUIDE
into the cylinder head. REPLACER
ER6·112
�.
3) If the clearance between the valve 2) Correctly line up the bushing align
guide and valve stem is less than the ment mark on the rocker arm with
maintenance standard after the the bushing gap, and drive the bush
valve guide is inserted into the ing into the rocker arm.
cylinder head when replacing the
18 valve guide, use a reamer (99662
ZSS00). Note
•
' After driving in the bushing, confirm
Clearance between valve guide
that the rocker arm and bushing oil
and valve stem
ET14-034
holes are aligned.
Maintenance standard
Intake: 0.02 to 0.05 mm
Exhaust: 0.05 to 0.09 mm
Outside diameter of the reamer
+0.012
r/>9
REPLACING VALVE GUIDE +0.006
1} Using a valve guide remover (99667
ZS00O), drive out the valve guide
from the bottom side of the cylin
der head.
OIL HOLE
·, VALVE EF6-025
GUIDE
REMOVER
3) Measure the inside diameter of the
press-fitted bushing and the outside
VALVE diameter of the rocker shaft. If the
__., INSERT
clearance between them is less than
VALVE
the maintenance standard, ream the
GUIDE inside diameter of the bushing.
Maintenance standard
EP6·28 0.02 to 0.06 mm
EF6-011
CYLINDER HEAD AND VALVE MECHANISM 5-7
CYLINDER HEAD
REASSEMBLING
11 12'.
2 9. 30, (3_;)
EF6-026
J
8 Nozzle holder dust seal 18 Inside spring 28 Intake valve
9 Nozzle holder sleeve 19 Cylinder head 29 Exhaust valve insert
10 Nozzle holder ass'y 20 Valve stem seal 30 Exhaust valve
31 Exhaust valve guide
VALVE
STEM SPLIT COLLAR TOOL ROCKER SHAFT
SEAL
1) Insert rocker shaft bracket A onto
the rocker shaft and lock the shaft
VALVE to the bracket with the stopper
GUIDE
bolt.
Note
Install the rocker shaft to the bracket
E F6-017 so that the oil hole in the rocker shaft
ER6-104
can face downward.
Notes
6) Measure the distance between the BRACKET A
1. Use new valve stem seals.
valve and the lower surface of the /
2. Always assemble the valve stem
cylinder head.
seal by pushing the seal in by hand.
Never drive it in with a hammer, Distance between valve and
etc. cylinder head
Maintenance standard
3) Insert the intake and exhaust valves
Intake 1.32 to 1.84 mm
respectively to their original posi EF6-027
Exhaust 0.82 to 1.34 mm
tions.
5-8 CYLINDER HEAD AND VAL VE MECHANISM
EFS-02B
NOZZLE TUBE
1) Apply a thin coat of soapy water
to the O-ring and install the O-ring
to the nozzle tube at 8 mm from
the upper end so as to prevent
cutting and transformation when
driving in the nozzle tube.
,.
:•; '.
Jc
;·11
The lubricating system consisting of an oil pump, oil cooler, short valve as
sembly, oil filter and other compornents, and flow of oil after the main
gallery are illustrated in the lubricating system diagram.
I
GEAR TRAIN
IDLER GEAR
OIL PRESSURE
SWITCH
OIL COOLER\
SHORT VALVE\
REGULATOR
RELIEF VALVE
VALVE
i TO OIL PAN
II
,1, EF7·013
i
"dI
1 i ·j J1 'Iii '1
1/:,:11,I
1 •. :.
,
r,I.!·I
Li:' Valve opening pressure
Maintenance standard
Oil pump relief valve
10.5 to 11.5 kg/cm2
Oil filter short valve
0.8 to 1.2 kg/cm2
Oil cooler short valve
2.8 to 3.2 kg/cm 2
Regulator valve
4.3 to 4.7 kg/cm2
Oil jet cut-off valve
1.8 to 2.2 kg/cm 2
Oil pressure switch operating
pressure
Maintenance standard
0.4 to 0.6 kg/cm2
6-2 LUBRICATION SYSTEM
OIL PUMP
DISASSEMBLY
1 Nut
2 Lock washer
3 Pump drive gear
4 Gasket
5 Oil pump case
6 Gasket
10 7 Key
8 Drive shaft
9 Pump gear (drive side)
10 Pump gear (driven side)
11 Relief valve
12 Valve spring ·:\ii
13 Gasket '.!!.lV
14 Plug
15 Oil pump cover
16 O-ring
17 Lock washer
18 Bolt
19 O-ring
20 Lock washer
21 Bolt
22 Lock washer
23 Bolt
24 Lock washer
25 Bolt
26 Outlet pipe
26 EF7·014
REASSEMBLY
1 Lock nut
2 Lock washer
3 Oil pump drive gear
4 Key
5 Case
6 Key
A·A SECTION 7 Drive gear
8 Drive shaft
9 Driven gear
10 Bushing
11 Driven shaft
12 Cover
13 Relief valve
14 Valve spring
A B 15 Gasket
16 Plug
B-B SECTION
EF7-015
6-4 LUBRICATION SYSTEM
Before reassembling, apply clean en Clearance between pump gear Repair limit 0.20 mm
gine oil to each rotating or sliding sur and cover Pump gear backlash
face. Maintenance standard Maintenance standard
1) Install the relief valve, valve spring, 0.04 to 0.10 mm 0.16 to 0.27 mm
gasket and plug. Repair limit 0.15 mm Repair limit 0.50 mm
2) Insert the drive and driven gears Clearance between pump gear Cover tightening torque
into the case, then ensure that each tooth end and case 1.6 to 2.0 kgm
clearance and backlash measured is Maintenance standard
within the repair limit, and install 0.04 to 0.10 mm 3) Install the pump drive gear.
the cover through the packing.
EF7·016
1) Remove the water outlet pipe. 4) Perform a water pressure test on 7} Examine the valve spring for breaks
2) Remove the cover. the element. If faulty, replace the or aging. If faulty, replace the short
3) Remove the element. element. valve assembly.
4) Remove the plugs, valve springs, 8) Measure the strength of the valve
Test standard
short valve and regulator valve. Direct hydraulic pressure of
spring, and record the results. If
Loosen the short valve assembly cap, 10 kg/cm2 to the element to
faulty, replace.
and remove the valve spring and short check for any sign of water Maintenance standard
valve. leakage. Short valve 9.42 kg
(When compressed to 54.4 mm)
CLEANING AND INSPECTION Regulator valve 13.5 kg
(When compressed to 44 mm)
1) Use a caustic soda solvent to clean ATTACHMENT
the inside of the oil cooler housing
and the exterior of the element
REASSEMBLY
completely removing scales or any When reassembling, be sure to replace
other foreign matter. Then, rinse all rubber rings, gaskets and packing.
and dry completely. Install the short valve assembly.
HYDRAULIC PUMP
2) Completely remove carbon, sludges, (99570 25000) Note
etc. Which may have accumulated Apply a coat of engine oil to the slid
:1,,. 1.11
ER7-108
in the element's oil passage. ing surface of the short valve, and en
3} Always clean each part of the short
(ii
5} Check the housing for damage. I( sure that the valve itself moves
valve assembly with cleaning sol smoothly without binding.
faulty, repair or replace.
vent, and then rinse and dry com
6) Examine the condition of short
pletely.
valve and valve seat contacting sur
Note face for damage or uneven wear. If
Remove all traces of the gasket from faulty, replace the short valve as
the pump body. sembly.
OIL FILTER
FULL-FLOW & BYPASS OIL FILT �
�
DISASSEMBLY
� �
®-
I-----IL4
Centrifugal bypass oil filter and full flow oil filter EF 7-017
6-6 LUBRICATION SYSTEM
fr/_l
I/
V
EF7-018
Depth type bypass oil filter and full flow oil filter
Note CLEANING AND INSPECTION 4} Check for bent center bolt and
Drain oil form the filter prior to dis clogged oil passage. If necessary,
1) Clean all the disassembled parts
assembling. repair or replace.
except those made of rubber with
cleaning fluid, then wash with 5) Check for damage or excessive wear
1) Disassemble both the full-flow and on the contacting surface of each
water and dry them thoroughly.
bypass filters, beginning with their valve and valve seat. If necessary,
2) Inspect the element for damage. If
center bolts. repair or replace.
it is damaged, it should be replaced
2) Remove the valve spring and short 6) Measure the strength of each valve
as a unit. Also replace the element
valve. spring, and record the results. If
when the next specified inspection
period corresponds with the re faulty replace each spring.
placement period. Strength short valve spring
3) Check the body and cover for dam Maintenance standard
age, cracks or weakened welded 1.04 to 2.04 kg
joints. If faulty, repair or replace. (When compressed to 57.7 mm)
REASSEMBLY
When reassembling, be sure to replace
all the packings with new ones.
1 lock nut
2 Case
3 Spindle
4 Rotor assembly
5 O-ring
6 O-ring
7 Clamp assembly
8 Body
9 O-ring
10 Center bolt
11 Element
12 Case
13 Washer
14 Spring
15 O-ring
16 O-ring
17 Plug
18 Plug
19 Gasket
20 Spring
21 Valve
EF7-019
1 Center bolt
2 O-ring
3 Spring
4 Plate
5 Rubber seal
6 Element
7 Filter case
8 O-ring
9 Gasket
10 Filter cover
11 O-ring
12 Element
13 Center bolt
14 Washer
15 Spring
16 Filter case
17 O-ring
18 Drain plug
:1:;
:w
19 O-ring
20 Plug l1il
21 O-ring
22 Spring l:1i
·,;'I
23 Short valve 11!_;
:/ Ji
[:1 1 i!i!1
EF7·020
Depth type bypass oil filter and full flow oil filter
1) Install the short valve, valve spring Center bolt tightening torque 3) Install the drain plug through the
and plug. 4.5 kgm O-ring.
2) Insert the spring, washer, element,
etc. into the case. Then install the Note Tightening torque 2.3 to 2.7 kgm
case to the filter cover through the Apply a coat of engine oil to the slid
center bolt. ing contact of the short valve, and en
sure that the valve moves smoothly
without binding.
LUBRICATION SYSTEM 6-9
:, i
7. COOLING SYSTEM
D '
EFS-003
WATER TANK
/:
,,
RADIATOR
EFB-004
',
!l:
:r:
!':
' I
·!:i.,
·!
,.
:;:
7-2 COOLING SYSTEM
WATER PUMP
EXTERNAL EXAMINATION of the seal assembly. If the seal is 2} Check for interference of the im
AND CORRECTION damaged, it should be replaced. If peller with the vehicle body. If the
traces of grease leakage are noticed, bearing's axial or radial play is ex
1} If any trace of water leakage is
check the condition of the ball cessive, replace the two ball
noticed at or around the water
bearing. If necessary, replace faulty bearings as a unit.
drain hole on the underside of the
parts.
vehicle body, check the condition
DISASSEMBLY
/�
� 1 Flange
2 Snap ring
3 Ball bearing
4 Spacer
5 Ball bearing
6 Shaft
7 Body
8 Grease nipple
9 Seal assembly
10 Impeller
11 Packing
12 Cover
13 Screw
v
EFB-005
1} Remove the cover and press out the 2} Remove the snap ring and press out
flange. the shaft assembly from the impel
ler side and remove the impeller.
EFB-006 EFS-008
CLEANING AND INSPECTION 1) Press in the ball bearings and spacer 4) Press fit the flange.
into the shaft. At this time, press fit
1) Remove water scales and rust from
the ball bearing (impeller side) fully
the body and impeller, and clean all
until it contacts the bearing stopper
the parts except those made of rub
of the shaft.
ber with cleaning fluid, then wash
with water and dry thoroughly.
2) Check the impeller and body for
rust, corrosion or scratches. If faul
ty, replace.
3) Check the seal assembly for
damage. If faulty, replace.
4) Measure both the inside diameter of
the impeller and the outside diame
ter of the shaft to see if they are
within the specified maintenance
standard values.
EFS-012
If either part is beyond the speci
fied values, replace the pulley and/
or shaft.
5) Using a press, install the impeller
Maintenance standard while measuring with a feeler gauge
Shaft OD so that the clearance between the
13.03 to 13.05 mm impeller and the body in within the
Impeller ID maintenance standard.
12.99 to 13.01 mm EFS-010
Maintenance standard
Fitting tolerance
:I
2) Press the shaft assembly into the 0.30 to 0.80 mm
0.02T to 0.06T mm
body and install the snap ring.
Remarks
T = Tight fit Note
Be sure to apply grease to the outer
5) Inspect the shaft for bending, wear periphery of the shaft assembly.
and damage to the threaded por
tion. If faulty, replace or repair.
6) Check the ball bearing's sealed plate
,, for noise, play, thermal discolora
i'I
11I
tion, or damage. If faulty, replace.
'I REASSEMBLY
iI :11:,'I 1 11
I
.,,11··
6) After assembling the water pump,
j."
apply grease through the grease fit
ting.
EFS-011
THERMOSTAT
REMOVAL Valve opeing temperature
°
76.5 C
Wear limit
° STIRRING BAR
Less than 71.5 C,
° THERMOMETER
More than 81.5 C
°
82.0 C
Wear limit THERMOSTAT
° HOLDING PLATE
Less than 77.0 C.
°
More than 87.0 C
°
88.0 C
EFS-014
Wear limit
°
Less than 83.0 C
1 Water manifold 4 0-ring °
More than 93.0 C
2 Gasket 5 Water outlet
3 Thermostat 6 Bolt
Valve lift
°
76.5 C
-
Maintenance standard
-.�",;,; ----- -
°
Remove the water outlet and remove More than 10/90 mm/ C
/ _./
FLUSHING THE COOLING 4) Remove any dirt and dust accumu Water tank cap and radiator cap
SYSTEM lated between the radiator core fins
Measure the operating pressure of the
and tubes.
1) Pour cleaning solvent into the cool valve. If the measured value exceeds
ing system, and allow the engine to the specified value, replace.
idle for approximately 30 minutes.
INSPECTION
Radiator cap
Note Radiator unit and water tank unit More than 1.1 kg/cm 2
Close the radiator shutter (if so equip 1) Check the exterior for dents, cracks 0.8 to 1.0 kg/cm2
ped) in order to maintain the tempera and other damage. If faulty, re Wear limit
ture of the cooling water above the place. More than 1.1 kg/cm2
opening temperature of the thermo 2) Plug all openings with wooden taps, Less than 0.7 kg/cm 2
stat. dip the entire radiator and tank Water tank cap
unit into a container of water, and Maintenance standard
direct the specified air pressure to 0.6 to 0.8 kg/cm2
2) Thoroughly drain the flushing fluid,
the water to determine if air leak Wear limit
and fill the radiator and engine with
age is noticed. If air leakage is no More than 0.9 kg/cm 2
clean tap water, and run the engine
ticed, repair or replace the radiator Less than 0.5 kg/cm 2
again for additional flushing.
3) Flush repeatedly with tap water un and/or tank unit.
til the water drained from the cool Specified air pressure
ing system is completely clean. 0,5 kg/cm2
COOLING SYSTEM 7-5
Antifreeze density
Check the density of the antifreeze,
using a density tester. If the density is
too low, add antifreeze until the speci
fied density is reached.
Specified density
45 to 60%
ESB-11
ESS-12
'
1) Check the cooling fan for dents, tion, cracks and damage. If faulty, shaft from the bearing support.
bending, cracks and damage. If replace.
·faulty, repair or replace. 4) Check the tension pulley for de
2} Check the crank pulley and V-belt formation, cracks and damage. If
for deformation, cracks and dam faulty, replace.
age. If faulty, replace.
DISASSEMBLY
Fan pulley bracket assembly
EF8·016
Idler pulley assembly 2) Check each part for damage and Tension pulley assembly
cracks. If faulty, repair or replace.
3) Check the ball bearing for excessive
play, noise, uneven rotation, dis
coloration, uneven wear and
damage. If faulty, replace.
REASSEMBLY
Always discard old oil seals and install
new ones, then apply a coat of grease
to their sealing lips. Aslo coat the ball
bearing with engine oil.
EFS-018
'
the pulley front edge to the bracket
rear edge is 86.5 mm.
EFS-019
1) Clean all parts except those parts 3) Insert the bearing support and
made of rubber with cleaning fluid, install the snap ring and nut.
then wash with water and dry 4) Install the screw plug and con 3) Install the grease nipple and apply
thoroughly. nector, then apply grease. grease.
8. FUEL SYSTEM
'·;.!·].
EF9-56
SEPARATING EACH
COMPONENT
Removing the timer
1) Lock the timer coupling with the
special wrench (157916-4320) and
L-type handle, remove the round EF9-061
EF9·012
EF9-013
2) Remove the timer bracket.
8-2 FUEL SYSTEM
RSV
4) Remove the cover from the
housing, slide the plate spring of 4) Remove the idling sub-spring.
the link connected to the control (RSV)
rack down from the top with a
screwdriver as shown in the figure
EF9-065
and disconnect the link from the
hole at the front end by sliding the Removing the governor
link to the left and right
(with the type RFD, RSV, governor) ,jl,
. .' ,
ER9·225
EF9·063
5) Remove the start spring from the 5) Loosen the lock nut with a socket
spring eye with needle noosed wrench (RFD ... 157914-0100,
pliers. Then remove the spring eye. RSV ... 157914-0500) and remove
the idling spring assembly.
EF9-064
6) Remove the round nut and spring
washer using the socket wrench
(157915-0100).
3) Remove the closing cover. 6) Remove the governor cover.
ER9·132
FUEL SYSTEM 8-3
7) Remove the starting spring from 4) Remove the cap nut fastening the
the spring eye, and floating lever idling spring assembly with the
link from the control rack. Then wrench.
remove the governor assembly.
EF9-101
EF9-107
EF9-111 EF9-115
10) Extract the governor shaft to 14) Remove the snap ring fastening 18) Remove the U-Type lever.
gether with the spring seat out of the sensor lever with long-nose
the governor housing. pliers.
EF9-110
17) Remove the guide plug on the
13) Remove the nut from the sensor opposite side of the full load setting
lever. lever with wrench. EF9-014
FUEL SYSTEM 8-5
OISASSEMBL Y
EF9·066
1) Remove the screw plug at bottom 5) Loosen the setting screw tightening
of the housing using the L-type the governor housing and remove
handle {157910-1120). the housing from the injection
pump housing by tapping the left
and right sides of the housing
lightly with a wooden mallet.
>-:: EF9-070
TAPPET
INSERT EF9-017
':'''!:;,
7} After pulling the plunger spring
holder, insert the tappet clamp
(157931-6120) from the bearing EF9·072
insertion hole of the pump housing 11) Remove the delivery valve holder
and pull the tappet out. and delivery valve spring.
EF9-068
EF9-018
EF9-020
8) After removing the tappet, insert
the plunger insert (157921-4120) 12) Remove the delivery valve and
EF9·069 from the screw plug hole and pull gasket by threading the delivery
the plunger with the lower spring valve extractor (157920-0320) onto
seat. the delivery valve.
FUEL SYSTEM 8-7
ES9-36
Tappet ES9-36
Check the tappet, roller pin, and 1 Bearing cover 2) Fit the washer and shim plate to
needle rollers, looking for wear, 2 Oil seal the camshaft and force the inner
scoring, and other defects. If defects 3 Outer race race into position with a press.
4 Extractor
are found, replace it with a new
5 Nut
tappet.
Tappet assembly
Control rack and control sleeve 2) Pull and replace it with a new oil
Remove the tappet guide, pull the
1) Check the control rack, making seal.
roller pin and remove the roller
sure that it is straight and that the 3) Fitting bearing outer race into
bushing and roller.
teeth are not damaged. If defects governor housing
Loosen the adjusting nut and remove
are found, repair or replace the Use the two-piece guide, as shown
the adjusting bolt nut from the tappet.
subject part. in the figure, to press the outer race
2) Check the clearance of the control into the bearing hole provided in
sleeve and plunger collar and re the bearing cover. The guide is a
place when the wear limit is ex special tool (157925-8120).
ceeded.
Maintenance standard
0.03 to 0.08 mm
Repair limit 0.12 mm
Springs
When plunger or delivery spring de
fects are evident, replace the subject
spring.
BEARING COVER
EF9·196 REASSEMBLY
PART REPLACEMENT Before assembling the fuel injection
pump, clean parts thoroughly and
Oil seal and bearing outer race apply a thin coat of engine oil to
1) Use the outer race extractor rotating and sliding parts.
(157925-0120) and remove the 1) Mount the pump to the universal
outer race from the bearing cover. Inner race of camshaft bearing vice.
Install the outer race extractor and 1) Place the inner race extractor 2) Assemble the plunger barrel.
tighten the nut to force the flared (157925-4120) over the inner race Assemble the plunger barrel by
portion of the tool between the of the bearing and pull the inner aligning the knock pin driven into
outer race and the oil seal. Hold the race from the camshaft. At the the housing and the groove of the
bearing cover and tap the- knurled same time remove the shim plate barrel with the barrel escape hole
portion of the tool with a hammer. and washer. facing the front of the housing.
FUEL SYSTEM 8-9
EF9·072
EF9-079
EF9-071
EF9-080
EF9-019
delivery valve holder. is the same at the left and right. EF9-082
8- 10 FUEL SYSTEM
11) Assemble the tappet to the pump of the bearing. In this case, first
housing using the tappet clamp measure the end play of the cam
(157931-6120) and tappet insert shaft with the measuring device
(157921-0120) the same as when and then adjust to 0 to 0.02 mm
disassembling. Push the tappet itself dividing the end play equally at
forcefully and install the plunger the front and rear with the shim.
spring holder.
Maintenance standard
EF9·069 0 to 0.02 mm
Repair limit 0.1 mm
TIMER SIDEQ
EF9·083
' ·I . EF9-014
iii ;
lock the pin with the plate spring.
Then install the governor cover.
ii··
:i�
4) Install the idling spring assembly Installing the governor 5) Install the sensor lever.
with the socket wrench (RFD ... (with the type RLD governor)
157914-0500, RSV ... 157914- 1) Install the start spring mounting use
0100). spring eye to the governor housing.
EF9-014
EF9-110
3) Install the full load control shaft 7) Fitting the governor to the pump
EP9·104
and spring. Have the control rack side of
supporting lever pulled out toward
the governor housing, and then
mount the sleeve. Next, admit the
ball joint {on control rack side) into
the slot of the floating lever. This
sequence makes it easier to attach
the governor cover assembly to the
pump.
ER9-225
6) Install the closing cover together 4) Install the U-type lever, guide plug,
with the O-ring or gasket. full-load set lever, etc.
EF9-119
FUEL SYSTEM 8- 13
GUIDE SCREW
EF9·120
1) Place the fuel feed pump in a vice, • Apply a wrench to the Hex Check valve
remove the plug, gasket and pull section at the bottom of the 1) If the valve seat is scored or ex
out the piston spring and piston. cylinder and remove the priming cessively worn, replace the check
pump assembly. valve with a new one.
• Remove the check valve spring 2) If excessively worn or broken, re
and check valve. place with a new spring.
� Piston
1) If the periphery of the piston is
excessively worn or scored, replace
the piston with a new one.
2) If excessively worn or broken, re
place with a new spring.
Clearance between housing and
EF9-086 piston
2) Removing the tappet
EF9-088 Maintenance standard
• Place the feed pump in a vice
0.03 to 0.06 mm
upside down.
Wear limit 0.15 mm
• Remove the piston retaining INSPECTION
snap ring and pull out the tappet
Feed pump housing Tappet
and push rod.
1) Check valve seat contact test 1) If the periphery of the tappet is
A steel seat is inserted in the check worn or scored, replace it with a
valve in the fuel feed pump new one.
housing. 2) If the inside or outside is damaged
When this contact of this seat is or excessively worn, replace the
improper, the oil feed capacity will tappet roller with a new one.
decrease and the· pump housing Roller and pin clearance
assembly must be replaced (with Wear limit 0.3 mm
the push rod).
2) The push rod hole
If the push rod hole is excessively
EF9·087
worn, part of the fuel from this
area may enter the fuel injection
pump camshaft chamber.
3) Disassembling the priming pump When the push rod hole is worn
It is recommended that the priming excessively, replace the housing and
pump not be disassembled unless push rod.
the rubber seat in the piston part of Then ensure that resistance is en
the pump has becomes defective or countered when the thumb is
the piston sized or rusty. applied to the push rod.
FUEL SYSTEM 8- 15
REASSEMBLY
EF9·089
· .: I i
, I
·Jj
..
between the pump housing and the COMPRESSED AIR
2
2 kg/cm (28.47 psi)
push rod is less than that of millet CYLINDER
grains.
When larger bubbles continue to
escape, replace the feed pump.
FEED PUMP
EP9-118
DISASSEMBLY
EF9-090
)
EF9-094
' ....
taking care not to cause damage to 1 Control lever 4 Snap ring
draw the speed adjusting bolt in the 2 Lever shaft 5 Sliding lever
the chrome plated surface at the tip 3 Nut
governor cover.
.I'",."l·
IHI of the shifter.
Flyweight assembly
ii
•I
I 1) Clamp the flyweight assembly in a
I
vise. Use the governor spring ex
i
,-·-·
,:::_·-·
">'"'"' ·-· SLEEVE
tractor to remove the adjusting nut
Ir-,.,__,_.....,._.,._
(with tab) securing the governor
_,__,,_...,___,,...-, i
springs. Then remove the outer
spring seat and the governor springs
l. ____ j
(inner, outer, and central).
EF9-092
EF9·134
EF9·093
6) Remove the lever shaft nut and
4) Remove the snap ring inside the lock washer and pull the control
sleeve which connects the sleeve lever assembly out of the cover
and the shifter of the guide lever housing and the sliding lever, toge
assembly using needle nosed pliers, ther with the lever shaft, into the 1 Knock pin
and remove the shifter and sleeve. inside of the cover housing. 2 Bell-crankshaft
8- 18 FUEL SYSTEM
3) Bring the tool of a press into con ly, the governor must be checked with 3) Confirm that the dimension from
tact with the bell-crankshaft and a pump tester. the end of the bushing with the
force out the shaft to complete sleeve assembled to the flyweight to
governor disassembly. This step REASSEMBLY the end of the governor housing is
may be accomplished by using a within the 33 to 33.4 mm range. If
punch hammer. Flyweight assembly not within this range, adjust to
Assemble in reverse sequence of dis within the prescribed limits by in
assembly. The only requirements are creasing or decreasing the shim be
insuring that clearances conform to tween the shift and sleeve bushing.
the maintenance standards and observ Note
ing the following cautions. Measure the above dimension with the
The flyweights have been machine flyweight lifted fully.
balanced. Do not use the flyweights of
another governor. Be sure to replace it
as a set.
(!:)
Sleeve points.
1) Assemble the flyweight assembly to l:!;
::;,
Inspect the contact surfaces and re the camshaft with the round nut ";!,
place when damaged, excessively and a lock washer.
,,,:
i:i 1
worn, discolored, etc. :;,ii
Round nut tightening torque ilI!�
:f!I
'
Wear is accelerated if the level of 2) Press the plate bearing correctly in
lubricating oil in the governor case is the sleeve and force the bushing
low. If wear is evident, replace the into the shifter.
flyweight assembly. EF9·096
Check the pin and bushing play and 1 Governor housing 3 Shim fill!!,\
2 Flyweight
replace as an assembly when play is
excessive.
f. :::-:,.--·7
Flyweight pin and bushing clearance.
Maintenance standard
I. I 4) Assemble the tension lever and
I
PLATE
speed adjusting bolt to the governor
I
0.02to 0.05 mm BEARING
Wear limit cover. At this time, insert the pin
0.08 mm press fit to the tension lever into
L_ __ _
the groove at the top of the sliding
Each lever
SLEEVE lever.
Check the tension lever, speed setting
lever and guide lever hole and pin
clearance and replace of repair to with
in the maintenance standard when the
play is excessive.
Tension lever, speed setting lever,
guide lever hole and pin clearance.
Maintenance standard
0.02 to 0.09 mm
Repair limit SHIFTER
0.2mm
Governor springs
Visually check the springs, making
0 SHIM
EF9-097
the springs are not weak or contacting 5) Install the governor spring to the
each other. To determine whether or speed setting lever and install to the
not the governor is functioning proper- EF9-135 tension lever.
FUEL SYSTEM 8- 19
EF9-098
TI
DISASSEMBL V
EA9·182
RFD governor
1 Gasket 17 Bracket 33 Sleeve assembly 49 Bushing
2 Governor housing 18 Screw 34 Shim 50 0-ring
3 Lever assembly 19 Gasket 35 Set bolt 51 Snap ring
4 Plug 20 Governor cover 36 Woodruff key 52 O•ring
5 Gasket 21 Plug 37 Damper spring 53 Closing cover
6 Spring eye 22 Snap ring 38 Nut 54 Sub spring
7 Starting spring 23 0-ring 39 Cap nut 55 Nut
8 Guide lever assembly 24 Bushing 40 Gasket 56 Gasket
9 Guide lever collar 25 Plug 41 Lever shaft 57 Cap nut
10 Floating lever link 26 Plate 42 Sliding lever 58 Control lever
11 Snap ring 27 Tension lever 43 Snap ring 59 Shim
12 Tension lever 28 Plug 44 Lever 60 0-ring
13 Idling spring assembly 29 Woodruff key 45 Washer 61 Bushing
14 Nut 30 Flyweight assembly 46 Collar
15 Swivel lever 31 Lock washer 47 Shim
16 Governor spring 32 Round nut 48 Oil seal
8-20 FUEL SYSTEM
Jj; ii:!:
7 Gasket Plug Gasket
8 Governor housing 40 Tension lever 70 Gasket 101 Damper spring
9 Plug 41 Idling spring assembly 71 Tension lever shaft 102 Nut 11Fi 1 ::
10 Bolt 42 Nut 72 Plug 103 Gasket
11 Spring eye 43 Cotter pin 73 Shim 104 Cap
12 Bolt 44 Shim 74 0-ring 105 Cover
13 Starting spring 45 Link 75 Bushing 106 Lock washer
16 Swivel lever 46 Snap ring 76 0-ring 107 Bolt
17 Governor spring 47 Shim 77 Snap ring 108 Gasket
18 Limiter 48 Shim 78 Control lever 109 Plug
19 Gasket 49 Cotter pin 79 Shim 110 Nut
20 Floating lever link 50 Bolt 80 Woodruff key 111 Screw
21 Floating lever 51 Snap ring 81 Collar 112 Cap
22 Cotter pin 52 0-ring 82 Shim 113 Nut
23 Pin 53 Bushing 83 Bolt 114 Gasket
24 Lever 54 Plug 84 Control lever 115 Bolt
25 Lock washer 55 Plain washer 86 Shim 116 Cap
26 Cotter pin 56 Shim 87 Oil seal 117 Gasket
27 Adapter 57 Spring 88 Bushing 118 Nut
28 Gasket 58 Push rod 89 Governor cover 119 Idling sub spring
29 Bolt 59 Lock washer 90 Bolt 120 Bolt
30 Flyweight assembly 60 Gasket 91 Set screw 121 Gasket
31 Woodruff key 61 Diaphragm 92 Nut 122 Nut
32 Lock washer 62 Gasket 93 Nut
FUEL SYSTEM 8-21
ER9-235
EP9-130
.,
ER9-236
ER9-237
INSPECTION
Inspect the parts for cracks, damage,
abnormal threads, rust, etc. and repair
or replace when faulty. Moreover,
never re-use O-rings, gaskets and other
consumable parts, replace them in
stead.
Inspection points for each main part
are given below.
Governor spring
Check the governor spring for damage,
mutual contacting of the spring and EP9-135
broken springs.
However, judge the quality by per
forming a governor test with a pump 2) Insert the shim and collar to the 5) Install the governor spring between
tester. swivel lever shaft. the swivel lever knuckle and the
tension lever, installing the tension
lever in the governor cover.
REASSEMBLY
Boost compensator {If so equipped)
1) Install the push rod to the lever.
2) Install the spring, diaphragm and
lock nut.
EP9-132
Note
Measure the above dimension with the
flyweight lifted fully.
Maintenance standard
RSV 19 mm
RFD 33 to 33.4 mm
EP9-127
��
EP9-136
8) Insert the tension lever shaft 10) Install the idling spring in the
through the tension lever to the tension lever. At this time, make
guide lever and secure the bush to sure that the distance between the
the governor cover. tension lever end and push rod end
is 1.5 ± 0.1 mm and secure the
spring with the lock nut. (RSV)
EF9·096
1 Governor housing
2 Flyweight
'd 3 Shim
7) Install the sleeve assembly together 9) Install the bracket and tighten the
with guide lever assembly into the bolts to the governor housing and
governor cover and install the float
plug. (RFD)
ing lever to the sliding lever and
boost compensator link (If so
equipped).
8-24 FUEL SYSTEM
DISASSEMBLY
EF9-127
EF9-121
8) When the torque cam is to be re
placed, extract the snap ring with
the long-nose pliers.
2) · Remove the guide screw together EF9-124
with the lock nut out of the gover
nor cover. 5) Ex tract the shaft.
EF9-128
EF9-126
EF9·123 EF9·129
7) Extract the guide lever together
with the bushing. Extract the 10) Extract the lever assembly to the
cancel spring at the same time. inside of the governor cover.
8-26 FUEL SYSTEM
Governor spring
Check the governor spring for damage,
mutual contacting of the spring and
broken springs.
EF9-130 However, judge the quality by per
forming a governor test with a pump
11) The lever assembly consists of the EF9-136 tester.
parts as shown in the figure and is
connected by the snap ring.
INSPECTION REASSEMBLY
Tension lever
1) Abnormal abrasion or seizure in the
EF9-131
shifter pin
2) Abnormal abrasion or seizure in
EF9-136
12) When the sleeve replacement the tension lever shaft portion
becomes necessary, remove the 3) Presence or absence of the play in i•."
2) When the shifter is-assembled to th� :
snap ring and extract the pin. !. :
the governor spring sheet. sleeve assembly, the sleeve is press !':::<
4) Presence or absence of the play or ed against the flyweight holder so
seizure in the pin for driving the that the lift of the flyweight be
torque cam. comes the state of O and it is so
adjusted that the size L 1 from the
Guide lever and rack connecting link governor cover adhered surface· to
Presence or absence of abnormal the center of the pin hole of the
abrasion or seizure in the ball joint shifter may be maintenance
EF9-132
portion. standard by means of the adjusting
shim.
13) Remove the snap ring connecting Governor cover Maintenance standard
the sleeve and the bearing with the 1) Presence or absence of abnormal 28.8 to 29.2 mm
long-nose pliers. A functional difficulty will occur if
abrasion or seizure in the bush of
the tension lever shaft portion. the dimension L 1 is set to take a
2) Scratch of the oil seal in the control value off the specification:
lever shaft portion • Too large a value of L 1 causes
the flyweights to open apart too
Floating lever wide, making the slider come off
the sleeve to rub and wear the
Presence or absence of abnormal
contacting surface of the sleeve.
abrasion in the fork portion
This wear is evidenced by a
surface offset.
Sensor lever
Presence or absence of abnormal • To small a value of L 1 prevents
abrasion in the fork portion or the the flyweight to move for
claw portion making the maximum lift.
FUEL SYSTEM 8-27
9) Install the plug to the tension lever 10) Connect the torque cam to the
shaft ends. rod of the tension lever.
After the plug of the tension lever 11) Install the guide screw and lock
shaft is pressed in the governor nut.
cover, coat the periphery of the 12) Install the governor shaft, spring
plug with sealing agent. Unless seal seat, springs and lock nuts.
ing agent \s used, the lubricating oil 13) Install the idling spring and lock
may leak out. nut.
L, = 29t0.2
EF9-137
TIMER
:j
.:. I DISASSEMBL V
,;i
J,;
;i
I'
!i
EF9-130
EF9·139
8-28 FUEL SYSTEM
EF9-144
EF9·147
5) Remove the lock plate, adjusting
EF9-142 shim and thrust washer.
8) Remove the adjusting shim from
the hole at the pin part of the timer
2) Place the timer assembly into the
flange.
base and align the hole of the
flyweight holder with the pin of the
base.
3) Remove the 6 bolts and lock
washers and remove the injection
pump drive gear.
INSPECTION
Flyweight and flyweight holder pin
EF9-145 Check the clearance between the
flyweight and the flyweight holder
6) Mount the thrust bushing
pin. If either part is excessively worn,
(157924-1900) to the threaded part : i
replace it.
of the bushing guide, compress the
spring with the special wrench Timer spring
(157916-4320), and remove the
timer flange by prying with a lever Check the timer spring. When defects
while loosening the thrust bushing. are evident, replace the spring..
EF9·146
FUEL SYSTEM 8-29
i:IEASSEMBLY
TIMER
THRUST WASHER SPRING
ADJUSTING
SHIM
NUT
FLYWEIGHT DRIVE
HOL.DER GEAR
TIMER
FL.ANGE
EF9·148
1) Clamp the base and bushing guide 3) Insert the shim into the hole at the Note
in a vice and place the flyweight pin part of the timer flange. Confirm that the springs are entered
onto the base by aligning it with 4) Cover by matching the timer flange into each pin hole of the flange and
the pin hole of the base. mark and direction of the key holder fully.
groove of the flyweight holder,
hook the special wrench to the
flange hole and install the thrust
bushing to the threaded part of the
bushing guide.
ii
l.i
II
I:
:1
1,
11
1!
i
EF9·149
;,]
2) Coat the hole of the flyweight with
grease, install to the flyweight
holder, insert the timer spring EF9-152
support (157932-0200) at the
bottom of the spring and place on
the flyweight. 6) Insert the thrust washer and lock
plate without the adjusting shim
EF9-151
entered and tighten with the nut.
5) Turn the special wrench in the 7) Measure the lock plate and thrust
direction in which the spring is washer clearance with a thickness
compressed, thread in the thrust gauge, select the adjusting shim so
bushing and remove the spring that this clearance becomes speci
supporter. Next, insert the spring fied value and insert the shim
into the hole of the flange with a between the thrust washer and lock
lever and install the flange com plate.
pletely by threading in the thrust
bushing fully. Maintenance standard
0.02 to 0.10 mm
8-30 FUEL SYSTEM
EF9-154
EF9-153
NOZZLE
EP9-155
Exercise care to avoid damaging ADJUSTING INJECTION PRESSURE Checking spray and fuel leakage
the surface which the nozzle During adjustment of the initial in
needle contacts. The use of com Adjustment
jection pressure with the nozzle tester,
pressed air may clog the open Clean the nozzle and tester carefully. note the state of the spray and look
ings with foreign particles. Al Make sure that the light oil to be used for fuel leakage. If a problem develops,
ways use the special tool, in in the tester contains no dirt. the nozzle needle and nozzle body seat
stead. 1) With the nozzle holder adjusting are worn or scored. If the extent is
screw loosened, attach the nozzle slight, repair can be effected by lap
to the tester. Eject fuel two or ping with compound. Otherwise, the
� . •[,:Qet·�
three times to force out any dirt. nozzle body and needle must be re
2) Operate the lever of the tester at placed as a set.
sixty strokes per minute and read
NOZZLE BODY '· the gauge during fuel ejection.
CLEANING TOOL 3) Either tighten the adjusting screw
or adjust by loosening it so that the
EP9-156 injection pressure becomes the
specified pressure. Make this adjust
ment using a screw driver in accord
ance with the gauge reading. 4 X
EF9·156
I I I I I I I ·
4) Loosen the bleeder screw of the Scale plate indication ..• 0
°
- 60
° °
- 120 - 180 - 2 40 - 300 - 360
° ° ° °
Test condition
Nozzle
injection
175 200 220
pressure
(kg/cm2 )
Feed
pump oil
1.6 1.6 1.6
pressure
(.kg/cm2 )
Injection
pipe
6 X 2 - 600 6 X 2 - 626 6 X 2 - 626
(OD x ID
+: ! -L) (mm)
JIS No. 2 light oil JJS No. 2 light oil JJS No. 2 light oil
Test oil (ASTM No. 20) (ASTM No. 20) (ASTM No. 20)
or Bosch OL61VII or Bosch OL61VII or Bosch OL61VII
l;J
·· i :i
Test oil
temper· 40-45 40- 45 40- 45
°
ature ( C)
Note The fuel injection pumps (P/N: DKKC No. 101681·9170, 101681·9150, 101691·9120 and 101691-9130) have been checked under
the test conditions specified in the on-vehicle adjustment specifications. All other pumps have been checked under the test conditions
specified in the standard adjustment specifications.
Piping outline
OVERFLOW VALVE
(OPENING PRESSURE 1.3 kg/cm• I
FUEL
FILTER
FUEL PUMP
FUEL EF9-001
TANK
8-36 FUEL SYSTEM
RFD governor
• DKKC No. 101691-9220
1) JIS No. 2 light oil (ASTM No. 2D)
RSV governor
• DKKC No. 101681-9150
J IS No. 2 light oil (ASTM No. 2D)
10.7 Standard
800 66.6 - 69.4 ±2
(above 300)
Measuring the injection amount At the time of setting the control Max. (min.) injection
rack to the "O" position, the amount of each
1) Determine the "O" position of the
stopper bolt shall always be made Injection plunger - average
control rack.
loose. amount = injection amount x 1 00
• RAD and RLD type irregularity Average injection
2) Operate the control rack or pinion
Set the measuring device to "O"
and confirm that the full stroke of amount
with the position at which the
the rack is 21 mm.
governor spring is pulled so that
In addition to the above, confirm Injection amount adjustment
high speed control is started at a
that the control rack will move
pump speed of 500 to 600 rpm by When the measured results are not
smoothly in the direction of maxi
the speed adjusting bolt (RAD within the average injection amount
mum injection by the force of the
type) or governor shaft (RLDtype) and irregularity range, adjust by chang
start spring. In case the control rack
with the governor damper spring ing the control pinion and control
does not move smoothly the in
disconnected, (RAD type) the sleeve combination angle.
jection pump shall be checked and
speed is increased still further, the connected so that it will move 1) Loosen the pinion clamp screw
control rack is pulled in the "O" tightening the control pinion.
smoothly.
position direction and the end of 3) Tip the control lever in the stop
the control rack or the control
,., pinion is pushed fully in the no
direction as far as it will go, then
set the stopper bolt so that the .
injection direction and becomes
control rack position will be 0.5 -
static as the rack "O" position.
1.0 mm. (RSV type only)
Note This is done in order to prevent
Since the link mechanism and other undue force from being exerted on
parts inside the governor may be to the link mechanism inside of the
damaged by setting the "O" position governor in case the control lever is
of the control rack by operating the pulled towards the stop direction.
,. 1 control lever, setting the "O" position 4) Remove the rack guide screw at the
by means of the control lever must be rear of the pump housing, insert the
avoided. (RAD and RLD type) lock screw (157976-3100) in its
place and fix the control rack at the 2) Insert the pin into the hole of the
adjustment standard position with control sleeve and change the in
the control lever. jection amount by shifting the posi
Note tion of the plunger relative to the
As for idling, fix the rack with the control rack by moving the sleeve
lock screw. little by little while tapping the pin.
When the control sleeve is turned to
the right, the injection amount in
creases and when it is turned to the
left, the injection amount de-
'I
l·i:\
,,.,\ • RFDtype
Stretch the governor spring with
the speed control lever so that
control will start at a pump r.p.m.
of 500 - 600. While increasing the
r.p.m., let the control rod pulled
toward the "O" position and at the
same time push the top of the 5) Drive the tester and drive the pump
control rod or control pinion in the at the prescribed speed.
no-injection direction. The position 6) Make the feed pressure to the pump
where the rod or opinion thus stops 1.6 kg/cm2 and measure the in
is the "O" position, and the "O" jection amount of the prescribed
position on the scale is made to be stroke (1000 strokes) by means of a EF9-034
matched to that "O" position. female cylinder.
• RSV type 7) Measure the injection amount at
Tip the control lever towards the the prescribed speed and rack posi 3) After adjustment is finished, lock
non-injection side as far as it will tion in the same manner and calcu the pinion clamp screw.
go, then match the "O" position of late the irregularity by referring to 4) Remove the lock screw of the
the control rack with the "O" posi Injection amount adjustment stand control rack and install the guide
tion of the scale. ards table. screw.
8-40 FUEL SYSTEM
FUEt. EXCESSIVE
5) Refer to Injection amount adjust 2) Adjusting idling control
ment standards table for standard START: 9,6�8·
SETTING FOR
2mm
When the fuel injection pump rpm
injection amount adjustment values. 9 is set at "Nb (Nd + approx. 50
belo
Eo. 1750 --�.... rpm), adjust the control lever posi
=1 soA:
0 �4
6 •U1----1----=.....,. tion so that the control rack is
ADJUSTING GOVERNOR w positioned at "Ra." While in state,
w
adjust the idling spring assembly
(Type RAD governor) �se0-+20 ·1--+-�1---+---�� (located under the tension lever) so
::>
a. below 1--1--�,.._l-----+-L,... that the control rack is positioned
RAD governor performance curve 465··
·3010-+--+-�... at "Re" when the pump rpm is
FUEL. EXCESSIVE
SETTING FOR reduced to a point of idling "Ne".
START : 10.2 :g·2-
0 2.5t0.5 5
7. above9_4
below EF9-193
1750 9.3
lg
1600 ::: CONTROL ROD POSITION (mm)
1100 :301--__...._______, DKKC No. 101691-9320
1300,lO
1) Adjusting the flyweight lift and the Nb
1
full load position. Refer to the
em ·20,1---i.----+--+..::..U--1... Type RAD-K mechanical governor 0 Ne
Nd
w
u,.Mk,w performance curve.
!I, llO IL•
' lOO • 10,�1---4...
. 0
The full lift of the flyweight is
a. L
300
divided into the lift required while ::E
:::,
idling and the lift required at high L .,,::-
speed. Increase the fuel injection Ra Re Rd
0 U · 0.3 5 6 U 10 U above 14
abo111e pump rpm, and adjust the control RACK POSITION (mm) -
CONTROL. ROO POSITION (mm) EF9-037
EF9·161 lever movement until the control
rack is positioned at "Ra" when the
DCKK No. 101691-9080, 101691-9060,
fuel injection pump starts to re
101691-9180, 101691-9160 and
volve at a high speed. At this point,
101691-9170
set the full load stopper bolt Next,
decrease the pump rpm, and deter-·
r�
FUEL EXCESSIVE mine the flyweight lift (i.e. the full
SETTING FOR START:
load position Rb) at high speed
"ebelow using the stroke adjusting screw.
e,1150
Then, adjust the speed adjusting
�1&00::�
LIi 1800 t30 bolt so that the governor speed
� 1300t 10 ·.1
begins to decrease, starting with the
t
,n670t20
Q. below
specified rpm of "Nh".
� ,:o.,
11. 300.
Nh -,------------
'
I
3.4 =0.3 5• 6 1.2 10 9.7 10.2 above 14
above' I
CONTROL ROD F'OSITION (mm) I
EF9-162 I
0 3) Adjusting the damper spring
w
Ill After making the idle adjustment,
DKKC No. 101691-9100
operate the pump rpm so that the
::> control rack is positioned at "Re -
L
FUEL EXCESSIVE Rb 0.1 mm" (The control lever should
SETTING FOR RACK POSITION (mm)- be at the same position as for the
START: 11.s:g-2-
idle spring adjustment), then adjust
EF9-035
[below the damper spring until the control
.=, I 750 rack is positioned at "Re" mm.
�1&oot:X
I.LI 4) Adjusting stopper bolt
0.. After the damper spring has been
� 660 :t30 properly adjusted, stop the pump
:::, 540 ,:20 rotation to ensure that the control
0.. 390,:t25
300 rack is in the "Rd" position. From
that position, move the control
2.6 3.5 8.9 10.6 10.3 14.5
above above lever so that the control rack moves
CONTROL ROD POSITION (mm)
to the "Re - 1" mm position. At
EF9-163
this point, tighten the stopper bolt
DKKC No. 101601-9070 and 101601-9150 until it touches the control lever.
FUEL SYSTEM 8-41
E
I
L __
l J __________ --
� Ng�------------
0
w
w
MAIN SPRING SET
position "Ng." e
l&J
DAMPER SPRING
1300 · 50-----<SET. 1.7 -0
o.t"""
&
After this adjustment has been
! ..,...
.. l50·20t--ts---H----+-�
that when pump speed reaches 2) After idling the engine, adjust the
1,600!�8 rpm, high-speed control damper spring so that damper
begins and the control rack also effect begins, starting with the rack
begins to move from its preset posi position of 6.7 -8.2mm.
tion {step 1 above).
Note
If the rack position is less than
6.7 �8. 2 mm, damper effect will be
weak; if the position is greater than
6.7 -8. 2 mm, the idle speed will be EP9-185
higher than specified value and de
celeration performance will deterio
rate. 3) Adjust the idle sub-spring by in
creasing the pump rpm until the
rack is positioned at a point of 6. 7
mm. At this point, adjust the idle
sub-spring tension until resistance
3) After adjusting the starting point of begins, beginning at a rack position
high speed control, determine the of 6.7_3 2 mm.
speed fluctuation rate by gradually _
increasing pump speed beyond
1,600 rpm. By doing so, make sure
the pump speed is less than 1,750
EP9-183
rpm when the control rack gradual
ly moves to a point of 6.0 mm.
3) Adjust the damper spring then the
stopper bolt. When the pump stops
Low speed adjustment operation, the control rack is posi
1) To adjust the idling spring, move tioned at a point of 10 mm. From
the speed control lever all the way that position, turn the stopper bolt
to "fuel increase," and position the so that it contacts the load control
load control lever so that the lever when the rack is positioned at
control rack is positioned at a point a point of 8.2 mm using the control
of 3.7 mm when injection pump lever. Turn switch adjustment
speed is 1,000 rpm. In this condi Adjust the stopper bolt so that the
tion, adjust the idle spring located turn switch is switched on at the pump
on the lower end of the tension speed 375 rpm with the control lever
lever so that the control rack is positioned at a control rack position
positioned at a point of 8.2 mm of 7.2 mm.
when the injection pump speed is
decreased to 300 rpm. Also check
to make sure that when pump
speed is less than 500 rpm, the
control rack is positioned at greater
than 10 mm and pump speed again EP9-184
begins to increase and that the rack
is positioned at a point of 3. 7 mm
when the pump speed reaches
650±20 rpm.
EP9-190
03•01
DKKC No. 101691-9120 &
101681-9170
..
9; 1-----+--- 750 ± 5or 900 ± 5
BOOST STROKE o.2 0
120: � ROO LIMIT:
14•01
� '". '°t-""
' -.::--f------+--'j
....
U 1.2 U
CONTROL ROD POSITION (nwn)
ROD LIMIT EF9-169
J 7S0dl-----+----'=-.l
injection pump speed is 750 rpm.
Rackposition
Checking and adjusting the speed
variation factor
t_.
c _--1,_o�.J ±0.1
DKKC No. 101691-9130 1) The speed variation factor is ex
IL •• -=o�f----4----� 9.5mm pressed in percent, and is obtained
� 4io±SOr-"""'"':::---t-----!--Q.. DKKC No. 101681-9150 by subtracting the rated speed from
IOO 10.7mm the maximum speed without load
DKKC No. 101691-9120 and dividing the remainder by the
U 7.J IU ''�I 9.6mm rated speed.
CONTROL ROD POSITION (mm) DKKC No. 101681-9170
EF9·167 10.4 mm VARIATION FACTOR
� Nd 1-_-
1-_-'_=_"'_"'"---+.,_
_"":_--::C: -.b
l Ne:
::,,,,
C Nbl-----+----t
ti •
EP9·236
o------,R"-a---,.Rb""'R,!-c-......__
RACK POSITION
2) To determine the starting point of ES9-200
high-speed control, move the stop
1.2 10
abov• lever to "Full" and the control
CONTROL ROD POSITION (mm)
EF9·168
lever all the way to "fuel increase."
With the levers held in those posi 2) After adjusting the starting point of
tions, gradually increase injection high-speed control, determine the
DKKC No. 101691-9130 pump speed. Adjust the stopper speed fluctuation rate by gradually
bolt so that when pump speed increasing the pump speed beyond
reaches the specified rpm, high the high-speed control beginning
speed control begins and the point. By doing so, make sure the
control rack also begins to move pump speed is the specified rpm
from its preset position (step 1 when the control rack gradually
above). moves to the specified position.
8-44 FUEL SYSTEM
e
.§
Readjusting after adjustment of the � 10.7 l---------"71-
adjusting knuckle i=
iii
Adjusting the adjusting knuckle 0
a.
changes the tension of the governor
spring. Therefore, tension of the gover
g 1 o. 5 1------r
a:
nor spring must be readjusted to ..J
0
correspond to rated speed. When the a:
1- 60±30 250±50
adjusting screw is tightened\. it in z
0 BOOST PRESSURE (mmHg)
creases the speed, and when it is u
EF9-197
loosened, speed is decreased. Thus, the
maximum speed stopper must be
readjusted after adjusting the adjusting
knuckle adjusting screw.
FUEL SYSTEM 8-45
CONTROL ROD
LIMIT:
ADJUST BDLT
w EF9-171
w
0.. (600)
Ill
0..
500 !: 15
300
0..
(300)
below
225 2) Align the center pin of the adjust EF9-173
Preparation
Before the adjustment of the governor,
the following preparations are made
without fail: EF9·174
.."'..
screw of the governor shaft is N2
0
w
adjusted so as to be 14 ± 0.5 mm w
and the guide screw is fixed by the Assignment of the full load control
rack position ::E
lock nut. �
If this L 2 is out of the prescribed 1) Fix the control lever to a position
value, the following inconvenience where it comes in contact with the
may arise. full speed stopper bolt, and set CONTROL RACK POSITION (mm)
provisionally the full speed stopper EF9•180
bolt so as not to cause it to come
into the governor control area at
the prescribed pump speed Na =
I
about 1,500 rpm in the governor
performance charactei:istic diagram. �:
e
Ng �·
...."'::E�
Nf 0
w
w
EF9-176 e Na -l
I '' . '
1 I
-i-1 - I ._ Nt
j:
0
w
If L 2 too large:-
...
w I
I
I
Rt
Ii
...::i:
I
Governor shaft will extend too Ill I I
_L,._J--1- CONTROL RACK POSITION (mm) -
little to make the double nut serve
...:> +-�--l-+--
1 I I I EF9-187
the adjusting purpose easily.
---tI -
1 I I I
If L 2 is too small: -1--,--t-+
l I I I 3) Adjust the fastening of the full load
Guide screw will push on spring
Rf stopper bolt in order to obtain the
seat too hard to enable the fly
state of the solid line from the state
weight to run to full-lift position. CONTROL RACK POSITON (mm) -
of the dotted line in the governor
2) The control lever is fixed to the EF9·178 performance characteristic diagram,
position where it comes in contact
with the idle stopper bolt with the
adjusting device, and the double
nut of the governor shaft is adjust
ed so that the control rack posi e� N,
4) The works of the above items 2) 2) At this time, confirm by the scale
and 3) are alternately carried out in panel of the measuring device
order to obtain the prescribed governor that the control angle of Ng
governor performance characteristic the control lever is within the pre Nf
E
I
If the above adjustment is not con I
black smoke.
I
I decreased with the control lever held
I
Ag
at the full speed position.
CONTROL RACK POSITION (mm)_
High speed control adjustment 2) Stop the rotation of the pump
EF9-186
1) Fix the control lever to a position tester at the control lever position
where it comes in contact with the where the pump speed for obtain
full speed stopper bolt and adjust ing the idling control rack position
the full speed stopper bolt so that of the governor performance
the high speed governor control 4) Increase the pump speed further characteristic diagram is set (point J
may start at the prescribed pump and confirm that the control rack in the governor performance
speed Nf shown in the governor position Rg is obtained. characteristic diagram) higher than
performance characteristic diagram, If the speed droop does not reach, the idling prescribed rotation rate
and fix the full speed stopper bolt. replace the governor spring because (rotation of the point H).
the governor spring is considered to 3) Then confirm that the control rack
have been deteriorated. position of the start increase
volume can be obtained.
0
w
w
0.
"'0.
.J
::;
::>
0.
Confirmation of the limit of the
pump rotation rate for start volume
CONTROL RACK POSITION Jmml increase e
EF9·184
1) When confirming the start excessive _g
C Nh2 ---
w ' '
supply volume, manipulate the W ! I
control lever from the idling posi �
� Nh1 ___ :_____ . J H . :
tion to the full speed position by � -
Ni ::.·.-_t_-_ _-_-�:i._;-;:.::�
gradually decreasing the pump Cl. Nt ---�----�..:...�- -'.--r-�--
1 111
speed from about 500 r.p.m., and
Rh2 Rg Ri Re Rf
confirm that the control rack posi Rh2
tion Rt can be obtained at the
CONTROL RACK POSITION (mm) -
pump speed below Nt of the gover EF9-188
nor performance characteristic dia
gram. Then obtain the predeter
mined control rack position by
EF9-185 manipulating the control rack, or
the control pinion.
8-48 FUEL SYSTEM
�'Jiill-1-+-1-: ·I 1
cylinder).
4) Drive the pump, set the switch of
E:-_
DKKC No. 101691-9130 the stroboscope to ON, illuminate
the scale plate with the light from
��; SPRING CAPSULE
the stroboscope and measure the
angular change corresponding to
EF9-189 the change in speed.
5) When the standard timing is not
within the prescribed range, dis
TESTING TIMER assemble the timer and replace the
timer spring or adjust by means of
1) Timer performance curves. adjusting shims.
EF9·194 6) After measurement, always set the
switch of the stroboscope to OFF
before stopping the pump tester.
DKKC No. 101691-9060,
101691-9080,
101691-9090,
101691-9220,
101691-9100,
io0t50 900 101691-9180,
EF9·190
101691-9160,
101691-9170 and
DKKC No. 101681-9170 101691-9320
(3) 1-----------
( z.4tosl ,________
EF9-195
The air intake and exhaust system consists of a turbocharger, air cleaner
and exhaust brake.
TURBOCHARGERS
DISASSEMBLY
�
\
Compressor housing
2 Lock nut
3 Impeller
4 Back plate
:J
5 Clamp
6 Lock plate
7 Bolt
8 Thrust spring
9 Piston ring
10 Thrust collar
11 Thrust bearing
12 Seal ring
13 Screw
14 Center housing
15 Gasket
16 Oil inlet adapter
17 Screw
18 Lock plate
19 Bolt
20 Heat shroud
21 Retaining ring
22 Journal ring
23 Piston ring
24 Shaft wheel
8 25 Turbine housing
ER15-113
26 Bolt
27 Lock plate
28 Clamp
T048model
9-2 AIR INTAKE AND EXHAUST SYSTEM
EP15·017
9) Remove the piston ring. 12) Remove the thrust collar, and
thrust bearing and seal ring.
Note
Once removed, the piston ring must
always be replaced with a new ring
when reassembling. However, since
the shaft wheel can be reused, be care
ful not to damage it.
ER15-117
T048model
6} Remove the impeller.
• Using a handle (99773 96000), re 13) Remove the journal bearing.
move the lock nut, and then re
Note
move the impeller by hand.
Be careful not to damage the center
Notes housing when removing the retaining
1. Since bending of the shaft is also re ring.
lated to the life of the turbo
charger, be careful not to bend it. 10} Unbend the lock plate and re- • Using retaining ring pliers (99546
2. Support the shaft wheel by hand move the back plate. 25500), remove the impeller side
while loosening the lock nuts. retaining ring and journal bearing.
Note
When the back plate cannot be remov
ed by hand, tap the center housing
lightly with a wooden mallet ind then
remove.
EP-15-029
• Using retaining ring pliers (99546
25500), remove the turbine side re
p;,r 11) Pull out the thrust spacer from taining ring and journal bearing.
the center of the back plate and re
move the piston ring from the
thrust spacer.
The piston ring can be removed by
hand.
ER15-121
INSPECTION
1) Inspect parts visually, replacing as
necessary.
Impeller. o Corrosion.
o Scratches caused by interference with housing.
0 Blade breakage and deformity.
o Gauging in shaft holes.
Center housing. 0 Wear and scratches on journal bores and inner surfaces of piston
rings.
o Obstruction in oil hole.
2) Measure the shaft wheel outside 6) Measure and record the inside diam
diameter and record the results. If eter of the center housing. If mea·
the calculated value exceeds wear sured values exceed wear limits, re
limit, replace the sahft wheel. place the center housing.
Journal part Bearing part (1)
Maintenance standard Maintenance standard
10.16 mm 15.80 mm
Wear limit Wear limit
10.13 mm 15.81 mm
EP15-035
Piston ring part Piston ring part (2)
Maintenance standard Maintenance standard
17.34 mm 4) Measure and record the inside diam 18.03 mm
Wear limit eter of the back plate and the Wear limit
17.29 mm distance from thrust collar contact 18.08 mm
surface to the back plate end. If
measured values exceed wear limits,
replace the back plate.
Maintenance standard
0.011 mm 5) Measure and record the thickness of
the thrust bearing. If the measured
Note value exceeds the wear limit, re
Since the turbine side is heavy and the place the thrust bearing.
front end of the shaft will float when Maintenace standard
the shaft is supported by V-block, use 4.36 mm
a magnet V-block or place another V Wear limit
block stop the journal part. 4.35 mm
AIR INTAKE AND EXHAUST SYSTEM 9-7
REASSEMBLY
ER15-124
T048 model
i
.
I,
0
REASSEMBLING
TURBOCHARGER PROPER Note
Ensure that the bosses are ready to be
1) Install the journal bearing. detached from the flanged portions of
�+D·I
Note the inlet and outlet.
Be careful not to damage the center
housing when installing the retaining
ring.
2. When tightening the nut, be careful 8) Seat the dial gauge to the radial
not to give the bending force to the play measuring tool (99764 96000)
shaft. and replace the dial gauge adapter
3. Keep the rated tightening torque with the radial play adapter (99765
and tightening angle. 96000).
11) Temporarily install the compres 14) Install the oil inlet adapter and oil
sor housing. Attach the measuring outlet adapter.
element to the compressor housing Inlet adapter tightening torque
and measure the end play of the 115 to 150 kgcm
shaft to determine whether it is Outlet adapter tightening torque
within maintenance standards. 184 to 219 kgcm
Maintenance standard
0.025 to 0.080 mm
Wear limit EA15-129
0.10 mm
EF15-011
OIL OUTLET
Note '/!::
![(
Apply a "gauge-preventive" com
pound to bolts. Do not confuse these
bolts (designed especially for high tem
1
: : :i:;:) :!LH
perature use) with other conventional
bolts.
EF15-010
OIL OUTLET
AIR CLEANER
INSPECTION
Cyclone type
l
1 Dust indicator
2 Cap
3 Body assembly
4 Inner element
5 Gasket nut
6 Clamp
� 7 Vacuator valve
8 Outer element
9 Gasket nut
10 Cover
1) Check the external portion of the for cracks or damage. If faulty, re 1) Visually check the body assembly,
body assembly, cup assembly {dust place (if so equipped). oil pan assembly and rubber hoses
pan assembly) and rubber hose for 3) Check the element for deterioration for cracks or other damage. If
cracks or other damage. If faulty, or damage. If necessary, clean or re necessary, repair or replace dam
repair or replace. place. If the replacement period is aged parts.
2) Check the evacuator valve assembly close at hand, replace the element. 2) Check the level of oil and oil con
tamination. If necessary, add or re
palce. If it is time for an oil change,
Element Work Work interval drain and replace oil.
Oil lev.el check
Every 8,000 km or 200 hours of operation (4,000 Every 1,000 km of operation
Inspect/Clean km or 100 hours in extremely dusty areas) or Oil change
When red signal appears on the service indicator
Outer Every 4,000 km of operation
element
Every 48,000 km or 1,200 hours, or when red 3) Check the air cleaner element for
Replace signal appears on the service indicator even after excessive clogging or other damage.
cleaning both the outer and inner elements If necessary, replace or clean it. If
the periodic service time has elaps
If red signal apperars on the service indicator even ..
Clean ed, clean or replace the element as
though outer element is cleaned
Inner
element
necessary.
.)V . '
Element cleaning ,. ,
�.
1 Cleaner case
2 Damper
3 Packing
4 Element
5 Packing
6 Retaining ring
7 Cover
8 Wing nut
9 Washer
ET J-028
AIR INTAKE AND EXHAUST SYSTEM 9 13
EXHAUST BRAKE
PREFORMANCE CHECK lever of the exhaust shutter is con 4) Depress the clutch pedal and check
tacting the stopper bolt which sets if the exhaust shutter is at the fully
When idling adjustment or accelerator
the fully open position at this time. open position. Also check if the
pedal and clutch pedal adjustment has
("EXH. B" pilot lamp lighted) lever is set to the fully closed posi
been performed or a switch has been
3) Check if the exhaust shutter is at tion when the clutch pedal is
replaced, check the performance of
the fully open position when the released.
the exhaust brake control system as
accelerator pedal is depressed. 5) Finally, set the exhaust brake
follows:
Moreover, confirm that the lever switch to the "OFF" positon and
1) Start the engine and confirm that
contacts the fully closed position confirm that the exhaust shutter is
the "VAC" warning lamp is ex
stopper bolt when the accelerator returned to the fully open positon.
tinguished.
pedal is released. ("EXH. B" pilot ("EXH. B" pilot lamp extin
2) Set the exhaust brake switch to the
lamp lighted) guished)
"ON" postion. Confirm that the
ACCELERATOR
PEDAL
OFF
PUSH SWITCH
J_
ON
INJECTION
PUMP
VACUUM �-----.--.�-j
PUMP .,. ACCELERATOR
SWITCH
EXHAUST SHUTTER
EF15-013
MUFFLER
9- 14 AIR INTAKE AND EXHAUST SYSTEM
OISASSEMBL Y
EF15-014
Dismounting
1) Disconnect the vacuum hose from
the frame side.
2) Loosen the sleeper mounting bolts
of the muffler bracket.
EF15-019
EF15-017
REASSEMBLY
0 0
EF15·020
1
2
Bolt
Cover
10
11
Seal ring (spindle ttte)
Bracket
19
20
Push rod
Lock nut
28
29
Spring guide
Spring
:;\!:i,;:) r:r:;I
1) Assemble the diaphragm plate and 5) Install cylinder shell A and spring 11) When in full open position, adjust
diaphragm retainer to the dia to cylinder shell B by turning the the stopper bolt until the dimen
phragm. connector of cylinder shell A. sions "A" and "B" are equal.
FF15·021
EF15-025
EF15-006
2) Install the gasket and piston washer 6) After installing the filter and gasket
to the diaphragm. to the push rod in that order, install 12) When in full close position, adjust
the clevis. the stopper bolt so that 0.1 to 0.4
7) Install the two seal rings to the. mm of clearance exists between the
exhaust brake valve body. valve and body.
Note
Install the seal rings so that the body
tight side is at the front as illustrated
below.
·::::
2
EF15-027
STOPPER
BOLT
EF15-005
EF15·024
9- 18 AIR INTAKE AND EXHAUST SYSTEM
,,,,
,,
10. ELECTRICAL SYSTEM
EF10·010
i\
The electrical system consists of a starting motor, generator, etc.
STARTING MOTOR
DISASSEMBi. Y 10
i·u.·1· ,.,·•;
'It:.;;!.
1 Bolt
24 2 Gear case
3 Shift lever pin
4 Shift lever
5 Lock washer
6 Nut
/·
7 Dust cover set
8 Plunger
9 Spring
10 Magnetic switch assembly
11 Metal bearing
12 Clip
EF10-011
13 Pinion stopper
14 Pinion assembly
15 Center bearing
S25-64 model 16 Armature assembly
17 Thrust washer
18 Field coil
19 Brush (+)
20 Brush(-)
21 Brush spring
22 Brush holder
23 Rear cover
24 Metal bearing
25 Lock washer
26 Bolt
10-2 ELECTRICAL SYSTEM
1 Gear case
2 Pinion assembly
3 Shift lever
4 Magneti c switch assembly
5 Dust cover set
6 Cover
7 Thrust washer
8 Metal bearing
9 Shift lever pin
10 Clip ' Ff':•
11 Pinion stopper
12 Shaft assembly
·ii'
:1J1
11!
13 Thrust washer °
14 Needle bearing .·, 'II '11• 1,1ir
15 Oil seal
ill/j:11
1 . .i'
i
,/1.
·d/1
16
17
Center bracket
0-ring :I111lj1
18 Ball bearing
,, !1.
19 Armature assembly (1,,
1i1''!
(
20
,, .j!
Field coil
21 Brush spring ·::·f'·;
22 Brush
23 Brush holder
\ EF10·012
24
25
Thrust washer
Ball bearing
�- 26
27
Rear cover
Bolt
S25-110 model
l· '•·
1) Remove terminal nut M and discon 3) Remove the magnetic switch as 5) Remove the through bolts. ··.,:
ER10-153
EPlO-6 ERlO-154
ELECTRICAL SYSTEM 10-3
7) Remove the rear cover and thrust 11) Remove the shift lever pin. 15) Remove the dust cover. (525-110
washer model only)
THRUST WASHER
EP10-9
EP10-16
EF10-013
8) Pry the brush spring from the brush 12) Pull the dust cover from the gear
hol_der and separate the brush. case. Next, pull out the armature 16) Remove the gear shaft assembly
and shift lever. (525-64 model together with the shift lever. (525-
only) 110 model only)
EP10-18
EF10-014
un
:;.11 9) Remove the brush holder assembly. 13) Remove the armature assembly. 17) Pull the pm1on stopper in the
li[i (525-110 model only) direction in which the pinion is
!!-1/ installed and remove the pinion
,j/.
!iii
'i i
stopper clip. Then remove the
pinion stopper pinion and center
bearing. (S25-64 model only).
EP10-15
10-4 ELECTRICAL SYSTEM
INSPECTION AND REPAIR Maintenance standard 2) Measure the clearance between the
Rear cover bearing outside diameter of the gear shaft
Armature shaft (S25-64 model) 0.03 to 0.07 mm (at the sliding portion of the pin
1) Support both ends of the armature Center bearing ion) and the inside diameter of the
shaft, place a dial gauge against the 0.13 to0.17 mm pinion. If the clearance exceeds the
sliding part of the center bearing Pinion bearing; wear limit, replace the shaft and/or
metal, turn the armature and meas 0.03 to0.07 mm pinion.
ure the run-out of the shaft by Gear case bearing Maintenance standard
reading the deflection of the dial 0.03 to0.07 mm 0.03 to0.07 mm
gauge pointer. Repair limit Repair limit0.2mm
The bend is 1 /2 of this reading. Center bearing 0.3 mm
When the bend exceeds the repair Other0.2mm 3) Measure the inside diameter of each
limit, replace. gear case side bushing and calculate
gear shaft diameter clearance. If the
Wear limit 0.1 mm Armature shaft (S25-110 model)
values exceed repair limit, replace
,:
1) Measure the armature shaft diame the bushing.
ter at the "A" point. If the measur
Maintenance standard ·j•
ER10-156
EP10-�f'
3) Measure and record the mica depth
between the commutator segments.
If the measured value exceeds the
repair limit, replace the commuta Brush and brush spring
ES10-23
tor. After undercutting, bevel the 1) Measure the brush height. If the
corner of the commutator with values exceed the wear limit, re
#500 or #600 sandpaper. place the brush.
Maintenance standard Nominal dimension
0.5 to 0.8 mm 19.5 mm (S25-64 model)
Repair limit 0.2 mm 18.0 mm (S25-110 model)
Wear limit
12.5 mm (S25-64 model)
Commutator 11.0 mm (S25-110 model)
1) When the sliding surface is rough,
�ACKSAW �
polish it lightly with #500 or #600 ��ADE �
sandpaper.
COMMUTATOR
Measure and record the eccentricity
and taper of the sliding surface of COMMUTATOR
BEVEL
� CAT00 �\\\1//j;
the commutator. If the measured � � �
values exceed the repair limit, re
place the commutator.
GOOD
Maintenance standard 0.05 mm NO GOOD
ES10-25
Repair limit 0.4 mm
10-6 ELECTRICAL SYSTEM
2) Check brush spring tension. To do exists, it indicates faulty insulation, 2) Check the continuity between the
so, attach the spring scale's hook to and the brush holder should be re magnetic switch terminal C and
the brush spring through a cloth placed. terminal M and replace when there
and read the scale's indication when is no continuity.
the spring is lifted off its contacting
surface.
Brush spring tension
2.45 to 3.05 kg (S25-64 model)
2.85 to 3.55 kg (S25-110 model)
5-TERMINAL
Pinion
1) Check the pinion teeth for wear or
damage. If necessary, replace the
Brush holder pinion assembly.
2) Ensure that the pinion slides
Check for continuity between the
smoothly. Replace when the pinion
positive (insulated) and the negative
bushing is scratched, burned or
{base) sides of the brush holder, using
otherwise damaged.
an insulation tester. If continuity ES10-29
REASSEMBLY
1 Metal bearing
2 Thrust washer
3 Brush
4 Brush spring
5 Field coil assembly
6 Magnetic switch assembly
7 Adjusting plate
8 Spring
9 Plunger
10 Shift lever
11 Gear case
®
12 Shift lever pin
13 Pinion assembly
14 Pinion stopper
15 Pinion stopper clip
EF10-001
16 Metal bearing
17 Rear cover
18 Armature assembly
17 18 19 19 Center bearing
S25-64 model
ELECTRICAL SYSTEM 10-7
1 Magnetic switch
2 Adjusting plate
3 Dust cover
4 Spring
5 Plunger
6 Shift lever
7 Shift lever pin
8 Gear case
9 Gear shaft
10 Thrust washer
11 Brush holder
12 Brush
13 Brush spring
14 Field coil
15 Screw
16 Yoke
17 Ball bearing
18 Bolt
19 Rear cover
20 Armature
21 Ball bearing
22 0-ring
23 Center bracket
24 Oil seal
25 Needle bearing
26 Thrust washer
27 Pinion
2s· Pinion stopper
29 Clip
EF10-016
30 Metal bearing
31 Thrust w11sher
S25-110 model 32 Cover
Before reassembling the starter motor, 4) Install the dust cover. (525-110
apply a coat of bearing grease to the model only)
following parts.
• Gear shaft
• Ball bearing
• Armature shaft
• Magnetic switch plunger
• Spline of buffer spring and pinion
assembly
1) Insert the center bearing (525-64
model only) and pinion assembly to
the gear shaft.
EP10-16
3) Insert the gear shaft assembly toge
ther with the pinion assembly, and
shift lever to the gear case. (525- 5) Install the center bracket to the
110 model only) gear case together with the thrust
washer. (525-110 model only)
EP10-20
6) Insert the armature assembly. (S25- 10) Insert the brush holder assembly. 14) Tighten the through bolts.
110 model only)
Ir
EP10-11
EF10·013 EP10-9
ER10-154
EP10-47
ELECTRICAL SYSTEM 10-9
18) Insert the lead of terminal M and When the L dimension is outside Remarks
tighten the nut with the washer and the maintenance standard, adjust Terminal voltage
lock washer. by inserting the adjusting plate. 24 volts
There are two adjusting plates, one
LEAD is 0.4 mm thick and the other is 0.8
mm thick.
i'/\
T
24V
� I '\ BATTERY
//\\ REVOLUTION
( COUNTER
EP10-48 ES10·19
ADJUSTING PLATE
ES10·34
ADJUSTMENT
2) Turn the switch on and off to en
The pinion pushout position dimen sure that the pinion gear pops
sion by the magnetic switch is called smoothly out and in.
the L dimension and is adjusted to L= INSPECTION AFTER 3) Measure the voltage required for
0.3 to 1.5 mm. Measure the starting REASSEMBLY the pinion gear to pop out. To do
motor as a single unit. so, gradually decrease the resistance
1) Test the starting motor without any
1) Pass current between the magnetic so that voltage applied to the start
load to determine whether all read
· switch terminal S and ground. er motor increases. The measured
ings are within the specifications in
dicated below. voltage should be within the main
tenance standard range.
SWITCH Maint enance standard
Current Maint enanc e standard
Specified value Less than 18 volts
BATTERY Less than 70 am peres
(S25-64 mod el)
Less than 110 am peres VARIABLE RESISTOR
(S25-110 mod el)
RPM
Specified value
EP10-49
Motor than 4,000 rpm
24VT
(S25-64 model) BATTERY
More than 3,500 rpm
2) Advance the pinion and stop at the (S25-110 model) ES10·20
pinion stopper position.
3) Measure the L dimension with the
pinion positioned as shown in the
figure.
Maintenance standard
0.3to 1.5 m m
0.3 to 1.5 mm
E11-17
10- 10 ELECTRICAL SYSTEM
GENERATOR
DISASSEMBLY
LT225-63,LT225-56B
LT240-04B,LT240-15
LT225-62,LT225-62S
LT215-39,LT240-14E
LR280-11B
EF10·17
� i�
17 Ball bearing
Screw set assembly
Screw set assembly
Screw set assembly
�@21 Diode
! 22 Holder assembly
I 23 Holder assembly
l��38 �: Diode
Terminal assembly
26 Terminal cover
36
27 E-terminal b olt
28 Washer
� 29 Rear cover
30 Brush cover
31 Washer
32 Screw
33 Brush holder assembly
34 Washer
E11-18 35 Screw
36 Washer
37 Through bolt
Without vacuum pump type 38 Lead wire assembly
,,
:I 1) Remove the three bolts holding the 2) Remove the brush cover. 4) Remove the through bolts.
ii
vacuum pump. Then pull out the
vacuum pump in the shaft direc
tion. (with vacuum pump type
only)
Note
Since the pump is equipped with an
oil seal, remove the pump slowly so as
not to damage this seal.
ER10·111
EA10-113
ER10-112 EA10-114
10- 12 ELECTRICAL SYSTEM
6} Remove the pulley nut, lock washer 10} Remove the diode holder. S
and plain washer.
�SW3
SW2� �
X
ER10·135
9} Use a soldering iron to unsolder the Stator coil and rotor coil
stator coil and diode holder solder Position of 1} Measure the resistance between the
connections, and separate the stator Continuity
test leads two coil terminals. If there is no
coil and diode:
Note
+ - continuity between the terminals
the stator is open and should be re
When using the soldering iron, select A E Yes placed.
an iron with a large heating capacity Resistance
and unsolder the connections quickly, E A No LR280-1 1B
while grasping the lead wire with ............ 0.03 ohms
A N Yes
needle nosed pliers below the point at LT240-04B,LT240-15,
which the soldering iron contacts the N A No LT240-14E
wire so that as little heat as possible is 0.1 1 ohms
transmitted to the diode. N E Yes LT235-48
E N No 0.17 ohms
LT225-63
F E Yes .•.......•.. 0.17 ohms
L T225-62,LT225-59,
LT225-5 6B
LT225-22C,LT225-62S
............ 0.24ohms
ES09-16 Measurement of output current LT225-6 6
ELECTRICAL SYSTEM 10- 13
STATOR COIL
LT215-20,L T225-62,
LT215-39,LT225-56B
ES10-46
LT225-63,LT235-48,
LT225-22C,LT225-62S
2) Perform a continuity test between LR280-11B,LT225-66,
the stator coil terminals and stator LT240-04B,LT240-14E
core. When there is continuity, the LT240-15
coil is shorted and must be re Nominal dimension 20 mm
placed. Wear limit 14 mm
ES10-49 LT225-59
Nominal dimension 14.5 mm
Wear limit 7.5 mm
Checking rotor coil continuity
REASSEMBLY
Reassemble the generator in the re
verse order of disassembly, being care
ful not to mistake the installation
order of the insulated washer.
1 Pulley
2 Fan
3 Screw
4 Front cover
5 Stator assembly
6 Rear cover
7 Lead \.vire assembly
8 Brush assembly
9 Terminal bolt
10 Vacuum pump
11 Pulley nut
12 Lock washer
13 Plain washer
14 Key
15 Spacer --··,)
16 Packing
17 Packing retainer
18 Ball bearing
19 Bearing protector .' .. ·
20 Packing , ,ti ,
21 Rotor assembly
22 Slip ring
23 Ball bearing
EF10-19
@®@@
\I \
\
'
'. '
1 Screw
2 Packing
3 Ball bearing
4 Spacer
,,
5 Key i.f/,:·.J' /j,;;_·;,,
6 Pulley nut assembly
7 Packing
8 Pulley
9 Bearing protector
10 Fan
11 Front cover
12 Stator assembly
13 Rotor assembly
14 Rear cover
15 Lead wire assembly
16 Brush cover
17 Through bolt
18 Brush assembly
19 Ball bearing
20 Slip ring
c· 21 Diode assembly
22 Insulating bushing
SECTION A-A" SECTION e-e· SECTION c-c· B' 23 Terminal bolt
24 Insulating bushing
25 E-terminal bolt
ER10-176
REGULATOR
INSPECTION Gaps in field relay
1) Inspect each terminal for corrosion
. or damage. If faulty, repair or re
place the terminal.
2) Using a 3.0-volt tester, measure re
sistance values between terminals. E F • IG
(BLACK) (WHITE( (BLACK/
If measured values are not within BLACK WHITE)
specified range, disassemble or re
ER10-138
place the regulator.
s IG 20 20 - N s 00 00 00
2) Use pliers to bend the adjuster to
adjust the core gap.
F E 77 77 - s N 261 261 - Maintenance standard
F N 196 196 - L s 00 00 00
0.8to 1.2 mm
F L 0 0 0 s L 65 65 -
3) Use pliers to bend the point to ad
just the point gap.
Maintenance standard
0.4to 0.6 mm
ADJUSTMENT 1) Loosen the screw and adjust the
yoke gap.
Gaps in voltage regulator
Maintenance standard
YOKE GAP @ 0.9 to 1.0 mm
Measurement of voltage regulator
2) Use pliers to bend the lower con under no load
tact to adjust the core cap.
1) Make wiring connections as shown,
Maintenance standard and turn the switch on.
0.8to 1.2 mm 2) Gradually increase generator speed
until it reaches 800 rpm �approx.).
3 ) Use pliers to bend the upper con Turn off the switch.
tact to adjust the point gap. 3) Gradually increase generator speed
Maintenance standard up to the rated rpm. Read the volt
0.4to 0.5 mm (TL2Z-17) age indication to see if the indica
0.45to 0.55 mm tion is within the specified voltage
1 Low contact
2 Upper contact (TL2Z-28, TL2Z-33) range.
3 Adjust screw
4 Screw
10- 16 ELECTRICAL SYSTEM
�
w
Cl
< CORE GAP LARGE
r--<........... ·····
1-
.J ,,----··-··-
0 NORM AL
ER10·141
>
0 CORE GAP SMALL
AIR HEATER
INSPECTION
EF1-002
;;�
AUXILIARY EOUIPMENT 0
,,., '
AIR COMPRESSOR
PULLEY DRIVE TYPE
DISASSEMBLY
EF11-006
�3
�
1) Clamp the drive gear in a vise 5) Remove the snap ring using a snap
through a copper plate and remove ring remover.
the nut and lock washer.
2) Using a puller, remove the drive
gear and key. SNAP
RING
EFl 1-012
EF11-13
EFl 1-14
EP11-089
12) Remove the crankshaft assembly 17) Remove the delivery valve spring, CLEANING AND INSPECTION
from the crankcase, tapping the delivery valve, packing, valve seat 1) Clean all parts except those made
crankshaft front end with a copper and packing from the cylinder of rubber with cleaning fluid, then
hammer. head. wash with water and dry thorough
18) Remove the connector of the un ly.
loader valve. 2) Inspect the cylinder head and
crankcase for damage. If faulty,
repair or replace.
3) Inspect the periphery of the piston
and the inside wall of the cylinder
for damage. If faulty, repair or re
place.
4) Inspect the piston ring for damage
or uneven wear. If faulty, replace.
5) Measure the clearance between the
EF11-16 piston ring and the ring grooves,
and record the results. If the
13) . Using a bearing puller, remove the measured value reaches the wear
ball bearing from the crankshaft. EF11·20 limit, replace the piston ring or
piston.
19) Remove the unloader valve guide Wear limit 0.1 mm
together with the shim.
EF11·17
EF11-22
7) Inspect the connecting rod for 9) Measure the side clearance of the 12) Inspect the delivery valve, un
cracks or damage. If faulty, replace large end connecting rod. If the loader valve, suction valve, valve
or repair. clearance exceeds the wear limit, seat, valve spring and valve holder
8) Measure the inside diameter of the replace the connecting rod or for damage and wear. If faulty,
small end connecting rod bushing, crankshaft. replace.
and record the results. Calculate the 13) Inspect the oil seal lip for damage.
Maintenance standard
clearance between the inside dia If faulty, replace.
0.2to 0.4 mm
meter of the small end connecting Wear limit Note
rod bushing and the outside dia 0.4mm Generally, the oil seal should be re
meter of the piston pin. If the placed with a new one when over·
calculated value exceeds the wear 10) Inspect the crankshaft for cracks hauling.
limit, replace the connecting rod or or damage. If faulty, replace.
piston pin. 11) Check the ball bearing for any
sign of uneven rotation, noise or
Wear limit 0.1 mm
heat discoloration. If faulty, re
place.
AUXILIARY EQUIPMENT 11-5
REASSEMBLY
Before reassembling, apply clean
engine oil to each rotating or sliding
surface. In addition, replace all
gaskets, packings and O-rings with new
ones.
-@
1---�r.:ri'l--�
.
�
32
- -·---®
1-------<.3 4
·.__...
EF11-023
1) Install the packing, suction valve 5) Using a test rod, measure the lift of
seat, suction valve, and suction each valve. Confirm that the
valve spring into the cylinder head. measured valve lift is within the
2) Using a valve holder tool (99744 specified values.
25001), temporarily tighten the Valve lift
suction valve holder to the cylinder Delivery valve (A)
head. approx. 1 mm
Unloader valve (Bl
approx. 3 mm
Suction valve (C)
approx. 2 mm
EF11·20
L·
and then install the unloader valve
I 1 . •11
guide assembly to the cylinder head Make sure that compression ring
·manufacturer's mark faces upward.
through the shim.
Tightening torque C
� 10) Install the clip to the one side of
5.0 to 6.0 kgm SUCTION VALVE the piston.
ER11-124
14) Install the ball bearings to the 18) Insert the crankshaft together 22) Install the cylinder head.
crankshaft. with the cylinder into the crank
case. Tightening torque
Note 1.4 to 1.8 kgm
Make sure that rear bearing (small) No.
mark side faces inside and front Notes
bearing (large) No. mark side faces 1. Make sure that the air intake port
outside. faces to the rear (bearing cover
�
side) (when equipped on tractor).
-1 2. Make sure that the air intake port
':..-
faces to the front (pulley side)
r (when equipped on bas).
'i='
�
EF11·26
EF11-32
EF11-27
! 1 cylinder.
EF 11-028
>-.
�,
1�
/11!!
;1::/:
4�
.1:.
fl
,
"•
;:ii'i'.··
EF11-33 !i
;:;1,,
ililt
jl"'
10-ring 14 Snap ring 27 Valve seat 39 Nut
i1:ili
2Cylinder 15 Bolt 28 Suction valve 40 Lock washer
3Bolt 16 Lock washer 29 Spring 41 Drive gear
4Lock washer 17 Nut 30 Suction valve holder 42 Crankcase
50-ring 18 Connector 31 Delivery valve holder 43 Ball bearing
.6Compression ring 19 Packing 32 0-ring 44 Key
7Oil ring 20 Snap ring 33 Spring holder 45 Crankshaft
8Piston 21 Unloader valve 34 Spring 46 Ball bearing
9Piston pin 22 Spring 35 0-ring 47 0-ring
10 Snap ring 23 Unloader valve holder 36 Delivery valve 48 Bearing holder
11 Connecting rod 24 Bolt 37 Valve seat 49 Lock washer
12 Metal 25 Lock washer 38 Cylinder head 50 Bolt
13 Connecting rod 26 Packing
AUXILIARY EQUIPMENT 11 - 9
1) Clamp the drive gear in a vise 5) Remove the bearing holder and O 11) Remove the delivery valve holder
through a copper plate and remove ring. and O-ring.
the nut and lock washer. 6) Remove the piston assembly and
upper metal.
7) Remove the crankshaft assembly.
0 ER11·112
ER11·105
8) Remove the ball bearing. 12) Remove the delivery valve spring,
2) Using a puller, remove the drive valve, O-ring and valve seat.
gear and key. 13) Remove the connector and pack
ing.
14) Remove the snap ring, unloader
valve, valve spring and valve holder.
ER11·106
9) Remove the compression rings and
JI 3) Remove the cylinder head assembly
oil ring.
and O-ring. 15) Using a valve holder tool (99744
25500), remove the suction valve
holder.
EP11·3 EP11·12
10) Remove the snap ring, piston pin
4) Remove the cylinder and O-ring. and piston.
16) Remove the suction valve spring,
valve, valve seat and packing.
3) Inspect the periphery of the piston 7) Measure the end gap piston ring, 12) Measure the outside diameter of
and the inside wall of the cylinder and record the results. If the the crank pin, and record the
for damage. If faulty, repair or re measured value reaches the repair results. Install the metal into the
place. limit, replace the piston ring. connecting rod and connecting rod
4) Measure the outside diameter of the Compression ring cap, and tighten the nut to the
piston and the inside diameter of Maintenance standard specified torque. Then measure the
the cylinder, and calculate of the 0.15 to 0.35 mm inside diameter of the metal and
clearance between them. Repair limit record the results. Calculate the
If the calculated value exceeds the 1.0mm clearance between the metal and
repair limit, replace the piston or Oil ring crank pin from the measurements.
cylinder. Maintenance standard If the calculated value exceeds the
Top 0.15 to 0.35 mm repair limit, replace the metal or
Maintenance standard Repair limit crankshaft.
0.19to 0.25 mm 1.0mm Maintenance standard
Repair limit 0.017 to 0.083mm
0.28mm Repair limit
Skirt 0.1mm
Maintenance standard
0.07 to 0.13mm 13) Inspect the delivery valve, un
Repair limit loader valve, suction valve, valve
0.18mm seat, valve spring and valve holder
for damage and wear. If faulty,
5) Inspect the piston ring for damage replace.
or uneven wear. If faulty, replace. 14) Measure the valve spring tension
6) Measure the clearance between the and free length. If the measured
EP11-39
piston ring and the ring grooves, value exceeds the repair limit, re
and record the· results. If the 8) Measure the outside diameter of the place the valve spring.
measured value reaches the repair piston pin and the inside diameter Free length
limit, replace the piston ring or of the piston pin bore, and calcu Delivery valve
piston. late the clearance. If the calculated Maintenance standard
Compression ring value exceeds the repair limit, re 13mm
Maintenance standard place the piston or piston pin. Suction valve
0.02to 0.06 mm Maintenance standard Maintenance standard
Repair limit 0.01L to 0.02T mm 11mm
0.10mm Repair limit Tension
Oil ring 0.05L mm Delivery valve (When com
Maintenance standard Remarks pressed to 9.5 mm)
0.03to 0.08mm T = Tight fit Maintenance standard
Repair limit L = Lose fit 0.46 kg
0.10mm Repair limit
9) Inspect the connecting rod for 0.37 kg
cracks or damage. If faulty, replace Suction valve (When com
or repair. pressed to 7 mm)
10) Measure the inside diameter of
the small end connecting rod and
record the results. Calculate the
clearance between the inside dia
meter of the small end connecting
rod and the outside diameter of the
piston pin. If the calculated value
exceeds the repair limit, replace the
connecting rod or piston pin.
Maintenance standard
0.02to 0.04mm
Repair limit
EP11-13 0.07 mm
Maintenance standard 15) Inspect the oil seal lip for damage. REASSEMBLY
0.45 kg If faulty, replace.
Before reassembling, apply clean
Repair limit
engine oil to each rotating or sliding
0.36 kg Note
surface. In addition, replace all
Generally, the oil seal should be re
gaskets, packings and O-rings with new
Note placed with a new one when over
ones.
The value of free length is mentioned hauling.
for reference. Then, judge the need
for replacement of the valve spring 16) Check the ball bearing for any
by measuring its spring tension. sign of uneven rotation, noise or
heat discoloration. If faulty, re
place.
EF11·034
1) Install the packing, suction valve 8) Install the packing and connector
seat, suction valve, and suction to the unloader valve holder.
valve spring into the cylinder head. Tightening torque
2) Using a valve holder tool {99744 3.0 to 3.5 kgm
25500), install the suction valve
holder into the cylinder head. 9) Install the piston ring into the
Tightening torque piston.
10 to 12 kgm Note
Do not install the piston ring with its
gap facing in the direction of the
piston pin and vertical direction of the
piston pin but with the manufacturer's
6) Using a test rod, measure the lift of mark facing up.
each valve. Confirm that the
measured valve lift is within the
EP11·12
specified values. •
Valve lift
3) Install the unloader valve holder, Delivery valve (A)
valve spring, unloader valve and approx.1 mm
snap ring. Unloader valve (B)
approx. 2 mm
Tightening torque
Suction valve (C)
10 to 12 kgm
approx. 3 mm
SUCTION VALV.E
ER11-124
4) Install the delivery valve seat, O
ring, delivery valve and valve spring. 7) Using a punch, stake the suction
5) Install the O-ring and delivery valve valve holder in three locations.
holder.
Note EP11-113
Tightening torque Do not stake the same portion that has
10 to 12 kgm previously been staked. 11) Install the ball bearing.
Note
Apply a coat of 0.2 - 0.3 cc adhesive
to three threads of the delivery valve
holder on the side of the cylinder
head.
EP11-19
ER11-112
·,
?I
VACUUM PUMP
i i,
'.,ii
lj
t1 J1:. ..:·_:.':., ,:. !,
!i
iii
J
EF11·036
15
2) Remove the pump cover.
3) Remove the rotor from the housing 3) Housing • Replace hardened or discolored oil
and remove the vane from the Inspect the sliding surface with the seals. (Inside diameter of oil seal
rotor. At the same time also remove rotor for damage and replace when must be within 19 mm.)
the 0-ring from the housing. worn or damaged, especially when As a rule, replace all the oil seals at
the inside diameter is worn or the time of each disassembly.
damaged. • Replace any discolored copper
4) Others packing. Moreover, check the
• Replace the 0-ring at each dis threads of each part for damaged
assembly. and replace when damaged beyond
use.
REASSEMBLY : : +d
:rn
J.ii!
il'ii
1,l.i.fl,l,,1'/./;
1
1/f!·I
11:,
.,,11
i l•l
Cleaning
Remove dirty oil, dust, metal powder,
etc. clinging to each part and then
clean each part.
Since unexpected damaged can be
easily detected while cleaning, perform
cleaning work carefully.
After cleaning, dry each part with
compressed air.
Inspection
1) Vane
Measure the length, height, and
thickness of the vane and replace EF11·039
when over the wear limit.
Length
Nominal dimension
41.0 mm 1 Ball bearing 7 Plug 12 Connector (exhaust)
2 Oil seal 8 Valve assembly 13 Bolt
Wear limit
3 Rotor 9 Housing 14 Connector
40.5 mm 4 Vane 10 Generator 15 Pump cover
Height 5 0-ring 11 Bolt 16 Packing
Nominal dimension 6 Packing
23.5 mm
Wear limit
22.0 mm
Thickness·
Nominal dimension
7.0mm
2) Pump cover
Check for damage at the sliding 1) Assemble the four vanes with the EF11-40
surface with the rotor and replace end having the round chamfer at 1 Rotor
when worn or damaged. the outside. 2 Vane
A UXJLIAR Y EQUIPMENT 11- 15
2) With the side having the rotor "+" 3) With the cover oil supply port at 5) Hold the pump perpendicular and
shaped oil groove at the cover side, the housing exhaust side, install the mounted to the generator as shown
align with the shaft hole and insert pump cover with the three bolts in the figure and install with the
into the housing. At the same time and lock washers. three bolts and lock washers.
also install the O-ring. Tightening torque Tightening torque
0.6 to 0.7 kgm 0.6 to 0.7 kgm
4) Align the rotor shaft hole and
Note
housing oil seal shaft hole as shown
in the figure at the right. (Left Be careful that the oil seal is not
figure eccentric state) damaged by the spline of the shaft.
EFl 1·038
1 Vane 3 0-ring
2 Rotor 4 Housing
EF11·41
EF11·42
/'/
I
19
20
21
Bolt
Lock washer
Bracket (front)
½
22 Oil seal
23 Body
24 0-ring
25 Key
/:;@ 26 Shaft
,:;: I
27
28
29
30
Spring
Spring
Relief valve
0-ring
�
EFl 1-43
31 Connector A
32 Connector B
11- 16 AUXILIARY EQUIPMENT
EF11-050
EF11-47
EF1 i-44 6) Remove the clip using pliers. CLEANING AND INSPECTION
Note The cartridge assembly is a sub
Take care not to damage the shaft, assembly consisting of a rotor, vane,
rotor and vane. cam ring, pressure plate, side plate,
2) Clamp the front bracket in a vise
and straight pin.
and remove the rear bracket.
1) Clean all parts except those made
of rubber with cleaning fluid, then
wash with water and dry thorough
ly.
2) Insert vanes into the rotor slots,
making sure that they are free to
move.
EF11-48
Note
The above is on criteria for the in
4) Remove the front bracket. 8) Remove the connector and dis dividual parts. The final usage limit is
5) Remove the cover and side plate A. assemble the relief valve assembly. determined by overall judgement of
AUXILIARY EQUIPMENT 11- 17
the performance after it is actually exceeds the wear limit, replace the 12) If the oil pressure fluctuates or if
installed to the vehicle as the power body. it is outside specifications, replace
steering oil pump. Moreover, since Wear limit 0.1 mm the flow control valve assembly.
wear is produced by the gradual sliding CM80 and RM80
of related parts, abnormal wear of one Maintenance standard
part may also result in trouble in other 82.5 to 90 kg/cm 2
parts. 9) Check the valve spring for fatigue.
If fatigued, replace. Repair limit
1O) Check the passage between the Less than 80 kg/cm 2 ,
power steering oil pump and valve More than 90 kg/cm 2
6) Check the ball bearing for free play,
for clogging. If it is clogged, pass a CK80
uneven rotation and rotating noise.
wire through it and blow away dirt Maintenance standard
Replace if faulty.
with compressed air. 92.5 to 100 kg/cm 2
Repair limit 0.04 mm Repair limit
11) Measure the outside diameter of
the relief valve and inside diameter Less than 85 kg/cm2 ,
7) Generally all rubber parts should be More than 100 kg/cm2
of the body, and calculate the clear
replaced with new ones.
ance. If the calculated value ex
8) Measure the outside diameter of the
shaft and the inside diameter of the
ceeds the wear limit, replace the REASSEMBLY
body bushing, and calculate the body and valve.
Before connecting reassembly, dip all
clearance. If the calculated value Wear limit 0.03 mm parts in clean power steering oil.
",,
,,1
;,
j,:'
;'i'
1; ,1 ,
EF 11-003
1
2
3
Cam ring
Rotor
\:lane
j Cartridge
11
12
13
Stud
Seal washer
Clip
21
22
23
Bracket (front)
Body
Bushing
31
32
33
Lock washer
Spring
Seat
4 Dowel pin 14 Collar 24 Shaft 34 Ball
5 Side plate A 15 Reservoir 25 Oil seal 35 Spring
6 Cover 16 Side plate B 26 Key 36 Spool
7 Bolt 17 0-ring 27 Lock washer 37 Ball
8 Bracket (rear) 18 0-ring 28 Nut 38 Ball support
9 Nut 19 0-ring 29 Pulley 39 0-ring
10 Lock washer 20 Spring 30 Bolt 40 Connector A
41 Connector B
11- 18 AUXILIARY EQUIPMENT
1) Insert the relief valve spring and 2. Assemble the ten vanes with the 7) Install the O-ring to the body and
relief valve. And then install con end having the round chamfer on coat with grease. And then install
nector A together with the O-ring the outside. the reservoir, seal washers and
and install connector B. bolts.
Tightening torque Tightening torque
Connector A 3.5 to 4.0 kg
7 .5 to 8.5 kgm
Connector B
3.5 to 4.5 kgm
EF11-052
EF 11-051
DISASSEMBL V
r
1 Plug 21 Plate
2 0-ring 22 Spring
3 Spring 23 Dowel pin
24 Rear body
cooUol ,al,e 25 0-ring
4 Seat 26 Plug
5 Shim 27 Lock washer
6 Poppet 28 Bolt
7 Spring 29 Nut
8 Shim 30 Lock washer
9 Spool valve 31 Key
10 Bolt 32 Shaft
11 Lock washer 33 Snap ring
12 Seal washer 34 Ball bearing
13 Connector 35 Collar
14 Plate 36 Snap ring
15 0-ring 37 Oil seal
16 Connector 38 Ball bearing
17 0-ring 39 Front body
@
18 Vane 40 0-ring
19 Rotor 41 0-ring
l,ji
20 Cam ring 42 0-ring
-----
1) Remove the front body assembly_ 4) Remove the snap ring from the 5) Press out the drive shaft.
front body.
EP11-144
6) Remove the snap ring and then CLEANING AND INSPECTION Note
press out the ball bearing. The above is on criteria for the indivi
The cartridge assembly is a sub-assem
dual parts. The final usage limit is
bly consisting of a rotor, vane, cam
determined by overall judgement of
ring, pressure plate, side plate, and
the performance after it is actually
straight pin.
installed to the vehicle as the power
1) Clean all parts except those made
steering oil pump. Moreover, since
of rubber with cleaning fluid, then
wear is produced by the gradual sliding
wash with water and dry thorough
of related parts, abnormal wear of one
ly.
part may also result in trouble in other
2) Insert vanes into the rotor slots,
parts.
EP11·55
making sure that they are free to
move.
6) Check the ball bearing for free play,
uneven rotation and rotating noise.
7) Remove the oil seal.
Replace if faulty.
Note
Repair limit 0.04 mm
Do not remove the oil seal unless an
oil leak is present. If it must be re
moved, discard and install a new one. 7) Generally all rubber parts should be
,;. ,., ..
replaced with new ones.
,,)!) :::,:
1/1!1
8) Check the valve spring for fatigue.
If fatigued, replace.
9) Check the passage between the lj::!
[. ..
EP11·144
power steering oil pump and valve
for clogging. If it is clogged, pass a (''
3) Inspect the vane chamfer. If faulty,
replace the cartridge assembly. wire through it and blow away dirt
4) Check the side plate, and pressure with compressed air.
10) If the oil pressure fluctuates or if
plate vane contact surfaces, making
sure that they are not scratched. it is outside specifications, replace
the flow control valve assembly.
Replace the cartridge assembly ex
hibiting defects. If repair seems Maintenance standard
feasible, dress the parts with an 67.5 to 75 kg/cm 2
oilstone. Repair limit
5) Inspect the pressure plate rotor and Less than 65.0 kg/cm 2 ,
side plate contact surfaces for wear. More than 75 kg/cm 2
8) Remove the plug, O-ring, spring and If faulty, repair them or replace the
flow control valve assembly. cartridge assembly.
A UXJLIAR Y EQUIPMENT 11-21
REASSEMBLY
Before connecting reassembly, dip all
parts in clean power steering oil.
EF11·057
',
I
1 Plug 12 Lock washer 23 Lock washer
2 0-ring 13 Bolt 24 Nut
3 Flow control valve assembly 14 0-ring 25 Shaft
4 Spring 15 Connector 26 Rear body
5 0-ring 16 0-ring 27 Spring
6 Plug 17 Front body 28 Plate
7 0-ring 18 Oil seal 29 Dowel pin
8 Connector 19 Collar 30 0-ring
9 Bolt 20 Ball bearing 31 Ball bearing
10 Lock washer 21 Snap ring 32 Snap ring
11 Seal washer 22 Key
1) Install the flow control valve as 4) Insert the drive shaft into the front 5) Install the three O-rings to the front
sembly, spring, O-ring and plug. body and install the snap ring. body.
2) Install the oil seal. (if removed) Note
6) Fix the two dowel pins on the front
3) Press the ball bearing onto the drive body and install the rotor and cam
After forcing the ball bearing into
shaft and install the snap ring. ring.
place, turn the drive shaft and verify
Note that it rotates freely.
Be careful not to damage the oil seal
contact surface of the drive shaft with
the snap ring.
7) Face the rounded end outward and 8) Install the plate, spring and rear
insert each vane in turn into the body.
rotor slot. Tightening torque
3.5 kgm
EA11·153
METER DRIVER
DISASSEMBLY
INSPECTION
Inspect the gears for wear and damage
and check the ball bearing play and
the bushing for wear and replace
when faulty.
REASSEMBLY
When reassembling, reassemble in the
reverse order of disassembly by
referring to the figure.
Reassembly precautions
1 Housing 6 Ball bearing
1. When installing the drive gear, pack
2 Grease nipple 7 Clip
3 Pin 8 Driven gear the hole of the housing shaft with
4 Bushing 9 Bushing grease. Moreover, add more grease
5 Drive gear 10 Connector from the grease nipple after re
assembly.
2. Coat the connector and set screw
with lock tite when installing them.
12. ENGINE TEST PROCEDURES
EF1-002
This chapter describes the test procedures for engine diagnosis and for break
in and performance checks, as well as how to check timing following engine
overhaul.
::tn"";.,·"
bly, and insert the compression Note
HI gauge into the nozzle hole. Measurements should be made two or.
'
:,i ,,
Notes three times for each cylinder while the
._;,;
1. Remove all nozzle holder assem engine is still warm. An average of the
blies from their cylinders and place measured values should then be ob
covers on their openings to prevent tained. Measurement should be made
the entry of dirt or dust. on all the cylinders. EF12-001
Note
Perform this measurement at leas t two
times, and obtain the average value.
6) The sequence of measurement is as
follows:
1. Exhaust valve opens.
2. Intake valve opens.
3. Exhaust valve closes.
4. Intake valve closes.
If the engine emits excessive smoke Tightening torque 4) The delivery valve holder will stop
during operation, lacks power, or 4.5 kgm discharging fuel at a specific
knocks frequently, the fuel injection flywheel position, which will be the
timing should be measured. 3) Install the timing plate and needle starting position for injection when
Fuel injection timing pointer. the engine is started. Read and
FD6 record the value indicated on the
°
B.T.D.C. 15 30' timing plate.
FD6T
°
MEASURING FUEL INJECTION Note
B.T.D.C. 17 TIMING Perform this measurement at least
1) Rotate the flywheel in the reverse three times, and calculate the average
direction until the No. 1 piston is value. ·,· .
:··;;;
PREPARATORY OPERATION 20
°
B.T.D.C. on compression ii····
Engine performance tests should only the engine, then check the oil level BREAK-IN OPERATION
be conducted after making sure that again.
1) Crank the engine with the starter
each portion of the engine is operating 2) Connect pipes to the outlet and
without fuel injection, making sure
normally without oil or water leakage inlet of the power steering oil
that the needle of the oil pressure
during the break-in operation. pump, respectively, and add power gauge is moving. Then, start the
steering oil to the oil reservoir (if so engine.
equipped). 2) Idle the engine for more than two
PREPARATORY OPERATION 3) During preparatory operations, minutes, and make sure that the oil
1) Check engine oil level. If the engine remove the cooling fan from the pressure exceeds 1 kg/cm 2 •
has not been operated following engine, but leave the generator and 3) Make sure that oil is fed properly to
reassembly, splash a small amount air cleaner installed to it. the rocker shaft, injection pump,
of engine oil to both the rocker engine rear P.T.O. and other areas.
shafts and valves, idle the engine for
a prolonged period of time, stop
ENGINE TEST PROCEDURES 12-3
(kg) (minute) 8
� (rpm) 100% Load test
1 600 0 10 1) Run the engine, and measure and
2 1,600 10 10 record the following items at in IDLING TEST
2,000 16 crements of 200 rpm, starting with Perform this test with the dynamo
3 5
1,200 rpm, up to 3,200 rpm. meter disconnected, simultaneously
4 1,400 16 5
2) The items to be measured are as checking for idling speed, temperature
5 2,000 20 10 follows: and pressure of engine oil, cooling
6 2,400 26 10 1. Dynamometer load water inlet and outlet temperature,
7 2,800 33 10 2. Fuel quantity consumption rate color of exhaust smoke, hunting, etc.
8 3,200 Full load 10 3. Engine oil pressure
Idling (Water and oil temperature
4. Engine oil temperature °
60 C 580 to 620 rpm)
Length of dynamometer arm 5. Cooling water inlet and outlet
0.716 m temperatures
Note
6. Exhaust temperature
The engine should not be stopped
7. Room temperature, humidity
5) During the break-in operation and pressure
using sudden acceleration and/or de
period, measure the following 8. Others: Check for leakage of oil,
celeration.
items, making sure that all data is fuel, cooling water and gas. Also
within the maintenance standard. check the color of exhaust NO-LOAD MAXIMUM SPEED
Oil pressure smoke and other operating con TEST
Maintenance standard ditions. Perform this test with the dynamo
Idling Higher than 1.0 kg/cm2
3) Calculate shaft output, shaft ·torque meter disconnected, simultaneously
3,200 rpm
and fuel consumption. The calculat checking for operation of governor,
Higher than 4.0 kg/cm2
ing formulas are as follows: temperature and pressure of engine oil,
Cooling water outlet temperature cooling water inlet and outlet temper
Maintenance standard 21r2WN atures, color of exhaust smoke, etc.
' .
•,.:
° p = = CWN
70 to 80 C 60 x 75 No-load maximum speed
Lubricating oil temperature
(Water and oil temperature
Maintenance standard T = WQ °
60 C)
i .!; 70 to 100 C
°
3.6b
Water, oil and fuel leakage F =-- Maintenance standard
ji[! .,;.·,.
t Less than 3,450 rpm
:,1; t_;:,' .:,. !J::,;:· No sign of leakage should be
Ii !i '�
1 000 Fr = 3,600 br
1:ij'! detected at any spot. f = 1
p Pt
'.,1''\/1!; Noise ACCELERATION AND
j
Engine should not make DECELERATION TEST
abnormally loud gear noise, 749 7
K = '.2 3+8 Perform this test with the dyna
Pa- Pw 293
X
etc.
mometer disconnected. Using a stop
6) After completing the break-in oper P: Shaft output [PS] watch, measure the time needed for
ation, retighten the cylinder head T: Shaft torque [kgm] acceleration from idling speed to maxi
F: Quantity of fuel consumed per mum speed and the time needed for
bolts, and check and adjust valve
hour [liters/h] deceleration from maximum speed
clearance.
f: Fuel consumption [g/PS-h] back to idling speed.
Retightening torque
Q: Length of dynamometer arm [m] Accelerating time
15 kgm
W: Dynamometer load [kg] (Water and oil temperature
Cylinder head bolt tightening
N: Number of revolutions [rpm]
°
60 C)
sequence
C: Coefficient of dynamometer [in Maintenance standard
case of PS] Below 1.5 sec.
b: Quantity of fuel consumed during Decelerating time
measuring period [cc] (Water and oil temperature
t: Fuel consumption time [Sec]
°
60 C)
r: Specific gravity of fuel at the time Maintenance standard
EF3-086 of measurement Below 3.0 sec.
12-4 ENGINE TEST PROCEDURES
DIAGRAM FOR OBTAINING WATER VAPOR PRESSURE (Pw) FROM DRY BULB TEMPERATURE AND WET
BULB TEMPERATURE
ci
:r 55
E
E
�
"'::,
/!l
a
15
a.
"'...
�
ES12-7
13. SERVICE DATA
EF1-002
This chapter tabulates engine performance data, various standards for servic
ing the engine, repair limits, wear limits and tightening torques for easy
reference.
Maintenance
Item Nominal value Repair limit Remarks
standard
Valve
valve Close
°
47 A.B.D.C. - - Valve clearance:
timing
Exhaust Open
°
53 B.T.D.C. - - 0.3 to 0.4 mm
valve Close
°
9 A.B.C.D. - -
°
FD6 15 30' B.T.D.C.
Fuel injection timing - - Crank angle with engine
FD6T
°
17 B.T.D.C. stopped.
13-2 SER VICE DATA
Flatness of
Lengthwise - Less than 0.10 Repair if main- 0.50
cylinder head
tenance standard (Grinding
mounting
Sidewise - Less than 0.02 is exceeded. allowance)
surface
�
0
Out-of-round - Less than 0.02 - -
...
JS
4)
Liner
fitting Fitting Upper - 0.01 SL - 0.065 - - L: Loose fit
T: Tight fit
-
"O
.5 bore allow-
>- ance Lower - 0.02T - 0.025L -
u
Clearance between bearing
cap and engine block
- 0.05T - 0.02L - - L: Loose fit
T: Tight fit
Inside Inside
100 - - 100.25 Measuring
diameter diameter
positions:
(Measure with
...
<II
the liner fitted Out-of-
round
- Less than 0.02 - - (From top end)
25, 70,120
to the cylinder
- -
4)
:§ and 180 mm
block.) Taper Less than 0.02 -
-
4)
- -
"O
.5 Flange projection from the 0.02 - 0.09
>-
u top surface
of block Difference
between - Less than 0.03 - -
adjacent
cylinders
Measuring
position:
Outside diameter 100 99.86 • 99.90 - - 24.5 mm from
the bottom of
piston skirt.
C
<II
0:
Clearance between cylinder
liner and piston
- 0.10 - 0.17 - -
C
ring groove 2nd (3rd) - 0.04 · 0.08 0.40
...
·;::
C
0
<II
and piston
ring Oil ring - 0.02 - 0.06 - 0.20
0:
End gap - 0.30 - 0.50 - 1.5
-
0:
Clearance between pin and - 0.03 - 0.05 0.10
bore in connecting rod
SER VICE DATA 13-3
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
us - - -
u"" Crank pin 0.25 61.675-61.695
outside 0.50 us - 61.425-61.445 - -
diameter
0.75 us - 61.175-61.195 - -
Out-of-roundness of crank pin - Less than 0.01 0.02 -
-
Crankshaft end play - 0.06 - 0.14 0.40 -
Clearance between journal - 0.05 - 0.12 0.15 -
and main bearing
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
Eccentricity between
�
Ill
9
crankshaft and flywheel 0.20 ...
Ill
w
Q)
<l.l
housing
.c:
� Runout on con�cting
� Less than 0.15 0.18
I.I.. surface of clutch disc
12 - 18 mm
V-belt tension A WATER PUMP
GENERATOR PULLEY
(Belt deflection when midpoint is PULLEY
pressed with a force of approx.
10 kg)
CRANK PULLEY
TEN·
SION
PULLEY
EF13-001
12 to 18 mm
GENERATOR WATER
PULLEY PUMP
PULLEY
ETl-055
EF 13-002
SER VICE DATA 13-5
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
.::
4>
.c:
Width Less than 0.05 0.20 0.30
4>
angle Exhaust 45
° °
45 00'. 45 30'
°
- -
.::
4>
> Width of contact Intake 2.2 · 2.4 3.5 -
iii between valve
> Exhaust -
and valve insert 2.0 - 2.2 3.5
Intake 30
° °
29 30' . 30 00'
° - -
Valve face angle
Exhaust 45
° °
44 30'. 45 00'
°
- -
.,,
Valve head Intake 2.0 - - 1.8
iii
> thickness Exhaust 1.5 - - 1.3
:if
I, ·:5 Intake 0.02 - 0.05 0.15
too Clearance between
> - -
4>
valve stem Exhaust 0.05 · 0.09 0.20
iii
>
Projection above cylinder
15 - - -
head
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
{mm) (mm)
Free length Outer spring 57.12 - - - For reference
(Both intake
and exhaust) Inner spring 54.26 - - - For reference
..
(Both intake
-
·;:
"' and exhaust) Inner spring
12.35 - 11 kg
When compress-
13.65 kg ed to 40.5 mm
For both inner
and outer
Squareness - Less than 2.0 - 2.8 springs of intake
and exhaust
valves.
Free length 60 - - -
Inside spring
Tension - 2.2 - 3.2 kg - 1.7 kg
When compress-
ed to 33.5 mm
..
... Cam follower outside
diameter
20 19.96 - 19.98 - 19.85
0.3 or more
Valve clearance - should go, 0.4 - -
should not go.
Valve clearance adjusting sequence:
1 2 3 4 s 7 8 9 10 11
5
6 12
Valve arrangement
IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 piston at TDC
on compression stroke
• • • • • •
No. 6 piston at TDC
on compression stroke
• • • • • •
SERVICE DATA 13-7
LUBRICATION SYSTEM
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
Clearance between
driven shaft outside
Cover
side
- 0.03-0.08 0.20 -
0.
diameter and driven
0. gear bushing inside Case - 0.03 - 0.07 0.20 -
side
0 diameter
More than
Relief valve opening pressure - 10.5-11.5 - -
kg/cm 2
... - 0.8- - -
.::
Q.)
Opening pressure
�r.;:
1.2 kg/cm 2
- -
=. "'
3: � Short
0 "' Spring free length 66.2 64
Et:"' valve
0.
::, >-
1.1...J:J Spring tension - 1.04 · 2.04 kg - 3.15kg
When compress-
ed to 57.7mm
<.)
Opening pressure - 2.8- - -
0 3.2kg/cm 2
Short
valve
Spring free length 68.6 - - 59
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
.s
tlO Valve opening pressure 2.0 kg/cm2
1.8.
2.2 kg/cm2
- -
o0 ..,.�
u._
C::
Valve spring free length 15.9 - - -
0 0
1,1:·1
SERVICE DATA 13-9
COOLING SYSTEM
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
Clearance between body and
impeller
- 0.3-0.8 - -
C.
:::,
C.
Outside diameter of impeller
fitting portion of shaft
- 13.03-13.05 - -
== Inside diameter of impeller - 12.99 - 13.01 - -
Fitting tolerance between
shaft and imepller
- 0.02T-0.06T - - T: Tight fit
Less than
76.5 74.5-78.5 - 71.5
Greater than
81.5
Less than
Valve opening temperature
O
( C)
82.0 80 - 84 - 77.0
Greater than
87.0
Less than
..."' 88.0 86-90 - 83
Greater than
93
°
76.5 C - More than
°
10/90 C
- Less than
°
9/90 C
Valve lift
°
82.0 C - More than
° - Less than
°
10/95 C 9/95 C
°
88.0 C - More than
° - Less than
°
10/100 C 9/100 C
Radiator leakage test pressure - 0.5 kg/cm 2 - -
Using com-
Water tank leakage test
pressure
- 0.5 kg/cm 2 - - pressed air
Less than
"' Water tank cap - 0.6 - 0.5 kg/cm2
.... type 0.8 kg/cm 2 Greater than
0
Valve 0.9 kg/cm 2
opening Pressure side
pressure Less than
Radiator cap
type
- 0.8-
1.0 kg/cm 2
- 0.7 kg/cm2
Greater than
1.1 kg/cm 2
13- 10 SER VICE DATA
FUEL SYSTEM
Difference in injection
interval of each cylinder
60
° °
59 30' . 60 30'
° °
59 . 61
° -
Tension lever, speed setting
lever and guide level hole - 0.02 - 0.09 0.20 -
and pin clearance
Type
RAD
governor
Flyweight pin and bushing
clearance
- 0.02 · 0.05 0.08 -
Load control lever and - 0.01 · 0.05 0.15 -
bushing clearance
Timer
Flyweight and flange - 0.02-0.10 - - Adjust with
clearance shims
i!
i:,,
/:
,.\
i:;1!
iii!i
13- 12 SERVICE DATA
Test condition
Nozzle
injection
175 200 220
pressure
{kg/cm 2)
Feed
pump oil
pressure 1.6 1.6 1.6
(kg/cm 2)
Injection
pipe
6 X 2-600 6 X 2 -626 6 X 2 -626
(OD X ID I '
-L) (mm)
Test oil
temper- 40-45
°
ature ( C)
Note The fuel injection pumps (P/N: DKKC No. 101681-9170, 101681-9150, 101691-9120 and 101691-9130) have been checked under
the test conditions specified in the on-vehicle adjustment specifications. All other pumps have bean checked under the test conditions
specified in the standard adjustment specifications.
SER VICE DA TA 13- 13
RAD governor
• DKKC No. 101691-9080, 101691-9060, 101691-9180, 101691-9160, 101691-9170 and 101691-9100
1) J IS No. 2 light oil (ASTM No. 2D) or ISO 4113
RFD governor
• DKKC No. 101691-9220
1) J IS No. 2 light oil (ASTM No. 2D) or ISO 4113
RSV governor
• DKKC No. 101681-9150
J IS No. 2 light oil (ASTM No. 20) or ISO 4113
±3 Boost press:
10.7 1,350 70 - 74
above 300
±2 Standard
10.7 800 66.6 - 69.4
(above 300)
a. 0 Q, 00 201f---+<----+-----+-...
300 o.s • o os ! ...,...
�00 II +3
Q. -0
410 �O>f--+---t--1,"1
CONTROL ROD POSITION (nwn)
lOO·
EF9·168
0 3.4 · 0 3 5 6 10 9.7 abov• 14
•bove
CONTROL ROO POSITION (mm) E F9-161 " DKKC No. 101691-9130
DKKC No. 101691-9080, 101691-9060, CONTROL ROO POSITION Imm) E F9• 164
101691-9180, 101691-9160
and 101691-9170
:!; u::·J'
FUEL EXCESSIVE
• Set the load control lever at "Full".
SETTING FOR START:
9
r2 =�·2mm 1.i " '
''i .
-- -
MAIN SPRING SET
I ,,. .
0
'f-- -t-- �=-;A
U•OI
t,J
0
w ROD LIMIT:
w 300 14 · D.I
Ul
....
3.4 :: 0.3 5 6 8.2 10 9.7 10.2 above 14 U U 91 U ,3
8.2 0
CONTROL ROD POSITION (mm)
above'
CONTROL ROO POSITION (mm)
CONTROL ROD POSITION (mm)
EF9-162 EF9-169
EF9·165
DKKC No. 101691-9100
DKKC No. 101691-9120
FUEL EXCESSIVE RSV governor performance curve
SETTING FOR
START : 11 6 :j1- BOOST STROKE U RLD governor performance curve
,..,
[below
� 1750
CONTROL ROD
f;j1600::� LIMIT:
lJJ
a.
l
0
DAMPER SPRING
�
i,.1ow
1750+,s
J
"'"' u·gr- 1600+25
(1550)
� 660±30
:> 540 d0
a. 390,±25
.. ,., ROD LIMIT
w
o. m w
300 ,.. Q,
Q,
2.6 3.5 8.9 10.6
above above Q,
CONTROL ROD POSITION (mm) B 7.2 10.1
CONTROL ROD POSITION {mm) 225
below
EF9-163 EF9·166
DKKC No. 101601-9070 and DKKC No. 101681-9150 above
101601-9150
FUEL EXCESSIVE CONTROL ROD POSITION (mm)
SETTING FOR EF9-170
START: 9.6 2mm �8· Boost compensator performance curve
9
- belo
[ 1750 t---='l"-
=16od'6-+---,---....;;:=-i
0 '+-4
J llO±ll----+---==-.J
- 0 .3 -tO.I
..SE 11.3
=�
er
5.5 7.2 10.4 18 0 120±50 225±10
O 2.5±0.5 5
7. above9,4 CONTROL ROD POSITION (mm)
EF9-193 BOOST PRESSURE (mmHg)
9.3
EF9-167
CONTROL ROD POSITION (mm) ER9·2 58
DKKC No. 101691-9320 DKKC No. 101681-9170
SERVICE DATA 13- 17
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
..r:::.
of shaft Piston
ring part
17.34 - - 17.29
:::l
I- Inside diameter of back plate 12.70 - - 12.73
Inside diameter
Bearing
15.80 - - 15.81
part
of center
housing Piston
18.03 - - 18.08
ring part
Clearance between
One side - 0.1 - 0.4 - -
�� only
"' ....
:::l ....
..c :::l butterfly valve
X..c
LLJ "' and body Total of
both side
- Less than 0.5 -
13-18 SER VICE DA TA
ELECTRICAL SYSTEM
STARTING MOTOR (S25-64B, S25-110)
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
525-64B 19.5 - - 11.5
..c
Brush height
525-110 18 - - 11
E
Eccentricity and taper of
sliding surface
- 0.05 0.4 -
E
0
� Rear cover - -
0.03 • 0.07 0.20
.::: bearing
..c Clearance
Vl
between Center bearing - 0.13 · 0.17 - 0.30
each part Pinion bearing - 0.06 - 0.10 - 0.20
and shaft
Gear case - 0.03 · 0.07 - 0.20
bearing
Shaft bend - - - 0.1
Clearance between pinion and
pinion stopper with plunger - 0.3 · 1.5 - -
clearance at zero
525- - Less than 70 - -
,._ Current 64B
<l.l
a. (A)
0 525- - -
a. Less than 110
,._ Under no 110
0
0 load Greater than
E 525-64B - -
Oil 4,000
·;. RPM
...
Vl 525-110 - Greater than - -
3,500
Pinion pop out voltage (V) - Less than 18 V - -
SER VICE DA TA 13- 19
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm}
(mm) (mm)
GENERATOR
Nominal Maintenance
Sec- dimension standard Repair limit Wear limit
tion Item Remarks
(mm} (mm) (mm) (mm)
,:i
! Spring LR288-11 B 255 - 345 g - - -
tension
-
'·
- -
!
LT215-20
LT225-22C
LT225-59 34 - - 33
LT225-66
Slip ring
LT235-48
outside
diam-
�"' eter
LT215-39
LT225-56B
LT225-62S
LT225-63 40 - - 39
LT240-04B
LT240-14E
LT240-15
LR280-11B 50 - - 49
LR280-11B - 0.03 - -
LT240-04B
Resist- LT240-14E - 0.11 - -
Stator
·o ance °
LT240-15 At 20 C
valve (n) coil
LT235-48 - 0.17 - -
LT225-63 - 0.19 - -
13-20 SERVICE DATA
Nominal Maintenance
Sec- dimension standard Repair limit Wear limit
Item Remarks
tion (mm) (mm) (mm) (mm)
LT225-22C
L T225-56B
L T225-59 - 0.24 - -
L T225-62
Stator L T225-62S
coil
LT225-66 - 0.29 - -
LT215-20 - 0.48 - -
LT215-39
LT215-20 - 18.0 - -
L T215-39 - 17.0 - -
·ou Resist-
ance LT235-48 - 13.7 - - °
At 20 C
valve (n)
LT225-22C
L T225-59 - 13.3 - -
LR280-11B
Rotor
coil LT225-63
L T240-04B - 13.1 - -
L T240-14E
LT240-15
I:···'·
L T225-56B
- - t.
L T225-62 - 12.8
L T225-62S
LT225-66 - 12.5 - -
AUXILIARY EQUIPMENT
COMPRESSOR PULLEY DRIVE TYPE
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
Piston ring
Compression - 0.2 -0.4 - 2.0
...., end gap
ring
Q.
0 Oil ring - 0.2 -0.4 - 2.0
..."'
. Q.
0 Clearance Compression - -
....,"'
Q.
between
piston ring
ring
0.01-0.044 0.1
Piston ring
Compression
ring
- 0.15-0.35 1.0 -
end gap
Oil ring - 0.15-0.35 1.0 -
.,
Q.
0
Width of
Compression
2.5 - - -
...
Q.
ring
"'.,"'
0
ring groove
Oil ring 4 - - -
Q.
E Clearance
u0 between
Compression - 0.02 -0.06 0.10 -
ring
piston ring
and ring Oil ring - 0.03 -0.08 0.10 -
groove
13-22 SER VICE DATA
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm) (mm)
(mm) (mm)
Clearance between pin and pin
bore of piston
- 0.QlL • 0.02T 0.05L - T: Tight fit
L: Loose fit
·=
Q.)
.s:: Tension 0.45 0.36
sed to 7mm
- - -
Q.)
"C
Free length 13 For reference
Delivery
valve spring Tension - 0.46 .0.37 - When compres-
sed to 9.5 mm
VACUUM PUMP
Nominal Maintenance
Repair limit Wear limit
Item dimension standard Remarks
(mm) (mm)
(mm) (mm)
Thickness 7.0 - - -
POWER STEERING OIL PUMP (PULLEY DRIVE TYPE)
Nominal Maintenance
Repair limit Wear limit
Item dimension standard Remarks
(mm) (mm)
(mm) (mm)
MS x 1.25 1.5-2.0
Flywheel housing mounting bolt and nut
Ml 2 x 1.25 7.0-7.5
'"
i; Oil pump mounting bolt 2.0
FD6 1.6-2.0
Air intake manifold mounting bolt
FD6T 0.9-1.2
Tightening torque
Tightening point Remarks
(kgm)
LUBRICATION SYSTEM
Tightening torque
Tightening point Remarks
(kgm)
FUEL SYSTEM
FD6 6 -8
Q) Nozzle nut
-;::;
0
FD6T 8-10
AUXILIARY EQUIPMENT
...
Cl)
Front bracket mounting bolt (belt drive type) 3.5 · 4.0
Cl)
ji
14. TOOLS
EF1-002
This chapter describes tools used when repairing the FD6 & FD6T engines.
For safety and efficiency, use tools covered in this chapter when disassembling
and reassembling the FD6 & FD6T engines.
SPECIAL TOOLS
ENGINE DISASSEMBLY AND REASSEMBLY
ET14-045C
ENGINE PROPER
ET14-006
�ci-�
99600 Z5001 Used to remove and install the cylinder
Cylinder liner tool assembly liner.
ET14·014A
ET14·012C
TOOLS 14-3
e::J'
ET14·043A
�.�,,
99655 Z5500 Used to remove the nozzle tube.
Nozzle tube remover
ET14·0208
ET14-033
ET14-030
99666 Z5000 Used for forcing the valve guide into the
Valve guide replacer cylinder head to the specified depth.
ET14-031 A
FUEL SYSTEM
/
99727 25004 For cleaning nozzle orifice.
Pin vice
EP14·121
/.,..
99726 25000 For removal of carbon from back side of
Nozzle cleaner· nozzle orifice.
,,,
157914-0500
fi:,,,
For removal and installation of delivery
lJ: j '
'
Socket wrench valve holder.
1,·:i�
EP14·136
EF14-003
14-6 TOOLS
0
EP14-139
•;, :·,:
>i:;;li !i;!
lilj
157912-0920 For removal of timer nut. ,;·!
·1ri
---::=:J !!,
Special wrench lHi
l'!/l
1
ER14-130 ,/'i
.: 11
:11:
;,!Id:
,:-
157910-1120 Used with socket wrench.
L-type handle
ES14•29
EF14·011
EF14-012
EF14-013
EF14·015
EP14·145
14-8 TOOLS
EF14..016
EF14-017
EF14-018
EF14-019
EF14-033
EF14-021
TOOLS 14- 9
EF14-022
•i·1: i
EF14·023
'i
.,, EF14-024
ii.ii!
1ji
i'
1,1
!/
ii
,i
,,
'I
��
w�
,,
·11 157840-4420 For connecting the coupling to the pump
;.1.
��
EF14·026
:o
105794-0020 Injection pump disassembly and re
Universal vice assembly stand.
.J
________,,,
,
EF14-027
14- 10 TOOLS
-,
EF14-029
ef
157916-4320 Used to prevent the timer flyweight
Special wrench holder from turning.
EF14-031
Turbochargers
EP15-059
EP15-066
0
IIl-i 99763 Z5500 Used when inserting the piston ring to
t!U.
Piston ring guide the shaft wheel. (T048 type)
EP15-056
ER14-131
0
99768 25500 Used when disassembling and assembling
Holding fixture the rotating assembly.
ER14-132
/
Torque wrench housing and center housing.
Torque 1.7 kgm
EP15-069
EP15-070
/
99537 25502 Used to tighten and remove the compres-
Torque wrench sor housing and back plate.
Torque 1.3 kgm
EP15-069
�"'"
TOOLS 14- 13
AUXILIARY EQUIPMENT
Air compressor
�.,
99754 96000 Used to install the piston of the air
Piston insert tool compressor.
ET14-089B
�-00,A
ET14-053
14- 14 TOOLS
WRENCHES
Part number Size [mm] Part name Application Shape
-�
10 16 153 150 ,o,
99538 25002 14
r
12 19 450 250
99538 25003 17 T-wrench 14 22 303 300
99538 25004 19 17 25 198 300
-
.
99538 25005 22 19 26.5 198 300
99538 25006 24 22 33 150 400
EP14-169
24 36 400 400
99535 25001 12
99535 25002 14 I (12)
� '5> '5>
�- 114) (10)
C--=�- w-;, ;
wrench
tightened to specification t ) t'.
; '
ES14-48 ; '
KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. North American English
245 E NORTH AVENUE Part Number SMEFDS1E00 NA
CAROL STREAM, IL 60188 U.S.A. Printed in U.S.A. • Bur