You are on page 1of 58

TECHNICAL INFORMATION

MODEL
2TE67L-BV on SV08-1

CONTENTS
1. Technical Data ..........................................................................................................................................................................1-1
2. Servicing Standards ..................................................................................................................................................................2-1
3. Measurement, Inspection and Adjustment ................................................................................................................................3-1
3-1 Measuring the Compression Pressure ..............................................................................................................................3-1
3-2 Adjusting the Valve Clearance ..........................................................................................................................................3-2
3-3 Checking the V-belt Tension .............................................................................................................................................3-3
3-4 Checking the Fuel Injection Valve .....................................................................................................................................3-3
3-5 Checking and Adjusting the Fuel Injection Timing (FID) ...................................................................................................3-6
3-6 Adjusting the Maximum (or Minimum) Idling Speed ..........................................................................................................3-7
3-7 Checking the Cooling Water System and Radiator for Water Leakage.............................................................................3-7
3-8 Checking the Sensors .......................................................................................................................................................3-8
4. Measurement Procedure, Service Data and Corrective Action .................................................................................................4-1
4-1 Cylinder Head....................................................................................................................................................................4-1
4-2 Cylinder Block....................................................................................................................................................................4-6
4-3 Valve Rocker Arm..............................................................................................................................................................4-8
4-4 Piston and Piston Rings ..................................................................................................................................................4-10
4-5 Connecting Rod...............................................................................................................................................................4-13
4-6 Camshaft .........................................................................................................................................................................4-16
4-7 Crankshaft .......................................................................................................................................................................4-17
4-8 Gears...............................................................................................................................................................................4-20
4-9 Trochoid Pump ................................................................................................................................................................4-21
5. Precautions for Reassembly......................................................................................................................................................5-1
6. Fuel Injection System ................................................................................................................................................................6-1
6-1 Fuel Oil Injection Pump .....................................................................................................................................................6-1
6-2 Disassembling Procedures................................................................................................................................................6-2
6-3 Reassembling Procedures ................................................................................................................................................6-3
7. Electrical Equipment..................................................................................................................................................................7-1
7-1 Starter Motor......................................................................................................................................................................7-1
7-2 Alternator ...........................................................................................................................................................................7-6
7-3 Glow Plug ..........................................................................................................................................................................7-8
7-4 Stop Solenoid ....................................................................................................................................................................7-9

1. TECHNICAL DATA

1. Technical Data
Item

Unit

SV08-1

Engine
Main specifications
Engine model

2TE67L-BV
Vertical type series water-cooled
4 cycle diesel engine

Type
Combustion system

Swirl pre-combustion chamber
pcs.-mm¯mm

2 - 67¯72

cc

507

kW (PS)/rpm

7.7 (10.5)/2400

Maximum torque / engine speed

N•m (kg•m)
/rpm

31.5 (3.21)/2000

Specific fuel consumption

g/kW(PS)•h

280 (22.8 or less)

Maximum idling speed

min-1 (rpm)

2575 to 2625

Minimum idling speed

min-1

1175 to 1225

Number of cylinders - Bore¯Stroke
Total displacement
Rated output / engine speed

Engine dry mass (excluding air cleaner and silencer)

(rpm)

kg

Lubricating method

60
(Exclude the air cleaner and the silencer)
Forced lubrication by trochoid pump

Specific lubricating oil consumption
Compression pressure

g/kW(PS)•h

0.1 to 0.8 (0.2 to 0.5)

MPa (kgf/cm²)

2.9 (30) at 300 min-1 (rpm)

Cylinder head
Intake valve
Exhaust valve

Open

bTDC

degrees

13

Close

aBDC

degrees

43

Open

bBDC

degrees

43

Close

aTDC

degrees

13

Intake valve clearance (Cold engine)

mm

0.2

Exhaust valve clearance (Cold engine)

mm

0.2

Intake valve seat angle

degrees

90

Exhaust valve seat angle

degrees

90

Piston
First compression ring
Second compression ring
Oil-ring

Ring shape

Barrel face

Ring quantity

pcs.

Ring shape

2
Taper face

Ring quantity

pcs.

Ring shape

2
I type (with coil expander)

Ring quantity

pcs.

2

Governor
Name

Mechanical all speed type

Type

Centrifugal type

Fuel feed system
Filter paper with automatic
air release device

Fuel filter
Fuel filter filtration area

cm²

Oil/water separator

432
Mesh filter screen

Feed pump

Mechanical, diaphragm

1-1

7 (125 to 135) Turbocharger Type -1 Revolution speed Turbocharging pressure min (rpm) - mmHg - Starting device Cold starting aids Ceramic glow plug Starting aids capacity V-W Battery type 11-93.9) pcs.2 (0. Ø1.5 hrs rate capacity V-Ah 12-30 Electrical equipment Type Alternator GP8146 Nominal output V-A 12-14 Rated speed -1 5200 min (rpm) 1-2 .0¯1 degrees 10 MPa (kgf/cm²) 11.22) Operating pressure of alarm switch kPa (kgf/cm²) 39.0) Full flow filter LO filter filtration area cm² 75 Filter valve opening pressure kPa (kgf/cm²) 80 to 120 (0.0 to 4.44 Fuel injection pump Injection pump type ND-PFR 2NC50A 2ND 828 Injection pump plunger diameter mm Ø4.9 to 12.5 44B-19L Battery voltage .4 to 0. TECHNICAL DATA Item Unit SV08-1 Engine Lubrication system Lubrication pump Trochoid pump LO pressure regulating valve opening pressure kPa (kgf/cm²) LO filter 353 to 451 (3.¯Ømm 7¯Ø230 ºC 107 to 113 Radiator cap pressure Radiator fan Operating temperature of water temperature alarm switch Air cleaner Type Cyclone type Filtration area m² 0.8 (0.5 Injection pump cam lifting height mm 6.1.8 to 1.5 degrees 15 to 17 Fuel injection timing (FID) Firing order 1o2 Nozzle Type ND10PD41 Nozzle hole diameter¯Number of holes Spray angle Fuel injection pressure Ømm¯pcs.2 to 58.6) Cooling device Forced circulation radiator cooling system Cooling system Fan belt size HM28 Thermostat opening temperature ºC 73 to 77 Thermostat full-open temperature ºC 87 or more kPa (kgf/cm²) 88.

2 Magnet shift - - Nominal output V-A - Regular V-A 12-0.1. TECHNICAL DATA Item Unit SV08-1 Electrical equipment Current limiter Type RS5161 Regulation voltage V Type Starter motor 14 to 15 Direct current type Nominal output V-kW Engagement 12-1.566 Moment V-A 12-3. 10¯2 Battery charge alarm lamp V-W 12-3 Engine oil pressure alarm lamp V-W 12-3 Water temperature alarm lamp V-W 12-3 Headlight V-W - Boom light V-W 12-27 Room lamp (for cabin) V-W - Wiper motor (for cabin) V-W - Cabin heater (for cabin) V-W - 1-3 .18 Horn V-W 12-30 Stop motor Stop solenoid Type Fuse Monitor lamps A¯pcs.75 Hour meter V-W 12-0.

000 to 18.955 Ø5. Ø17.965 to 17. Servicing Standards 1) Nominal and Allowable Values 2TE67L-BV Applicable model Item Unit Standard Wear limit mm 0.7 to 0.5 Ø5.000 to 10.05 or less 0. mm Oil clearance Valve sinkage Intake mm Exhaust Valve head thickness Intake Intake valve operating timing Open b.025 to 0.9 0.940 to 5.968 Ø11.8 0.9 Ø6.03 Cylindricity of cylinder 0.2 0.975 Ø5. 67.000 to 6.012 Ø6. TDC mm Exhaust Ø5. Exhaust valve Guide inside dia.775 to 1.12 degrees (°) 90  90  1.000 to 67.09 0.3 mm compressed] Intake / exhaust valve clearance Cylinder block Roundness of cylinder mm Valve rocker arm Rocker arm for Intake / exhaust valve Shaft outside dia.02 to 0.065 0.0 1.12 9.2.05 or less 0.2 0.2 Cylinder head Cylinder head distortion Valve seat angle Valve seat width Intake Exhaust Intake mm Exhaust Stem outside dia. 67.250 to 67.08 Ø0. Bush inside dia.053 0.075 1.5 13  43  degrees (°) 43  13  Free length mm 33  Inclination mm 1. Intake valve Guide inside dia.775 to 1. SERVICING STANDARDS 2.08 Ø0.980 Ø17.59 to 1.960 to 5.8 2. BDC Exhaust valve operating timing Open b.015 Ø10.9 Ø6.045 to 0. BDC Close a.05 0.032 to 0.7 to 0.9 6. Oil clearance Push rod bend Tappet mm Oil clearance 2-1 .03 Upper surface distortion 0.052 Ø0. Ø18.93 Guide hole inside dia.9 0.57 10.5 mm 0.018 Ø18.265 Over size 0.00 to 0.59 to 1.25 0.000 to 6.01 0.012 Ø6. TDC Close a.03 or less  Stem outside dia. mm Oil clearance Stem outside dia.2 0.12 Valve spring degrees (°) Tension [28.5 1.2 Cylinder bore dia.019 67.950 to 9.00 to 0.075 0.5 Cylinder bore dia.2 kg 6.072 Ø0.8 2.01 0.

470 to 1. Ø18.964 to 34.000 to 38.25 Piston 0.079 0. Minimum clearance between piston and cylinder Projection of piston from the upper surface of cylinder block Piston pin mm Ø18. 66.25 End gap 0.938 to 66.480 to 34.02 or less 0.90 to 28.6 Thickness of gasket 1.6 to 0.002 Ø18.05 26. 67.2.959  0.470 to 1.002 Ø18.100 to 0.953 67.03 or less 0.1 34.970 to 2.10 Ø18.188 to 67.030  Ring width (B) 2.010 to 3.2 0.0 #1.011  Ring width (B) mm Clearance between groove and ring Connecting rod Crank pin metal inside dia. SERVICING STANDARDS Applicable model 2TE67L-BV Item Unit Standard Wear limit Piston outside dia.98 0.0 Ring groove width 1.490  Clearance between groove and ring 0.3 Fuel pump 27.06 .5 to 0.2 0.004  Oil clearance 0.948 to 45.02 Ring groove width 1.964 to 42.520 34. Piston pin side Piston pin outside dia.130 to 0.996 to 19.25 End gap 0.00 27.503  Ø34.998 to 19.90 0.250 1.300 1.008 0.050 to 0.030 0.085  0. Oil clearance Twist and parallelism Oil clearance Cam Cam shaft bend Cam height Intake / Exhaust mm Injection pump Crank shaft Oil clearance mm Oil clearance Bend 2-2 45.550 to 1.031 to 0.100 to 0.2 0.490  0.90 Piston outside dia.040 to 0.0 Ø38.540 to 1.620 26.565 to 26.560  Piston ring Top ring Second ring Oil ring 1.015 to 19.2 0.004 to 0.081  0.484 to 1.280 1. 1.039 to 0.90 0.0 Ring groove width 3.017 to 0.035 to 0.026 Ø20.975 Ø34.3 Outside dia. 2 Journal Crank shaft 42. Oil clearance mm Bush hole inside dia.15 Ø19.996 to 19.15 End gap 0.570  Ring width (B) 1.975 39.047 to 0.092  #3 Journal Crank shaft Crank pin side Crank pin metal thickness Crank pin outside dia.020 to 0.060 0.990  Clearance between groove and ring 0.060 to 0.7 Thickness of gasket 1.203 Over size 0.98 Bush hole inside dia.100 0.088 0.090 0.08 or less for 100 mm 0.

7 at 3000 min-1 (rpm)  4.6 at 1000 min-1 (rpm)  Crank gear Backlash Cam gear mm Idle gear Others Lube oil pump discharge volume High speed L / min Low speed Oil pressure regulating valve opening pressure kPa (kgf/cm²) 382.1)  Oil pressure switch operating pressure kPa (kgf/cm²) 39.3  0.4 to 0.9 to 4.1 to 0. SERVICING STANDARDS 2TE67L-BV Applicable model Item Unit Crank shaft Side gap Oil pump mm Connecting rod Standard Wear limit 0.5 at 3000 min-1 (rpm)  °C 73 to 77  mm 6.1 to 0.3  0.2 (3.15  0.8 (0.2.2 to 58.0 or more at 87°C or higher  107 to 113  103 or more  Thermostat valve opening temperature Thermo-switch operating temperature Temperature Lift at opening ON °C OFF 2-3 .12  13.1 to 0.04 to 0.6)  Cooling water pump discharge volume L / min 26.4 to 422.

5 to 4.0 to 53.5 49.5 1) Apply 80% of tightening torque when tightened to aluminum.0 (4.2.8 to 142.3 to 2.0) Yes 2 Connecting rod nut M7 × 1.9 (4.3 to 1.1 to 58.5 to 3.5) M14 39.0) 2-4 .25 52.5 127.7) M12 24.8 (1.5) M12 × 1.0) Yes 4 Bearing holder upper and lower tightening M9 × 1.0) 1/2 58. Thread size × Pitch Item Tightening torque [Unit : N•m (kgf•m)] Lubricating oil 1 Cylinder head bolt M8 × 1.5 Fine thread R (PT) plug Pipe joint bolt Remarks 78.5 (24.0 to 5.0) M14 × 1.8 (1.0 to 10.3 (7.0 to 1.9 (6.5 84 to 93 (9.8 to 11.1 (8. SERVICING STANDARDS 2) Tightening torque for major bolts and nuts No. 166.7 (1.7 to 19.0 (17.5 to 147.0 to 15.0) M8 12.5 (2.4 to 86.0) 2) Apply 60% of tightening torque for 4T bolts and lock nuts.3 to 41.0) No 3) Tightening Torque for General Bolts and Nuts Item Hexagon head bolt (7T) Nut Coarse thread Thread size × Pitch Tightening torque [Unit : N•m (kgf•m)] M6 × 1 9.0 to 6.0 to 2. 323.0) 1/4 19.1 to 58.2) M8 × 1.0) M16 × 1.0 to 41.0 to 8.5 to 24.5 210.4 (3.2 (3.9) M10 × 1.0 (6.6 (2.1 to 2.0) 1/8 9.5 to 2.0 to 7.0) No 7 Glow plug M10 × 1.6 to 28.6 to 27.5) Yes 5 Crankshaft pulley tightening nut M12 × 1.0) 3) Use fine screw threads for 235.4 (2.25 14.7 to 16.5 to 34.25 34.6 (1.25 22.75 M14 × 2 M16 × 2 M18 × 2.0 to 21.3 (2.0) M20 × 2. 112.3 (21.0) 3/8 29.0 to 15.9 (5.2 to 49.8 to 206.0) M16 49.9 to 240.8 to 402.2 (12.0 to 29.5 to 6.5 to 98.0 to 55.5 44.2 (33.5 to 284.1 (13.0) engine only.0) Yes 6 Fuel injection nozzle tightening M20 × 1.0 22.6) Yes 3 Flywheel mounting bolt M10 × 1.9 (2.0 to 10.25 80.

This means that the compression pressure decreases as the engine parts are worn and lose durability through the use of the engine over a long period of time. INSPECTION AND ADJUSTMENT 3.3. Inspection and Adjustment 3-1 Measuring the Compression Pressure 1) Measurement Procedure (1) Warm up the engine.2 to 0. MEASUREMENT. and wear or breakage of any piston rings. Note : Never fail to attach the gasket to the tip of the adapter.3 (2 to 3) Compression pressure at 200 rpm MPa (kgf/cm2) 2) Trouble Diagnosis Through Measurement of Compression Pressure Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas (which causes contamination and increased consumption of lubricating oil. (2) Crank the engine before attaching the compression gauge adapter. and other trouble) and the engine starting failure. Note : Crank the engine when the regulator handle has been turned to "STOP" position (no injection state). Measurement. and (3) Gas leak through the nozzle gasket or the cylinder head gasket. according to the above step (2) and Note. Remove the fuel injection pipe and the fuel injection valve from the cylinder to be measured. [Engine compression pressure (Reference values)] Standard Allowable limit Variations of compression pressure among cylinders MPa (kgf/cm2) 2. the compression pressure is also decreased by scratches on the cylinder or the piston which are caused by dust or other foreign matters drawn in through the soiled filter element of the air cleaner.94 (30) 2. (3) Attach the compression gauge adapter and the compression gauge to the cylinder to be measured. In addition. (4) Crank the engine with the starter motor until the Measuring the compression pressure 002184-00E reading of the compression gauge is stabilized.45 (25) 0. (2) Degree of the clearance around the intake / exhaust valve seats . 3-1 . the condition of the engine should be diagnosed by measuring the compression pressure. The compression pressure is influenced by the following factors : (1) Degree of the clearance between the piston and the cylinder . Therefore.

) • Inspect and adjust the valve rocker arm. Intake / exhaust valve clearance Refer to Section "2 1) Nominal and Allowable Values". • Replace the filter element. 4-6 and 4-8. (Refer to Section 3-2. (3) Loosen the lock nut and the adjust screw.) • Valve timing • Improper valve timing • Improper valve clearance • Adjust the valve clearance. 2. • Valve clearance • Excessive or no valve clearance • Adjust the valve clearance.) • Replace the intake/exhaust valves. Tighten the adjust screw until the clearance listed below is attained. If the valve cap is worn or otherwise damaged in the head. 1 2 Item Causes • Filter element of air cleaner • Clogged filter element • Broken filter element • Defective filter element seal portion • Clean the filter element. (Refer to Section 2 2) of Chapter 2.) • Cylinder head gasket • Nozzle gasket • Gas leak through the gasket • Replace the gasket. (Refer to Section 3-2.) 3 4 5 6 Countermeasures 3-2 Adjusting the Valve Clearance (1) Inspect and adjust the intake / exhaust valve clearance while the engine is in the cold state. 002185-00X Adjust screw Notes : Lock nut 1. MEASUREMENT. the piston.3. piston ring or cylinder (Refer to Sections 4-2 3) and 4-4 8). • Piston • Piston ring • Cylinder • Gas leak due to scratches or wear of • Do the honing and use oversize parts. No. INSPECTION AND ADJUSTMENT Causes and countermeasures to be taken when the compression pressure is less than the limit value. (4) Insert a thickness gauge between the rocker arm and the valve cap. Check that the valve cap is free from inclination or foreign matter. (2) Set the piston in the cylinder to be measured to the top dead center (TDC) of compression. (Refer to Section 4-1 2). Check that the valve cap is fitted on the head of intake/exhaust valve. (Refer to Sections 4-3. replace it with a new one.) • Intake/exhaust valve • Valve seat • Gas leak due to worn valve seats or trapped foreign matters • Sticking of valves • Lap the valve seats. Valve clearance Valve cap Good No good (Adjusting the valve clearance) 003338-00E 003337-00E 3-2 . • Re-tighten the cylinder head and the nozzle at the specified torque.

read the pressure gauge on the nozzle tester the moment the nozzle starts fuel injection. MEASUREMENT.3.9 to 1. If not. INSPECTION AND ADJUSTMENT 3-3 Checking the V-belt Tension Press the center of the V-belt between the alternator and Fan pulley the cooling water pump with a finger by 49 N (5 kgf). If Adjusting plate the slack is about 4 mm. Technical Data"). replace the pressure adjusting ( Measuring the fuel injection pressure with a nozzle tester shim with a thicker one. 003341-00E Types of pressure adjusting shim thickness mm 0. Nozzle tester (2) While pumping the lever of the nozzle tester slowly. refer to Section "1. 3-3 .78 MPa (8 kgf/cm2).45 (every 0.025 mm) ) Fuel injection pressure adjustment Thicker adjusting shim by 0. Injection nozzle (3) If the measured fuel injection pressure is lower than the specified value. adjust the V-belt tension using adjusting plate of the alternator. Alternator Loosen the alternator holding cap screw and the nut on the adjusting plate in order to adjust the V-belt tension by moving the cap screw to arrowed direction. the V-belt tension is proper. (For the fuel injection pressure. (1) Connect the fuel injection valve to the high pressure pipe of the nozzle tester.1 mm increases the fuel injection pressure for 0. Crank pulley Alternator holding cap screw 003340-00E (Adjusting the V-belt tension) 003339-00E 3-4 Checking the Fuel Injection Valve 1) Measuring the Fuel Injection Pressure Note : Thoroughly remove carbon deposits from the injection nozzle hole before the measurement.

(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 4 degrees. (1) Check that the pattern is neither like a stream nor slivered. Technical Data"). check the spray pattern. If the spray pattern is not normal. [Normal spray pattern] [Abnormal spray pattern] 4 degrees 003343-00E (3) Spray fuel on a sheet of white paper placed about 30 cm below the nozzle. clean or replace the nozzle. (6) Test the injection with a nozzle tester . Replace the nozzle as a set if the fuel leak is still excessive.0 MPa (20 kgf/cm2). INSPECTION AND ADJUSTMENT [Reference : Structure of fuel injection valve] Nut Gasket Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle valve Nozzle body Nozzle case nut 003342-00E 2) Checking the Spray Pattern While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer to Section "1. MEASUREMENT. retighten the nozzle holder and test it again if there is excessive fuel leak from the overflow coupling. (4) No fuel should drip from the nozzle after injection. 3-4 .3. (5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower than the specified value : 2. The injection spray should form a perfect circle.

4) Nozzle Body Identification Number NP DN - 4 P D 117 Design code (Nozzle valve sliding test by self-weight) No code : Pintle type Code D : Throttle type 003344-00E Size : Size P (or S) Spray angle Type : Pintle type Bosch automotive type 003345-00E 3-5 . Check if the nozzle valve falls smoothly by self-weight when released.3. 1 / 3 of its length into the body. Hold the nozzle body vertical. the nozzle valve is good. INSPECTION AND ADJUSTMENT 3) Nozzle Valve Sliding Test Thoroughly wash the nozzle valve using clean fuel. If so. MEASUREMENT. and put the nozzle valve approx.

1 sequentially from the flywheel side).656 to 2.0 to 17.2 to 0. (4) When the cylinder head is removed. stop turning the crankshaft. (For the fuel injection timing.1.0 1. Every 0. the fuel level rises at the tip of the delivery valve spring holder. MEASUREMENT. refer to Section "1.1 003346-00E (3) Check the timing marks imprinted on the timing gear case and the crankshaft pulley.116 Crankshaft pulley 003347-00E (5) If the present injection timing differs from the specified timing.3 mm to advance the injection timing by approximate 2°. 003348-00E 3-6 . remove the fuel injection pump. and adjust the timing by increasing or decreasing the adjusting shim thickness between the fuel injection pump and gear case. INSPECTION AND ADJUSTMENT 3-5 Checking and Adjusting the Fuel Injection Timing (FID) (1) Using the crankshaft pulley. (2) When the crankshaft is turned in the specified direction. turn the engine in the specified direction. At that time. Technical Timing mark Data". Injection timing (BTDC) Piston movement (mm) 15.5 mm. (Cylinder are numbered from No. Check the injection timing with the delivery valve spring holder of the fuel injection pump for the cylinder No. • Decrease the shim thickness by 0. adjusting Adjustment shim shims are established.1 mm of thickness between 0. • Increase the shim thickness by 0. Cylinder No.3 mm to delay the injection timing by approximate 2°. set the dial gauge on the top of piston to confirm fuel oil injection timing by the piston movement.3.

7 kPa (0. gradually increase the Timing gear case engine speed up to the high idling speed. (2) Start operating the cooling water pump. If not.9 ± 0. INSPECTION AND ADJUSTMENT 3-6 Adjusting the Maximum (or Minimum) Idling Speed (1) First warm up the engine.7 kPa (0. Attach the cap tester body to the radiator. Check if the cap is opened at the set pressure.3 ± 14. (Refer to Section "1. find out the portion of the cooling water system from ) 003350-00E which cooling water leaks. Set the pressure of the tester to 88. Then.) Stop lever (2) If the high idling speed differs from the specified one. MEASUREMENT. because it is defective.15 kgf/cm2).9 ± 0. Cap tester Checking the cooling water system ( for water leakage Then. Any lower reading of the pressure gauge on the cap tester indicates water leakage from the cooling water system. (3) Set the low idling speed to the specified value.3 ± 14. and set the pressure of the tester to 88. Radiator cap (Checking the radiator cap) 003351-00E 3-7 . replace the cap.15 kgf/cm2). 2) Checking the Radiator Cap Attach the radiator cap to a cap tester. (1) Supply cooling water up to the normal water level in the radiator. High idling speed adjusting bolt Low idling speed adjusting bolt 003349-00E 3-7 Checking the Cooling Water System and Radiator for Water Leakage 1) Checking the Cooling Water System for Water Leakage Note : The cooling water system can be checked effectively while the engine is warm.3. Technical Data") by turning the low idling speed set bolt. (Refer to Section "1. Technical Data". adjust it by the cap screw on the timing gear case.

While measuring the liquid temperature. the thermoswitch is normal. If the tester shows continuity at a temperature of 107 to 113 °C. the hydraulic switch is defective. heat the water. While running the engine. While measuring the water temperature. If the tester shows continuity. heat the liquid. INSPECTION AND ADJUSTMENT 3-8 Checking the Sensors 1) Checking the Thermostat and the Thermoswitch (1) Thermostat Put the thermostat into the water in a container. Check Thermometer that the thermostat begins to work at 73. Thermostat 003352-00E (2) Thermoswitch Put the thermoswitch into the antifreeze or oil in a con- Thermometer tainer. Tester probes (Continuity test) 003354-00E 3-8 .3. Tester probes 003353-00E 2) Oil Pressure Switch Remove the connector from the switch. MEASUREMENT.0 to 77. bring the tester probes into contact with the switch terminal and the cylinder block.0 °C and fully opens at 90 °C.

Thickness gauge Cylinder head combustion Standard Wear limit surface distortion Refer to Section "2 1) Nominal and Allowable Values". if it is expected that any part within the allowable value will exceed the value before the next maintenance based on the record of its use. Service Data and Corrective Action For the maintenance of all parts. Measure the sinking depth and replace the valve and valve seat if the valve sinking depth exceeds the standard value. 4-1 Cylinder Head 1) Checking the Combustion Surface for Distortion Straight-edge (1) Remove the intake / exhaust valves and the fuel injection valve from the engine. Depth micrometer Valve sinkage 003357-00E (Measuring the valve sinkage) 003356-00E 4-1 . the combustion ( Measuring ) surface distortion 003355-00E (3) Visually check if the combustion surface is free from discoloration. combustion efficiency may drop. 2) Intake / Exhaust Valve Seat (1) Valve sinkage Over long periods of use and repeated lappings. If any part is found to be defective or if any part is not within the allowable value. However. Standard Valve sinkage Intake valve Exhaust valve Wear limit Refer to Section "2 1) Nominal and Allowable Values".4. SERVICE DATA AND CORRECTIVE ACTION 4. and crazing. replace it with a new one. Clean the surface of the cylinder head. make measurements according to the following measurement procedure. cracks. (2) Place a straight-edge along each of the four sides and each diagonal of the cylinder head. Measure the clearance between the straight-edge and the combustion surface with a thickness gauge. use the color check kit for cracks and crazing. MEASUREMENT PROCEDURE. Measurement Procedure. be sure to replace such a part beforehand. In addition.

and the valve guide inside dia. correct it by grinding the seat surface with a 70 degrees seat grinder or a seat cutter. 003359-00E [Procedure for using seat grinder and seat cutter] (1) Correct the roughened seat surface with a seat Angle T (degrees) Intake valve 45 Exhaust valve 45 15 Seat grindstone 70 grinder or a seat cutter. Exhaust (Measuring the valve seat width) [Valve seat correction procedure] 003358-00E Seat grinder (1) If the seat surface is worn or roughened slightly. Measure the seat width and angle using vernier calipers and an angle gauge respectively. apply pressure evenly taking care not to cut the seat surface unevenly. be sure to measure the oil clearance between the valve stem outside dia.4. (3) Knead a valve compound with oil and finish the valve seat by lapping with the compound. replace the valve or the valve guide before correcting the valve seat surface. Note : 003360-00E When using a seat cutter. If the oil clearance exceeds the wear limit. correct the seat surface using a seat grinder or a seat cutter. (For the oil clearance between the valve and the valve guide. Standard Valve seat width Valve seat angle Wear limit Intake Exhaust Intake Refer to Section "2 1) Nominal and Allowable Values". and finish it according to the above Grindstone step (1). lap the seat surface to a smooth state with a valve compound mixed with oil. Then. grind Valve seat the seat surface with a 15 degrees grinder so that (Valve seat correction angle) the seat width should be the standard value. Note : If any valve requires correction.) 4-2 . SERVICE DATA AND CORRECTIVE ACTION (2) Width and angle of the valve seat Remove carbon deposits from the seat surface. MEASUREMENT PROCEDURE. Seat width (2) When the seat width is enlarged from the initial value. (2) If the seat surface is worn or roughened excessively. refer to the subsection 3 in this section.

(6 mm) or more. (2) Valve stem and valve guide Oil clearance is the difference between the valve guide inside diameter measured with a three-point micrometer or a cylinder gauge and the stem outside diameter measured with a micrometer. If the oil clearance is near the wear limit. Thoroughly remove the valve compound or the grindstone powder. 2. Notes : 1.315 in. In this case. replace the valve with a new one. (Measuring the valve stem outside diameter) 003361-00E Guide inside dia. take the steps (3) and (4) only.236 in. replace the valve guide together with the valve stem. replace both the intake / exhaust valve and the valve guide with new ones. Oil clearance Stem outside dia. If the measured value is near the wear limit. (4 to 8 mm). Standard Thickness of valve head Intake valve Exhaust valve Wear limit Refer to Section "2 1) Nominal and Allowable Values".4. thoroughly clean the valve and the cylinder head using light oil or the like. lap the valve using only oil. After correcting the valve seat. Seat width Thickness Valve diameter Seat angle 003362-00E 4-3 . Note : Three-point micrometer : Used for an inside diameter of 0. 3) Intake / Exhaust Valve (1) Wear and bend of the valve stem Replace the valve stem if bent or worn excessively. SERVICE DATA AND CORRECTIVE ACTION (4) Last. Exhaust valve Refer to Section "2 1) Nominal and Allowable Values". Intake valve Guide inside dia.157 to 0. Oil clearance (3) Thickness of valve head Measure the thickness of the valve head with a micrometer. MEASUREMENT PROCEDURE. Standard Wear limit Stem outside dia. Cylinder gauge : Used for an inside diameter of 0. For slightly poor contact.

MEASUREMENT PROCEDURE. SERVICE DATA AND CORRECTIVE ACTION 4) Valve Stem Seal [Time of replacement] Valve stem seal (1) When oil loss is found excessive. ( Hatched portion indicates where to apply lubricating oil. ) 003364-00E 4-4 . Valve guide (3) When the intake / exhaust valve is removed. (2) When the valve stem seal is removed.4. thoroughly remove the burrs on the valve stem surface and then apply sufficient lubricating oil to the valve stem. Cylinder head 003363-00E [Precautions on installation] Before reinstalling the intake / exhaust valve.

SERVICE DATA AND CORRECTIVE ACTION 5) Checking the Valve Spring (1) Visually check if the valve spring is free from flaws and corrosion.0394 in. Standard Wear limit Free length Inclination Valve spring Tension [lbs. If such contact is uneven or if the cotter has sunk due to wear. (1 mm) compressed] Refer to Section "2 1) Nominal and Allowable Values". MEASUREMENT PROCEDURE.4. replace the cotter with a Surface plate new one. (2) Measure the free length (length of the spring) and inclination (squareness of the side of the coil). (Measuring the inclination of valve spring) 003366-00E 4-5 . (Measuring the free length) 003365-00E 6) Checking Valve Spring Holder and Cotter Inclination Check the contact of the inner surface of the valve spring holder with the outer surface of the cotter as well as the Square contact of the inner surface of the cotter with the notch in Free length the head of the valve stem. (kg)] [0.

Measure the cylinder bore diameters at the point a. b Obtain the distortion of the cylinder (the roundness and cylindricity of each cylinder) from the following measured c values : • Roundness : Difference between the max. MEASUREMENT PROCEDURE. check the portion by color check.79 in. and min. bore values on the same cross section of each liner. and min. (20 mm) below the crest of the liner. ) 003368-00E Wear limit Refer to Section "2 1) Nominal and Allowable Values". 4-6 . Roundness of cylinder Cylindricity of cylinder Cylinder bore measuring ( points 4 Piston and Piston Rings". and at the points b and c at equal intervals. (Measuring the cylinder bore diameter) 003367-00E 2) Measuring the Cylinder Bore and the Distortion of the Cylinder Measure each cylinder bore with a cylinder gauge. bore values in the same direction of each liner.4. Note : Measurement should be made at the points a. Make sure that it is not clogged. approx. (3) Thoroughly clean each oil hole. A • Cylindricity : Difference between the max. (2) Replace the cylinder block if badly damaged and unreparable. If any portion of the cylinder block might be cracked. 20 a 0. SERVICE DATA AND CORRECTIVE ACTION 4-2 Cylinder Block Cylinder gauge 1) Checking the Cylinder Block (1) Visually check if the cylinder block is free from water leak. b and c in the directions of A and B Note : For oversized pistons and piston rings. refer to Section "4- Standard Cylinder bore dia. Apply honing (honing and boring) if any measured value B exceeds the allowable limit. oil leak and cracks.

Notes : 1. Use the Flex-Hone at a speed of 300 to 1200 rpm. In this case. However. flaw or other damage is minor.00004 in. Insert the FlexHone into the cylinder and move it up and down for about 30 seconds while turning it at a cross hatch angle of about 30 to 40 degrees. The procedure for using it is described below. taking the maximum wear into consideration. Applicable bore dia.4. (For the oversized (Flex-Hone) 003369-00E pistons and piston rings. [1] Items to be prepared Power drill Flex-Hone. flawed. refer to Section "4-4 Piston and Piston Rings". 2. If the partial wear. with the power drill stopped. or otherwise damaged.) (2) Procedure for using the Flex-Hone Flex-Hone It is common practice to use the Flex-Hone for honing. it can be repaired only by honing with a Flex-Hone. and whether prepared oversized pistons and piston rings can be used. Use of the Flex-Hone at a higher speed may be hazardous. 4-7 003371-00E . (1 / 1000 mm) for honing with the Flex-Hone. and honing liquid Flex-Hone Yanmar code No. Any material needs a honing allowance of approx. apply honing after boring. MEASUREMENT PROCEDURE. extract the Flex-Hone while turn- 30 to 40 degrees ing it. SERVICE DATA AND CORRECTIVE ACTION 3) Honing (1) Application of honing Apply honing or boring to the cylinder if it is partially worn. if it is not minor. (mm) 129400-92400 63 to 70 Engine oil 50% Light oil 50% Honing liquid 003370-00E [2] Handling procedure Soak the Flex-Hone in the honing liquid. Never insert into or extract from the cylinder the FlexHone. power drill. it is important to examine whether the cylinder can attain perfect roundness after honing and / or boring. 0. Then.

Standard Intake / exhaust valve rocker arm Wear limit the rocker arm shaft ( Measuring ) outside diameter Shaft outside dia.C* and blow-by Increase in L. Oil clearance the rocker arm ( Measuring ) busu inside diameter 4-8 003374-00E . If the oil clearance is near the wear limit. 003373-00E Refer to Section "2 1) Nominal and Allowable Values". MEASUREMENT PROCEDURE. ) *L.C = lubricating oil consumption 003372-00E 4-3 Valve Rocker Arm 1) Measuring the Rocker Arm Shaft Outside Diameter and the Rocker Arm Bush Inside Diameter Oil clearance is the difference between the rocker arm bush inside diameter measured with a cylinder gauge and the rocker arm shaft outside diameter measured with a micrometer.O.5H1) Time for honing (H1) Increase in L.4.C and blow-by Honing Increase in L. SERVICE DATA AND CORRECTIVE ACTION 4) Overhaul of Cylinder (Reference) Service life of cylinder block (H3) (H3 = 3H1) Time for boring and honing (H2) (H2 = 1.O.O. replace the rocker arm shaft and the rocker arm with new ones.O.C and blow-by Boring ( Examine the applicability of oversized pistons and piston rings.O.C and blow-by Increase in L. Bush inside dia.

If any of them is excessively worn or partially flaked. (2) Wear of intake/exhaust valve rocker arm and valve cap Check the intake / exhaust valve rocker arm for the contact surface with the valve cap. MEASUREMENT PROCEDURE. Measure the tappet stem outside diameter with a micrometer. (Measuring the tappet stem outside diameter) 003376-00E Adjust screw Check of contact surface Check of contact surface of rocker arm Push rod 003377-00E 4-9 . Standard Wear limit Push rod bend Stem outside diameter Tappet Guide hole inside diameter Thickness gauge Refer to Section "2 1) Nominal and Allowable Values". (3) Check the portion where the valve clearance adjust screw is in contact with the push rod. (Measuring the push rod bend) Oil clearance 003375-00E 3) Other Inspections (1) Valve rocker arm shaft spring Check if the rocker arm shaft spring is free from corrosion and wear. replace it with a new one. replace the push rod or the adjust screw. Measuring the Tappet Stem Outside Diameter and Checking the Tappet Contact Surface Put the push rod on the surface plate to check that there is no clearance between the push rod and the surface plate. SERVICE DATA AND CORRECTIVE ACTION 2) Checking the Push Rod Bend. replace it. If not. If the portion is worn or flaked.4.

4. measure the long diameter of the oval hole in the vertical direction to the piston pin bush hole at a position which is 15 to 17 mm above from the lower end of the piston. SERVICE DATA AND CORRECTIVE ACTION 4-4 Piston and Piston Rings 1) Checking the Piston (1) Remove carbon deposits from the head and combustion surface of the piston while taking care not to damage the piston. Measuring position 15 to 17 mm 003378-00E 2) Measuring the Piston Outside Diameter To measure the piston outside diameter. the rocker arm ( Measuring ) busu inside diameter 3) Shapes of Piston Rings Top ring Second ring Oil ring 003380-00E 4-10 003374-00E . (2) Check the outer surface and ring grooves of the piston. and replace it if worn or damaged. MEASUREMENT PROCEDURE. Minimum clearance between piston and cylinder Refer to Section "2 1) Nominal and Allowable Values". Check if there are any cracks or damage. Standard Wear limit Piston outside dia.

and the End Gap To measure the piston ring groove width.4. End gap Ring groove width Ring width (B) Oil ring Clearance between groove and ring End gap 4-11 . Obtain the ring groove width by adding the ring width to the measured clearance. SERVICE DATA AND CORRECTIVE ACTION 4) Measuring the Ring Groove Width. Standard Wear limit Cylinder block Ring groove width Top ring Ring width (B) Clearance between groove and ring the end gap ( Measuring ) of piston ring End gap Ring groove width Ring width (B) Second Clearance ring between groove and ring 003383-00E Refer to Section "2 1) Nominal and Allowable Values". fit the piston ring into the ring groove after cleaning the groove carefully. MEASUREMENT PROCEDURE. 30 mm measure the end gap after pushing the piston ring into the sleeve to the portion which is less worn (approx. the Ring Width (B). insert a thickness gauge between both ends of the piston ring. Then. push the piston ring into the End gap sleeve using the piston head. 30 mm Piston ring from the lower end of the sleeve). Width (B) (Measuring the ring groove width) 003382-00E Thickness 003381-00E To measure the end gap. first measure the width (B) of the piston ring. Approx. If the sleeve is worn. Insert a thickness gauge between the piston ring and the groove to measure the clearance between them.

Oil clearance (Measuring the piston pin outside diameter) (Inserting piston pin) 003387-00E 003386-00E 4-12 . points of the piston pin (Measuring ) outside diameter 003384-00E Standard Wear limit Outside dia. so that they are not aligned along the piston. with the manufacturer's mark near the end of the piston ring facing upward (to the combustion chamber side). Replace the piston pin if one or both of the measured values exceed the wear limit. Apply lubricating oil to the piston pin before inserting it into the piston. Piston pin Bush hole inside dia. (2) After fitting all the piston rings. shift the end gaps of them at 120 degrees intervals. Refer to Section "2 1) Nominal and Allowable Values". SERVICE DATA AND CORRECTIVE ACTION 5) Installation of Piston Rings (1) Using a piston ring replacer. MEASUREMENT PROCEDURE. After fitting the piston ring.4. Apply lubricating oil to the piston pin before inserting it 003385-00X into the piston. fit the piston ring into the ring groove. check that the piston ring moves smoothly. 6) Measuring the Outside Diameter and Bush Hole Inside Diameter of the Piston Pin Measure the outside diameter and bush hole inside diameter of the piston pin.

Twist and parallelism Refer to Section "2 1) Nominal and Allowable Values". and the I-beam section of the connecting rod. MEASUREMENT PROCEDURE. distortion and discoloration : (1) Portions close to the boundaries between the chamfered parts of the large and small ends. 8) Oversized Piston and Piston Ring [0. m 0m 10 m 0m Parallelism 10 Twist Reference axis (Measuring the twist and parallelism) 003388-00E 4-13 . SERVICE DATA AND CORRECTIVE ACTION 7) Top Clearance (Reference) Top clearance Refer to Section "2 1) Nominal and Allowable Values". 2) Measuring the Twist and Parallelism Measure the twist and parallelism of the connecting rod with a connecting rod aligner.4.25 mm] Size classification Piston assembly code (including piston ring assembly) Piston ring assembly code 0. (2) Portion around the oil hole in the bush at the small end.250S 165000-47550 165000-47560 4-5 Connecting Rod 1) Visual Inspection Inspect the following portions for cracks.250S : Oversized by 0.

4. MEASUREMENT PROCEDURE. Piston pin side. and calculate the difference between them. SERVICE DATA AND CORRECTIVE ACTION 3) Measuring the Clearance Between the Crank Pin and Bush To measure the oil clearance between the crank pin and the crank pin metal. Piston pin outside dia Cylinder gauge Refer to Section "2 1) Nominal and Allowable Values". If the measured oil clearance exceeds or near the wear limit. Cylinder gauge making sure that each half of the metal is set in the correct way. 4) Measuring the Oil Clearance Between the Piston Pin Bush and the Piston Pin To measure the oil clearance between the piston pin bush and the piston pin. install the metal into the large end of the connecting rod and tighten the rod bolts at a specified tightening torque. Crank pin metal thickness Crank pin outside dia. and calculate the difference between them. measure the inside diameter of the piston pin bush and the outside diameter of the piston pin. and use an oversized crank pin metal. the inside diameter of ( Measuring ) the crank pin metal 003389-00E Wear limit Refer to Section "2 1) Nominal and Allowable Values". grind the crank pin. replace the crank pin metal. Rod bolt tightening torque (Apply lubricating oil to the rod bolt) Refer to Section "2 2) Engine Tightening torque for major bolts and nuts" Standard Crank pin side Crank pin metal inside dia. Oil clearance the inside diameter of ( Measuring ) the piston pin bush 003390-00E 4-14 . Standard Wear limit Bush inside dia. If the crank pin is excessively or partially worn. Note : To measure the inside diameter of the crank pin metal. measure the inside diameter of the crank pin metal and the outside diameter of the crank pin.

625 4-15 . Measure the side gap by inserting a thickness gauge between the connecting rod and the crank arm. tighten the rod bolts at a specified tightening torque (refer to the above 3 of this section). 8) Undersized Crank Pin Metal 003391-00X Undersized by 0. If the measured value exceeds the wear limit. MEASUREMENT PROCEDURE. with the marks at the large end of the connecting rod facing the fuel injection pump. (mm)] Standard 1. If the contacted surface of the metal occupies 75 % or more of the total surface. and tighten the rod bolts at a specified tightening torque (refer to the above 3 of this section) to check the contact of the metal. Instal the crank pin metal to the crankshaft. 165000-15870 Metal thickness [in. replace the crank pin metal or the connecting rod.25 mm Crank pin metal Part code No. the crank pin metal is good in terms of contact. 6) Installing the Piston and the Connecting Rod Install the piston with the connecting rod. Also. SERVICE DATA AND CORRECTIVE ACTION 5) Checking the Contact of the Crank Pin Metal Apply a blue ink or a minium to the inside surface of the crank pin metal. install the piston so that the recess of the combustion chamber is on the fuel injection pump side as seen from the top. Side gap Refer to Section "2 1) Nominal and Allowable Values".4. 7) Side Gap of the Connecting Rod After installing the connecting rod to the crankshaft.

SERVICE DATA AND CORRECTIVE ACTION 4-6 Camshaft 1) Removing the Camshaft Remove the tappets and fuel oil injection pump. and loosen two cap screws (M6) inside of the camshaft gear to remove the camshaft. and damage of the cam gear. 003393-00X 3) Measuring the Bend of the Camshaft Support the camshaft with V-blocks. MEASUREMENT PROCEDURE. V-block (Measuring the camshaft bend) 003394-00E 4) Measuring the Intake / Exhaust Cam Height Standard Cam height Intake cam Exhaust cam Wear limit Refer to Section "2 1) Nominal and Allowable Values". Using a dial gauge. seizure and wear of the bearing. Standard Wear limit Dial gauge Camshaft bend Refer to Section "2 1) Nominal and Allowable Values". Take 50 % of the measured runout as bend. 2) Checking the Camshaft Appearance Check the camshaft for the contact surface of the cam with the tappet. Micrometer (Measuring the cam height) Cam height 003395-00E 003392-00E 4-16 .4. measure the runout of the journal at the center of the camshaft while rotating the camshaft.

SERVICE DATA AND CORRECTIVE ACTION 4-7 Crankshaft 1) Side Gap Around the Crankshaft Before extracting the crankshaft and when installing it. MEASUREMENT PROCEDURE. If the measured value exceeds the wear limit. replace the rear end bearing holder (flywheel side) with a new one. Press the crankshaft to each of the right and left sides in the axial direction to measure the side gap. Side gap Refer to Section "2 1) Nominal and Allowable Values". Alternatively. Relief valve contact a dial gauge with the end of the crankshaft.4. Bearing holder 003889-00E 4-17 . Remove the relief valve beforehand. Allen head cap screws Cap screw 003888-00E 3) Removing the Main Bearing Remove two bearing holding cap screws to remove the main bearing. Dial gauge 2) Removing the Crankshaft Crankshaft Remove the three cap screws shown below to pull out 003396-00E the crankshaft to flywheel end. insert a thickness gauge directly into the clearance between the thrust metal in the reference part and the thrust face of crankshaft to measure the side gap.

6) Bend of the Crankshaft Support the journals of the crankshaft with V-blocks at both ends.4. If the damage is minor.25 mm) is available. seizure. melting. Replace the crankshaft with a new one. if it is unreparable. Measure the runout at the center journal with Bend a dial gauge while rotating the crankshaft to check the bend of the crankshaft. (Refer to Section 4-5. and the state of the contact spur face.) R R Crank journal Crank pin 003399-00X points of the crank pin ) ( Measuring and journal 003398-00E 4-18 . If the partial wear or the roundness exceeds the wear limit but the measured outside diameter is within the limit. taper angles of the crank pin and journal. Runout Dial gauge 7) Measuring the of Crank Pin and Journal Measure the outside diameters. An under sized crank pin metal by 0.0098 in. Replace the crankshaft if it is cracked or badly damaged. Bend Refer to Section "2 1) Nominal and Allowable Values". (0. roundness. 5) Checking the Metals Check the metals for flaking. 4-8 in this chap- V-block V-block (Measuring the crankshaft bend) 003397-00E ter. SERVICE DATA AND CORRECTIVE ACTION 4) Color Check of Crankshaft Clean the crankshaft and check it using a color check kit or a magnetic inspector. correct it by re-grinding. MEASUREMENT PROCEDURE. Replace any of the metals if it is damaged. correct it by regrinding.

Crank journal Main metal thickness Refer to Section "2 1) Nominal and Allowable Values". Outside dia. (2) The upper half of the metal on the cylinder block side has an oil groove. (4) Place the embossed mark "F" of the bearing holder to front (crankshaft pulley side). SERVICE DATA AND CORRECTIVE ACTION Standard Crank pin Wear limit Crank pin outside dia.125 4-19 .4. Install the bearing holder without the embossed mark "F" facing its chamfered side to front (crankshaft pulley side).25 mm and Bushings by 0.125 #3 Metal 165000-15900 2. (3) The aluminum bearing holders are on the flywheel side.125 #2 Metal 165000-15920 2. Part code No. Main metal (reference) Thrust metal (flywheel side) Main metal Metal cap (reference) Metal cap Metal cap 003400-00E 9) Undersized Main Metal by 0. Metal thickness #1 Bushing 165000-15850 2. Oil clearance 8) Precautions for Installation of the Metal Caps (1) The lower half of the metal on the holder side has no oil groove.25 mm No. MEASUREMENT PROCEDURE.

and measure the backlash.T. idle gear and fuel injection pump drive gear Wear limit Refer to Section "2 1) Nominal and Allowable Values". MEASUREMENT PROCEDURE. 3) Gear Train After installing all the gears. cam gear. Standard Backlash Crank gear. 2) Measuring the Backlashes Apply a dial gauge onto the pitch circle of the gear. or flaked. Cam gear Idle gear Crank gear *P. (Option) 003401-00E 4-20 . check that the matchmarkes of idle gear and camshaft gear.O. worn. SERVICE DATA AND CORRECTIVE ACTION 4-8 Gears 1) Checking the Gears Check the teeth surfaces of each gear and replace the gear if the teeth are damaged. idle gear and crankshaft gear are aligned as below.4.

MEASUREMENT PROCEDURE.4. Standard Wear limit Outer rotor Clearance between outer rotor and inner rotor Refer to Section "2 1) Nominal and Allowable Values". Adjusting shim Collar E-ring 003402-00E 1) Clearance Between Outer Rotor and Inner Rotor Inner rotor Insert a thickness gauge between the top of the inner rotor tooth and the top of the outer rotor tooth to measure the clearance. Thickness gauge the clearance between (Measuring ) outer rotor and inner rotor 003403-00E 4-21 . SERVICE DATA AND CORRECTIVE ACTION 4-9 Trochoid Pump Lube oil pump is installed in the idle gear. Remove the E-ring to disassemble the trochoid pump.

Alternatively. If the measured value exceeds the Dial gauge wear limit. PRECAUTIONS FOR REASSEMBLY 5. the crankshaft. check that the match marks (From the gear case side) idle gear .crankshaft gear and idle gear . dust. 1) Cleaning the Components Clean the cylinder block. sand. Cam gear Idle gear Crank gear *P. (Option) 003405-00E 5-1 . Precautions for Reassembly Reassemble the engine components in the reverse order of the disassembly procedure. and other foreign matter. Press the crankshaft to each of the right and left sides in the axial direction to measure the side gap.5. Follow the precautions below particularly before and during the reassembly. and the camshaft carefully so that they are free from chips. 2) Parts to be Replaced in Reassembly Be sure to replace the following parts with new ones in reassembly. insert a thickness gauge directly into the clearance between the reference thrust metal and the thrust surface of the crankshaft to measure the side gap. replace the thrust metal with a new one. O-rings and gasket packings 3) Measuring the Side Gap Around the Crankshaft Apply a dial gauge to the end of the crankshaft. Crankshaft 003404-00E 4) Gear Train After installing all the gears.camshaft gear. (1) Valve guide seal (2) Head gasket packing (3) All of the copper packings.O.T. Side gap Refer to Section "2 1) Nominal and Allowable Values". the cylinder head.

Apply lubricating oil 003407-00E 8) Installation Direction of the Piston and the Connecting Rod Front end of the engine Matchmarks 003408-00E Install the piston so as for the apex of the triangle on the top of piston to face the front end of the engine. After fitting the piston ring. Apply lubricating oil to the outside surface of the piston.5. PRECAUTIONS FOR REASSEMBLY 5) Applying Lubricating Oil to the Intake / Exhaust Valve guide Valve Stem Apply lubricating oil to the valve guide so that the oil spreads over the lower surface (hatched portion in the figure) of the valve guide. using a piston ring replacer. before reassembly. 003406-00E 6) Reinstalling the Piston Rings (1) Fit the piston ring into the ring groove. making sure that they are not aligned along the piston. check that it moves smoothly. (2) Install the piston their end gaps rings into their respective ring grooves so that their end gaps are shifted at 120 degrees intervals. with the manufacturer's mark near the end of the piston ring facing upward (to the combustion chamber side). 5-2 . Assemble the connecting rod so that the matchmarks of large end of the connecting rod face the fuel oil injection pump. 7) Applying Lubricating Oil to the Push Rod Adjust Screw Contact Portion Apply lubricating oil to the hatched portion of the push rod as shown in the figure. before reinstalling the valve guide.

㧡 㧟 㧝 㧥 㧣 Flywheel side Front end of the engine 㧞  㧤 㧢 㧠 008550-00E Tightening torque Refer to Section "2 2) Engine Tightening torque for major bolts and nuts".2 0.6 to 0.7 7610 1. Piston projection and gasket thickness Sink of piston (mm) Stamp No.3 6 008548-00E 008549-00X 10) Tightening Order and Tightening Torque of the Cylinder Head Bolts Tighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below. PRECAUTIONS FOR REASSEMBLY 9) Installation of the Cylinder Head Gasket Install the gasket with the part number stamp on it facing No. stamp up. The thickness of it is determined by piston projection from the top of cylinder block. 5-3 .6 7600 1.5. Carry Out a Verification Run of the Engine to Check That There is No Water or Oil Leakage.5 to 0. Thickness (mm) 0. 11) After Completing the Reassembly.

caps 3 are installed by the factory not to be readjusted the preset. 1) Injection Pump Disassemble the pump at a specified service shop only. The fly weight control spring is installed on the arm complete and tension bar so that the governor lever angle changes spring tension to control the engine speed. (As 3 shown to the right. FUEL INJECTION SYSTEM 6. The pump camshaft has pump drive cams and injection oil flow is controlled by a control lever in the gear case. The fly weight assembly is installed on the camshaft and its movement is conveyed through slider-control lever-link to the control rack of the pump. Part Code No. 165000-15210 2) Governor The governor is a mechanical all speed type and installed in the gear case.6. Fuel Injection System 6-1 Fuel Oil Injection Pump The injection pump is a PFR model of Bosch type. 008552-00J 6-1 . 003412-00X 3) High Idling Speed Set Screw The arm complete movement is restricted by the high idling speed set screw and idling speed is limited.

FUEL INJECTION SYSTEM 4) Smoke Set and Start Spring Smoke set 1 is installed on the cylinder block. R-pin Note : Remove the gear case after covering the key groove for crankshaft pulley with a friction tape or something so as not to damage the oil seal of the timing gear case. 008553-00E 6-2 Disassembling Procedures (1) Remove the engine stop solenoid. 008551-00X 5) Adjusting the High Idling Speed (Refer to 3-7) Start spring The set screw 2 is preset by the factory and sealed. (3) Pull up the injection pump a little and remove R-pin that connects the control rack and governor link to remove the timing gear case. It restricts fuel oil injection in high speed range and the angleich spring is installed in it so as to increase fuel oil injection 1 to gain a big torque in mid speed range.6. (2) Screw in and out the right hand side screw of the governor lever to increase and decrease low idling speed respectively. The start spring is installed on gear case and governor 2 link to increase fuel oil injection when the engine is started. the idling speed can be readjusted. however. (2) Remove the fuel oil injection pump holding screws and 4 nuts. The smoke set is preset by the factory and sealed by a cap 3 not to be readjusted locally. (1) Screw in the left hand side screw of the governor lever to decrease high idling speed. 6-2 008554-00E .

(2) Fix the control lever with the stopper lever and then Slider assemble the gear case.6. FUEL INJECTION SYSTEM 6-3 Reassembling Procedures Cam gear pin (1) Install the slider after aligning it and the cam gear pin. Note : Cover the key groove for crankshaft pulley with a friction tape or something so as not to damage the oil seal of the timing gear case. make sure if the link simultaneously moves when the stop lever Gear case pin is operated. 6-3 003418-00E . Note : Rotate the oil pump cover clockwise and counterclockwise. fix the spring pin hole in the center of its movement and install the timing gear case. 003416-00E Start spring Control lever 003417-00E (3) Align the gear case pin and oil pump cover hole Oil pump cover hole when the gear case is reinstalled. Note : Make sure if the start spring is securely installed. (4) After reinstalling of the timing gear case.

8 mm 0. and a magnetic switch which pushes out the pinion and turns on and off the principal current. ELECTRICAL EQUIPMENT 7.7 (1.5 to 2. a clutch .65 Standard / Wear limit Gap between pinion and pinion stopper 7-1 .3 / 7. the starter motor rotates the ring gear installed on the engine flywheel with the pinion gear engaged with the ring gear so that the force generated by the rotation exceeds the resistance including the engine compression pressure and all frictional force.6 (2.0/650 N•m / (kgf•m) / rpm 15.0 Standard spring force Commutator Less than 11/90 Speed Pinion DP or module / Number of pinion teeth Brush 1.7.2 / 2. 1) Specifications and Service Data Yanmar code 165000-47590 Applicable model 2TE67L-BV MITSUBISHI M000T84281 Starter motor model Nominal output / Weight kW / kg Rotation direction (viewed from pinion side) Clockwise Engagement method No load Load characteristics Magnetic shift Terminal voltage / Current V/A rpm More than 2800 Terminal voltage / Current V/A Less than 4.60) Torque / speed DP10 / 12 N (kg) 20.0 Outside diameter mm Ø29.5 to 22. The starter motor consists of the following major parts : a motor which generates torque .4 / Ø28.09 to 2. Electrical Equipment 7-1 Starter Motor To start the engine.31) Standard height / Wear limit mm 12. a pinion which transmits the torque to the engine ring gear .

7.1 7-2 . ELECTRICAL EQUIPMENT 1. Switch Brush Lever Internal gear Gear shaft Overrunning clutch Ball Armature Yoke Planetary gear Armature shaft Fig. Structure The starter is 4-P direct drive type motor and the overrunning clutch is activated by the solenoid.

4 mm) or something between the commutator and brush holder for inspection and reassembly. plate and packing according to disassembling order. (2) Remove the brush holding screws and through screws. Remove the rear bracket but do not remove the brush holders. 7-3 . 3. (4) Remove the armature and the yoke. Disassembly Note : Put two matching marks on the switch and yoke before disassembling. (5) Front Bracket / Rear Bracket Check metals of them for wear. It should rotate one way only. [2] Check the coil for ground. Remove the gear shaft assembly and lever at the same time. If any. If any wear and burrs in the pinion gear. (1) Remove the terminal nuts of the magnet switch to remove connector. replace it with a new one. [2] Remove the overrunning clutch from the armature shaft. If the snap ring is damaged. [3] Check the brush holder plate and brush holder insulated for connection. Unless they are connected. replace the overrunning clutch. If it is too much. If something is wrong. (3) Brush [1] Check brushes for wear. Inspection (1) Armature [1] Check the coil for short circuit. replace the brush holder assembly with a new one. If any. (6) Remove the overrunning clutch [1] Drive a pipe that matches the snap ring with a hammer to remove the stop ring and snap ring. Note : Never wash the overrunning clutch not to remove lubrication grease in it. line up the lever. (3) Slip in a socket (OD Ø29. (5) Remove the planetary gear and packing. (2) Gears Check for excessive wear or damage. replace the armature. (4) Overrunning Clutch and Pinion Gear Rotate the pinion gear with holding the clutch housing. replace the armature. (6) Switch Check the terminal M and body of the switch for connection. replace the armature. If it is too much. [4] Check the commutator for insulation depth.7. replace the switch with a new one. [3] Check the commutator for wear. replace them with new ones. If it grounds. Repair if it is inadequate. Remove switch holding screws to remove the switch and plunger. replace metals with new ones. [2] Check if the brushes smoothly move in the holder to verify the springs work well. ELECTRICAL EQUIPMENT 2. If it is too much. Note : For easy reassembling. replace the overrunning clutch.

Internal gear.7. Greasing points Grease a Front sleeve bearing MULTEMP #6129 b Rear sleeve bearing MULTEMP #6129 c Reduction device (Armature shaft gear. (1) Fill or coat grease on the following parts.2 7-4 . ELECTRICAL EQUIPMENT 4. Reassembly and Adjustment Reassemble in the reverse order of the disassembly procedures with observing the following instructions. Planetary gear) MULYKOTE RAG-650 d Overrunning clutch and lever friction part MULTEMP #6129 e Gear shaft spline and pinion friction part MULYKOTE RAG-650 f Ball MULYKOTE RAG-650 e a b c f d Fig.

ammeter and voltmeter readings with the service data. (2) Close the switch and compare RPM. 7-5 .7. ELECTRICAL EQUIPMENT 5. Non Load Testing Ammeter A Switch + Voltmeter B S V Battery 12V Starter motor Fig. Note : Use as bold wire as possible and securely connect all terminals. repeat the inspection mentioned above. (3) If anything is not within the standard.5.5 003422-00E (1) Arrange the test circuit with the voltmeter and ammeter as shown in Fig.

Specification V/A 14 / 8. ELECTRICAL EQUIPMENT 6.D.5 Alternator model GP8146 165000-15580 rpm 1600 to 5200 Maximum speed rpm 5600 Nominal output current A/V Less than 15 / 14 (5200 rpm) Working ambient temperature °C -40 to 80 Pulley diameter / V-belt size mm Ø65.3 mm 7. Service Data Standards or limit Non load performance V A RPM 11. 1 4 Fix the shaft tip. FM28 Ground polarity Applicable models Connection diagram Starter switch Alternator Current limiter Negative 2TN67-BV Load Working speed Battery Yanmar code Battery charge alarm lamp Nominal output voltage (Full-wave rectification) 003423-00E (Disassembly procedures) (1) Remove the alternator from the engine.4 mm 28. 3 3 1 Stater coil 2 Roter 3 Ball bearing 4 Flywheel 7-6 003424-00E .2.5 .7.0 mm Brush spring Pressure Limit 21.0 mm 7-2 Alternator The alternator is a revolving-field type three-phase AC generator.0 Less than 90 2800 Commutator O. Do not fix the flywheel 4. Limit 29. (3) Remove the flywheel 4.88 N Pinion gap 0. 2 (2) Remove the cap and cap screw (M10).57±15% N 5.8 mm Brush Length Limit 12. The AC electricity generated by the alternator is converted to DC through the full-wave rectification by the diode and is stored in the battery. Drive lightly the tip of M10 screw of the shaft.

(2) Rotation of flywheel Normal Rotate flywheel by hand 12 times of resistance develop at 1 turn but it smoothly rotates Not normal Cause Noise while rotating Bearing Foreign material No rotation resistance Poor magnetic force 7-7 .5 A at 14 to 15 V Charge current : 0 A Charge current flows but battery voltage is low. (Reassembly procedures) (1) Reassemble in the reverse order of disassembling. Combination of the alternator and regulator Normal Not normal Cause Charge current and battery voltage 1. Alternator (1) Performance Normal Non load voltage (between two sky blue wires) More than AC 28 V when running (about 5200 rpm) Connection Between two sky blue wires Insulation resistance (between a lead wire and coil plate) Not normal Cause Less than AC 28 V or nothing Poor magnetic force at flywheel.3 N•m (3. 14 A to 0.0 to 3. Battery (over discharging) 2. More than 14 A at 14 V or More than 14 A at 15 V or (5200 rpm at alternator) less more 2. Cutting in coil or wires.7. (5) Loosen two screws to remove stater coil 1 from coil plate. Connected Not connected Coil cutting More than 3 M: Less than 3 M: Poor Insulation of coil.4 to 34.5 kgf•m) (Inspection) 1. Mulfunction of regulator Alternator. Tightening Torque 29. Remove a M4 cap screw to remove the coupler. ELECTRICAL EQUIPMENT (4) Lead wire clamp of the coil plate. regulator or wiring.

15 kgf•m) The glow plug is ceramic glow. (1) When removing Loosen by a specified tool and remove by hand. which serves to warm the air in the combustion chamber to start the engine easily at low ambient temperature. never use it again.1 to 0. [3] Tighten it to 8 to 15 N•m (0.5 kgf•m) by a torque wrench. ELECTRICAL EQUIPMENT 7-3 Glow Plug The glow plug installed on the cylinder head is a starting aid in cold weather. (2) When installing [1] Screw in the plug for 2 .5 : Rated operating time Applicable models 6 sec.8 to 1. [2] No air tool is allowed. The glow plug is operated to warm the air in the combustion chamber by setting the starter switch key to "GLOW" and supplying electricity for about 6 seconds.0 to 1. Be careful of its handling. No air tool is allowed.3 threads by hand.5 N•m (0. (3) If a glow plug is dropped.8 to 1. (1) Specifications Yanmar code 165000-15620 Rating DC11 V / 0.7. 2TE67L-BV Tightening torque Glow plug body 8.0 to 15 N•m (0. 7-8 .5 kgf•m) Terminal mounting nut 1.

Note : Complete the pulling test in a short time. (2) The solenoid is normal as long as the plunger is kept holding in the body when the plunger is pushed in and battery’s (+) and (-) terminals are connected to the terminal B and body respectively. or wiring may be cut. ELECTRICAL EQUIPMENT 7-4 Stop Solenoid B B (for holding) A (for pulling) A Terminals of solenoid 003425-00E Inspection (1) The solenoid is normal as long as the plunger is pulled into the body when the terminal A is connected to (+) of the battery and body to (-).7. 7-9 .

.

. LTD. : Quality Assurance Dept. without the written consent of YANMAR CONSTRUCTION EQUIPMENT CO. 2006 Published by : Engineering & Development Dept.. Edited by Finished by : Yanmar Technical Service Co. Ltd.2TE67L-BV on SV08-1 Technical Information First Edition : Jan. . All Rights Reserved. Copyright c 2006 YANMAR CONSTRUCTION EQUIPMENT CO.. This manual may not be reproduced or copied in whole or in part. LTD.