Hino RB145 Motors Workshop Manual WO4D W04C-T PDF

wo4D Hino Motors,Ltd.FOREWORD ‘This workshop manual has beon prepared to provide information covering repair procedures on Hino Vehicle. Applicable models: WO4C-T engine When making any repeir of your truck, be careful not to be injured through improper procedures. ‘As for maintenance items, refer to the Driver's Hand Book. All information and specifiestions in this manual are based upon the latest product information a of printing. Hino Motors reserves the right to make changes at any time without prior notic HINO MOTORS, LTD.Jing WORKSHOP MANUAL HINO MOTORS, LTD. INDEX: ENGINE GROUP GENERAL INTRODUCTION ENGINE TURBOCHARGER INJECTION PUMP INJECTION PUMP GOVERNOR GENERATOR STARTER INJECTION PUMP CALIBRATION Rico MGNoeGENERAL INTRODUCTION Git G1-424E-02 CHAPTER GI GENERAL INTRODUCTION GENERAL PRECAUTIONS HOW TO USE THIS WORKSHOP MANUAL. . IDENTIFICATION INFORMATION. TIGHTENING TORQUE OF STANDARD BOLTGI2 GENERAL INTRODUCTION GENERAL PRECAUTIONS ‘Some recommended and standard maintenance services for your vehicle are mentioned in this section, ‘When performing maintenance on your vehicfe be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer. WARNING When working on your vehicle, observe the following general precautions to prevent personal injury and/or property in addition to the particular NOTES or WARNINGS. Using the inch system. ‘Always waar safety glasses or goggles to protect yaur eyes. ° © Remove rings, watches, ties, loose hanging jewelry and loose clothing hefore starting work on the vehicle. © Bind tong hair securely behind the head. ° When working on the vehicie, apply the parking brake firmly, place the transmission shift fever in neutral or “N”, and block the wheels. (Ute safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under = vehicle supported only by a jack. © To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, ‘muffler, exhaust pipe and tail pipe Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and Vsbelts when the engine is cunning. (© Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long as the engine is stopped. And turn off the starter switch, unless the operation requires the engine running. Removing the key from the switch is recommended. blocked, ° fit is necessary to run the engine, make sure that the parking brake is firmly applied, the wheels ‘and the transmission shift lever is in “Neutral” before starting the engine, Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide. Do not smoke while working om the truck since fuel and gages from the battery are flammable. ‘Take utmost care when working on the battery. It contains corrosive sulfuric acid. 0000 Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which ‘can result in personal injury and/or property dar ° Be careful not to leave any ton! in the engine compartment. The tool may be hit by moving parts and can ‘cause personal injury. Read carefully and observe the instructions placed on the jack when using it. O Becareful nat to damage lines and hoses by stepping or holding your fest on them.GENERAL INTRODUCTION GIS TOWING ‘When being toward, always place the transmission shift lever in Neutral and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 crossmember when attaching the towing chain, Never lift or tow the vehicle if the chain is in direct ‘contact with the bumper. 1) Front and towing (with front wheels raised off the ground) ‘When towing from the front end with the front wheels raised off the ground remove the rear axle shafts to protect the ‘transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or foreign matter. ‘The above-mentioned precautions should be observed for vehicles equipped with either the manual or automatic transmission, and for even short distance towing. After being toward, check and refill the rear axle housing with lubricant if necessary. 2) Rear end towing When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-ahead Position. *yG4 GENERAL INTRODUCTION HOW TO USE THIS WORKSHOP MANUAL. ‘This workshop manual is designed as a guide for servicing vehicle, ‘An INDEX is provided on the first page of each chapter. ‘TROUBLESHOOTING js dealt with cach chapter. When beginning operations, refer to the sections on for a guide to appropriate diagnoses, SPECIAL TOOLS are dealt with in each chapter. When ordering a special tool, make sure that the parts number is correct. opaz0.1442 PART NUMBER REPAIR PROCEDURES. Repolr procedures which are self-explanatory such as simple installation and removal of parts have been omittad, Mhustra- tions such as the one below have been provided to make such simple procedures clear. Only essential procedures requiring directions have been dealt with explicitly EXAMPLE TIMING GEAR AND CAMSHAFT T= 1,100—1,300 (90-94) saan ye T= Tightening torque kg-cm {1b.f2) 1, Thrust bearing 5. Bushing 8. Crankshaft gear 13. Frontend plate gasket 2 Camshaft gear 8, Idler gear thrust plate 10, Injection pump drive geat 14. Frontend plate 3. Oil pump drive gear 7, Straight Ein 11, Idler gear thrust plate 4, hier gear 8. teller gear shaft 12. Camshaft in some cases, iffustrations may be of parts which differ in some nonessential way from the parts found on your particular vehicle, In such cases, however, the principale or procedure being illustrated applies regardless of such nonessential differenceGENERAL INTRODUCTION GIS DEFINITION OF TERMS. This engine rotates clockwise seen from the timing gear side. IDENTIFICATION INFORMATION ENGINE SERIAL NUMBERS. Please quote these numbers whon ordering spare parts oF reporting technical matter as they will give you prompt service attention, The engine serial number is engraved on the engine cylinder block.GENERAL INTRODUCTION Cie (ky) "wonipuca Soneyen 200g] us-eits | tase wm | eee fener “axgeyeneun yen sgn| 19 | gececeare | cere oars waste | cee "oo | oq peyen “Asin “sorte sear ‘erg Bijan evan Gurung em mew | nese | nee weve wom pves wren cee out cervwses | meres | eee oe See “omy Ayumi woununye 20.404 149 mccmoses | array | csrmewee | ourecowce | cnet coer | omi-os | mecme | rss | enw | oe tenne | HE URNA "Hog papee envee | | \ “yr seg "tous Gatun wen "son pao Buywenn soo wi | ween | meee | ween “argeeamue yusoany 2 se | mela | otecue | terre 2109 pened "Aisny “sanguine ets 20 Sunny onan Baquen yy “swonpuoe worpeyy| SeeHEre @ =a] © © ron nveps wes 1708 auVANVIS 40 3NDWOL ONINSLHOLLENGINE ENA EN-B2E-08 CHAPTER EN ENGINE Models WO4D and WO4C-T DATA AND SPECIFICATIONS EN-DS4B - 1 TROUBLESHOOTING see EN-TS4A - 1 ENGINE OVERHAUL CRITERIA . EN.oc3c - 1 ENGINE MOVING PARTS . EN-MP4B - 1 CYLINDER HEAD ... EN-MP4B - 5 TIMING GEAR, CAMSHAFT AND OIL PAN ..... EN-MP4B -17 PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING ............0.00-0+ EN-MP4B -24 LIQUID GASKET AND APPLICATION POINTS ... EN-MP4B .39 LUBRICATING SYSTEM EN-LS4A - 1 OIL PUMP AND OIL STRAINER EN-LS4A - 2 OIL COOLER AND OIL FILTER EN-LS4A - 5 FUEL SYSTEM... EN-FS6C - 1 INJECTION NOZZLE . EN-FS6C - 2 FUEL FILTER EN-FS6C - 4 COOLING SYSTEM EN-CS22A- 1 COOLANT PUMP EN-CS22A- 2 THERMOSTAT . EN-CS22A- 5 RADIATOR EN.CS22A- 6 ENGINE COMPONENT PARTS DISMOUNTING AND MOUNTING . FUEL INJECTION PUMP ALTERNATOR STARTER ... TURBOCHARGER (For WO4C-T) CAR COOLER COMPRESSOR . VACUUM PUMP . NOISE SUPPRESSOR (For WO4D) ENGINE TUNE-UP PROCEDURE FOR INSTALLING AND GASKETS OF ENGINE PARTS ... EN-CP16A- 1 EN-CP16A- 1 EN-CP16A- 3 EN-CP16A- 4 EN-CP16A- 5 8 8 1 1 EN-CP16A- EN-CP16A- EN-NSIA - EN-TUAC - ENPRIB - 1ENGINE EN-DS4B-1 DATA AND SPECIFICATIONS Model...... Piston displacement Compression ratio . Firing order . . Direction of rotation... 2.4.5 Compression pressure ....... ‘Maximum revolution (at full load! Idling revolution . . Dry weight ++ WO4D : Approx. 335 kg (738.5 Ib) WOSC-T : Approx. 400 kg (881.8 Ib} Valve seat angle; Intake « teeter ees 0" Exhaust oe. eee ee ee 48° Valve face angle; Intake eee eevee eee 30° Exhaust oes eee cece ee 48? 7 Valve timing (flywheel travel), Intake opens .... 16° before top dead center Intake closes .... 40° after bottom dead center Exhaust opens . . . 55° before bottom dead center Exhaust closes ... 13° after top dead center Valve clearance (when cold) Intake. ++ 0,30 som (0,0918 in) Exhaust. = WOAD : 0,80 mm (0.0187 in} WOSC-T : 0.45 mm (0.0177 in) Injection nozzle opening pressure. . 220 kg/em? (3,128 Ib/sa.in} Thermostat oo... eee eee eee tence Wax type, bottom by pass system Injection timing (flywheel travel) WO4D : 14° before top dead center for No.1 cylinger de. = HINO WO4D and Wo4e-T WO4D : Diesel, 4-cycle, 4 cyl, vertical cylinder, in-line, overhead valve, water-cooled, direct injection type WOSC-T : Diesel, 4 cycle, 4 cyl, vertical cylinder, in-line, overhead valve, water-cooled, turbocharged, direct injection type sees ees, WOAD 1042 118 mm (4.09 x 4.65 in) WOOCT : 104 x 113 mm (4.09 x 4.45 in) seeeeseseses + WOSD 4.008 liters (244.6 cu.in) WOSC-T : 3.839 liters (234.3 cu.in) 73; 342 (A number of 2 cylinder is to be counted in order from the ‘timing gear end.) Counter-clockwise viewed from flywheel ‘33-36 ko/em? (469-612 Ib/sq.in) at 290-330 rpm 3,200 rpm 600-650 rpm ‘on compression stroke WO4C-T : 10° before top dead canter for No.1 cylinder ‘on compression stroke NOTE: In cate of equipped with fuel injection pump No. 22080-1470, sat the injection timing at 11° before top dead center for No.1 cylinder on compres sion stroke.ENGINE EN-TS4A-1 TROUBLESHOOTING Possible cause Excessive oil consumption ———— [Coolant] Insufficient coolant Defective thermostat... . Overfiow of coolant due to leakage of exhaust into cooling system Cooiant leakage from cylinder head gasket. . . Defective coolant pump . Ri Clogged with rust and scale Clogged with iron oxide due to leakage ‘of exhaust into cooling system Clogged radiator core due to mud... .. or other debris Defective radiator cap pressure valve ‘Abnormal combustion {Incorrect injection timing . Reduced injection pressure Poor fyel . . Poor nozzle spray . . . . © Unsatisfactory automatic timer advance angle .. [other probiems Defective or deteriorated engine oll ....... Unsatisfactory operation of oil pump Insufficient oi! . Brake drag . —[Pistons, eylinder liners, end piston rings ow F of piston ring and cylinder liner . . . ‘Worn, sticking or broken piston rings . . Insufficient tension on piston rings... Unsatisfactory break-in of piston rings Unsuitable oil (viscosity too low) . . . Incorrectly fitted piston rings (upside down) Gops of piston rings line with each other... ‘Add coolant. Replace the thermostat. « Repair. « Replace gasket, + Repair or replace. Clean radiator. - Clean coolant passage and correct exhaust leakage. Clean radiator. Replace radistor cap. «Adjust injection timing, Adjust injection pressure, Use good quality fuel. Adjust or replace nozzle. Repair or replace timer. « Change engine oil - Replace or repai ‘Add oil Repair or adjust. Replace piston rings and cylinder liner. Replace piston rings and cylinder liner, Replace piston rings and cylinder liner. Replace piston rings and cylinder liner. ‘Change oil as required and replace piston rings and cylinder liners, Replace piston rings. Reassemble piston ringsEN-TS4A-.2 ‘Symptom Excessive oll consumption: ENGINE Potsible cause Valve and valve guides! Worn valve stem 0-00. e eee Worn valve guide Incorrectly fitted valve stem seal... . Excessive lubricant on rocker arm Scheels © Oillevel too high .. 2... Pn eae ‘Other problems © Overcooied engine (low temperature wear) Piston seizure ~ Operation | Abrupt stoppage of engine after running . at highsoeed Hill elimbing using unsuitable gear oil © Insufficient oit ... © Dirty oil © Poor quality © High oil temperature © Lowoil pressure a © Defective oil pump (© Reduced performance due to worn. oil pump © Suction strainer sucking air. . fp {evotey Lack of power ican] © Clogged air cleaner... Overheating]. © Oil leakage from miscellaneous parts... ‘Abnormal combustion] .... +--+ +++. Remedy /Prevention Replace valve and valve guid Replace valve guide. Replace the stem seal. ‘Check clearance of rocker arm ‘and shaft, Replace oil levet gauge. - Drain excess oil, . Warm up engine before moving vehicle, Check coolit system. Rey ir. Operate engine property. Select suitable gear, « Add oil = Change oil. Repiace with proper engine oil, Reps Repair, = Repair oil pump. + See Symptom: «Replace oil pump, Add oll and/or repair strainer. “Engine overheating,” ‘See Symptom: “Engine overheating." Refer to CHAPTER IP, FUEL INJECTION PUMP. . Clean element or replace element. ‘See Symptom: “Engine overheating,”Symptom Lack of power: ENGINE Possible cause, Difficulty starting er Fuel and nozzle © Poor nozzle spray... seve © Clogged nozzle with carbon... . © Wear or seizure of nozzle © Airinfuslsystem 2.0.2... © Clogged fuel filter . © Use of poor fuel 6... cece cece ee | [Abnormal combustion] |—-{Piston, cylinder liners, and piston rings] [Other problems © Breakage of turbine or blower... Electrical system © Discharged battery . .. © Defective wiring in starter circuit © Loose or opencircuit battery cable © Breakdown of starter... 6.0... © Break of glow plug or intake... -- air heater {If s0 equipped) Injection pump] ..... 6. 02-22 eee [fair clearer] © Clogged element... Fuel system © No fuel in tank © Clogged fuel tine... © Ali sucked into fuel system through fuel line connections © Clogged fuel filter... eee © Loose connection in high-pressure line . . © Water in fuel 22-2... «+++ Adjust or replace injection nozzle, = Clean nozzle, Replace nozzle. «+++ Repair and bleed air from fue) system. Replace element. ity fuel. “Engine overheating.” ‘See Symptom “Engine overheating.” s+ Replace the turbine or blower ‘or turbocharger. + Charge battery. = Repair wiring of starter +++ Tighten battery terminal connec tions or replace battery cable. date eplace starter. «+ Replace ceeee Refer to CHAPTER IP, FUEL INJECTION PUMP. + Clean the element or replace the element, - « Supply fuel and bleed air from fuel system, <+ + Clean fuel line, + Tighten fuel line connections. ae Replace element. « Tighton sleeve nut of high pres sure line, Drain and clean fuel systemEN-TSOAS ENGINE Symptom Possible cause Remedy Prevention Difficulty starting engine Nozzle © Seized nozzle ceceesess Replace nozzle. © Broken or fatigued nozzle spring . «Replace spring. [Oil system © Oil viscosity too high... see eee ee [Other problems] (© Saized piston... © Seized bearing .....++. © Reduced compression pressure © Ring gear damaged or worn ‘© Improperly adjusted or broken... .. . accelerator cable Rough idling Leakage of exhaust [Cylinder head gasket Injection pump Nozzles © Uneven injection pressure Poor nozzle spray . . © Carbon deposit on nozzle tip . . © ‘Seized needle valve . Engine proper| © Improper vaive clearance... .... © Improper contact of vaive seat... © Idting speed too low... ‘© Compression pressure of cy! markedly different from one another © Fatigued gasket (aging) © Damage Teldec © Improper installation... . Use proper viscosity oi, or Install an off immersion heater and warm up oil. - Replace piston, piston rings, anct = Bapiace bearing and/or crankshatt. . Overhaul engine. = Replace the ring gear and/or starter pinion, Adjust or replace the accelerator cable, Refer to CHAPTER IP, FUEL INJECTION PUMP. = Adjust. Adjust or replace nozzle, Remove carbon, « Replace nozzle. Adjust valve clearance. Replace or repair valve and valve seat. Adjust idling speed. - Warm up engine, » Overhaul engine, « Replace gasker Replace gasket, Replace gasket,‘Symptom Leakage of exhaust ENGINE Ponsible cause Cylinder head bolts © Loose bolts alctetote ada © Elongated bolts... ‘© Improper tightening torque or tightening sequence [Cylinder block] © Cracking... © ‘Surface distortion . . © Fretting of cylinder liner insertion portion (insufficient projection of cylinder liner) }-—[cylinder head © Cracking . © Surface distortion . ‘Gylinder Tiners| © Cracking © Corrosion... Other problems © Incorrect injection timing ‘© Insufficient projection of cylinder liner . EN-TS4AS. Remedy/Pravention = Tighten bolt. «Replace bolt. «Tighten properly. Replace cylinder block, Repair or replace, Replace cylinder tiner or cylinder block. Replace cylinder head + Repair or replace. +++ Replace eytinder liner. «Replace cylinder liner, Replace cylinder finer. sere es Adjust injection timing.ENGINE EN-OS3C-41 ENGINE OVERHAUL CRITERIA SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools. ‘COMPRESSION GAUGE COMPRESSION GAUGE COMPRESSION GAUGE ADAPTOR (NOZZLE HOLDER) ADAPTOR (GLOW PLUG) ADAPTOR (09552-1070 FACTORS WHICH DETERMINE WHEN AN ENGINE OVER: HAUL IS NEEDED. 1. Lowered compression pressure ‘2, Before the measurement ‘2) Correct the valve clearance. b) Warm up engine [Bring the coolant temperature to about 80°C (76°F). cc} Charge the battery fully. 4d} Remove the air cleaner. b, Measurement 1) Measure at nozzle holder hole. 13) Remove the nozzle holders. 1D) Install the gauge adapter in the nozzle holder hole, ‘Special Tool: Compression Gauge Adapter (09408-1041) (09552-1070) ‘SAMPLE 2) Measure at glow plug hole. a} Remove the glow plug Install the gauge adapter in the glow plug hole ‘Special Tool: Compression Gauge Adapter (09552-1051) (09552-1070) S03. 388) ©) Connect a compression gauge to the gauge adapter. 4) Drive the engine with the starter and read the camoresson pressure. NOTE: Do not continously operate the starter for more than 15 seconds at 2 time. ©) Measure the compression pressure for each cylinder, If the compression pressure is low, be sure to repest the measuring. NOTE: Be sure not t0 leak through sealing face. Unit: ka/em? (Ib/q.in) Compreasion pressure Ditfarance between Engine apeed ee Standard Limit ‘ach cylinder (cpm) Word wosc-7 eee eee 25 (356) Less thon 3 (43) 350 woae-Ti 30-35 (627—468) 233) wood wosp 39-36 (469-511) 25 (356) a WwosD-T ‘30-33 (427—489) 22 (313),EN-OS3C-2 SAMPLE | i on ! ----4 r-- 5M3 349) ATMOSPHERIC TEMPERATURE a. Decreased oll pressure Check the oil pressure warning lamp when the oil and coolant, ‘temperature is hot [about 80°C (176°). | the warning lamp is lighted, check the oil level Cheek cil deterioration. {foil quality is poor, replace witha suitable grade oil Remove the oil pressure switch and install the oll pressure gauge. Moasure the oil pressure st coolant temperature 80°C (176°F) ‘or more. ‘Standard oil pressure: 0.5—5.0 kg/em? (7.11—71.10 tb/sq.in) Service timit: Less than 0.6 kg/em? (7.11 Ib/sq.in} weap oe Other factors ‘The blow-by gas increases. The engine does not start easily. Engine output decreases. Fuel consumption increases. Engine makes greater noise. Excessive oil consumption.ENGINE EN-MP4B-1 ENGINE MOVING PARTS DESCRIPTION | su3.808 sMa.1438 Representative engine model WO4D Representative engine model WO4C-T 1. Rocker arm 10. Engine mounting 19, Injection pump 2. Valve nn 20. Oil level gauge 3. Nozzle 2 21, Starter 4, Push rod 13. 22. Cylinder block 5. Teppet 4. 23. Connecting rod 6. Camshaft 15. 24, Crankshaft 7, Exhaust manifold 16. 28. Intake pipe, air & Oil cooler v7. 26. Turbocharger 9. Oi filter 18, Fuel filter 27, Feed pump.EN-MPAB.2 ENGINE SPECIAL TOOL Prior to starting an engine overhaul, itis necessary to have the following. SLIDING HAMMER ADAPTOR {USED WITH 09420-1442) ADAPTOR (USED WITH 09420-1442) DS 2 GF 09420-1442 CYLINDER HEAD BOLT WRENCH (09462-1370 for model WO4D EYE BOLT (USED WITH 09470-1022) (09462-1130 for model WO4C-T wire E ae 09411-1260 VALVE SPRING PRESS 09433-1070 VALVE LAPPING TOOL 09491-1010 VALVE STEM SEAL PRESS 09470-1022 CRANKSHAFT PULLEY PULLER 09431-1010 TIMER SETTING TOOL 09472-1650 IDLER GEAR SHAFT PULLER (08512-2090 for model WO4D (09512-2100 for model Wo4C-T 09420-1100ENGINE EN-MP4B-3 TIMING GEAR COVER OIL SEAL PRESS PISTON RING EXPANDER: CYLINDER LINER PULLER 0 o- 4 P LW ue 99482-1530 09442-1180 09420-1460 CYLINDER LINER GUIDE GUIDE PRESS SUB-ASSEMBLY i QD J 8 09480-1120 09481-1130 : 9233-10360 09402-1470 for model WO4C-T 09402-1460 for model WO4D GUIDE GUIDE BOLT er aoe maw 09051 or wo WORD overseerEN-MP48-4 ENGINE FLY WHEEL HOUSING OIL SEAL PISTON RING HOLDER PRESS 09441-1260 09482-1540ENGINE EN-MP4B-5 CYLINDER HEAD OVERHAUL ME11~040.00x02 (1310) T= 190-260 (14-18) T= 190-260 (14-18) 16 ‘T= Tightening torque kg-em (Ib. ft) 7. Push rod 13, Valve stem oil seal 8. Tappet 14, Valve spring tower seat 9. Cotter key 15. Exhaust valve 10. Valve spring upper seat 16. Intake valve 5. Rocker arm support 11. Inner valve spring (For WO4D) 6. Valve clearance adjusting screw 12. Outer valve springENMPQB-6 ENGINE OVERHAUL ‘T= 450-500 (33-36) T= 130-190 (10-13) T= 1,300-1,400 (94-101) T= 130-190 (10-13) T= Tightening torque: kg-om (Ib.ft) 1. Cylinder head 2. Oil filler cap 3. Cylinder head cover F head cover gasket 8. Expansion plug 9. Nozzle holder gasket 10, Packing ring 11. Shim 12, Nozzle holder 13. Nozzle 14. Nozzle holder adapterENGINE EN-MP4B.7 OVERHAUL, ME11-044-09x08 (1320), Model WO4D_ T= 190-270 (14-19) ME1 1038-0008 (1320) Model WO4C-T ‘T= Tightening Torque: kg-em (Ib.ft) 4. Exhaust manifold 5. Intake air pipe 9. Clamp 2. Exhaust manifold gesket 6. Heat insulator 10, Waste gate safety valve 3. Intake manifold gasket 7, Gasket 11. Oring 4, Intake manifold & Hose 12. Idle up actuator (If 10 equipped)EN-MP4B-8 sM3-886 | IMPORTANT POINTS ~ DISASSEMBLY CLEAN OFF SURROUNDING AREA OF THE NOZZLES AND. ‘THE FUEL LINE CONNECTORS. NOTE: If foregin matter is allowed to enter the combustion ‘chamber, engine trouble may result. REMOVE THE INJECTION PIPES, NOTE: Cover open ends of the pines to prevent entry of dirt. REMOVE THE NOZZLE ASSEMBLY. Using a special tool, if the nozzle is difficult to remove by ‘hand. ‘Special Tool: Sliding Hammer (08420-1442) ‘Adapter (08462-1370) for modet WO4D (09462-1130) for modal WO4C-T NOTE: © After removal of the nozzle holder, cover the nazzle holder with cloth. Also cover the cylinder heed with a cloth to prevant dust from getting in. REMOVE THE CYLINDER HEAD ADDITIONAL BOLTS AND ROCKER ARM SUPPORT BOLTS. Loosen the cylinder head additional bolts and rocker arm support bolts in the numerical order a shown, LOOSEN THE CYLINDER HEAD BOLTS AND REMOVE THEM. Loosen the cylindes head bolts littie by little in three stages and in the numerical order as shown. Special Tool: Wrench (09411-1260) * Mark position (Cylinder head additional botts)fA PLACE CHISEL, lat THIS ICORNER ONLY OY Up AND DOWN p 0.0 0 CYLINDER BLOCK t 53-802 enlenlandes lerlenles sMg-293 ENGINE EN-MP4B-9 UFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER BLOCK ANO PLACE IT ON WOODEN BLOCKS 4. If the cylinder heed is difficult 10 lift off, pry with a chvse! between the cylinder head and block. NOTE: Do not damage the machined surface of the head or block when removing the eylinder head, Special Tool: Eye Bolt (09433-1070) ‘Wire (09891-1010) REMOVE THE VALVE SPRINGS. 1, Remove the valve stem cotters, upper valve seats, and inner ‘and outer valve springs form cylinder head. ‘Special Tool: Valve Spring Press (08470-1022) 2. Remove the intake and exhaust valves. 3. Tag valves to identify their cylinder numbers and to eliminate valve lapping. IMPORTANT POINTS — ASSEMBLY CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SU! ABLE SOLVENT. NOTE: Be careful not to damage the cylinder head surface. IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT. Lightly appiy tapping compound to the valve face. Install the valve with @ special tool, tap and rotate the valve against the seat. ‘Special Toot: Valve Lapping Tool (09431-1010)EN-MP4B.10 ENGINE M3707 INTAKE EXHAUST M3904 vaLve: ARC WELDING (CUT THESE POSITIONS _$M3-805 ——c— 300) INTAKE INTAKE EXHAUST p i 45/ EXHAUST 9.896) IF NECESSARY, GRIND THE VALVES AND VALVE SEATS. NOTE: © Grinding of valves and valve seats should only be performed when handspping does not result in proper seating. © After grinding, always rechock the valve sink, Standat ‘Valve Seat (Intake): 30° ~ 30°30" Valve Face (Intake) : 29°30'— 30° ‘Valve Seat (Exhaust) : 45° — 45°30" ‘Valve Face (Exhaust): 44°30'— 45° IF NECESSARY, REPLACE THE VALVE SEAT. 1. Cut the circumference of a valve head at three places with 8 grinder and install it into the seat as shown and weld the valve to the seat. Then drive the valve and the seat out with hammer and a brass bor. 2. Valve seat section machining specifications. __ Unit: mm ( Intake Exhaust A 46.500-46,516 41,000-41,016 (1,8308~18313)_| (1.6142-1.8148) 8.8-9.0 72-73 (0.2466-0:364a) | (0,2896-0.2874) c 46.585—46.600 41,130-41.145, i (1.8341—1,8346) (1.6193—-1.6198) i 7 75-77 60-62 7 (0.2953-0.3031) | (0.2363-0.2440) 1 i dimension 3. Valve seat installation Heat the cylinder head to about 80° - 100°C (176 - 212°F) with hot water. On the other hand, cool the valve seat with dry ice or liquid freon for about 30 minutes. Hold the seat with pincers and place it into the heated cylinder head.VALVE GUIDE | priimoen wean 4 74 mim (231 in) £18 mm (059 ind ENGINE EN-MPQB-11 IF NECESSARY, REPLACE THE VALVE GUIDE. 1, Remove the vaive stem seal. 2. Using a brass rod and hammer, drive out the vaive guide. 3. Install the valve guide as shown. NOTE: Apply engine oil lightly to the valve guide outer circumference before installing. IF NECESSARY, REPLACE THE VALVE STEM SEAL. 1, Remove the vaive stem seal, 2. Install the valve stem seal. First, install the lower spring seat (for stopper of special tool) and valve. Then apply engine cil to the lip of the stem seal and ‘rive the special tool until it hits the lower spring seat. Special Tool: Valve Stem Seai Prass (09472-1650) NOTE: © After installing stam seal, make sure that check the rubber potition for cracks or any other darnage. © Do not use the special too! if its tip (surface contacting tower spring seat) is worn or deformed. ASSEMBLE THE CYLINDER HEAD. NOTE: © Apply engine oil to contact surfaces of all parts. (© Make sure that the valves are installed in the correct cylinders. © Install the valve springs with their painted side down, since they have variable pitches. Press upper spring seats and install the valve stem keys securely in the upper spring seats. ‘Special Took: Valve Spring Press (08470-1022) NOTE: © When pressing with the valve spring press, be careful not ‘to damage the stom seals by contacting the upper soats. © Drive the valve stem tightly with a hammer to assure proper fit the valve stem key.EN-MP4B.12 ARROW MARK TIMING GEAR SIDE INTAKE EXHAUST No.5 SUPPORT OIL HOLE 53629) INTAKE SIDE 5M3.201A, ENGINE ASSEMBLE THE ROCKER ARM. Lubricate the rocker arm shaft and bushing, NOTE: Confirm that oil hole of rocker arm assembly No. 5 support aligns with shaft oil hole. tmproper installation will result in burning of the entire valve assembly. INSTALL THE TAPPETS IN THE CYLINDER BLOCK IN COR- RECT ORDER. NOTE: Apply engine oil to the tappet faces and tappat guide when installing them in the cylinder block. INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEM- BLY. 1. _ Install the cylinder head gasket. NOTE: Always use new cylinder head gasket after cleaning the suctaces of the cylinder head, cylinder block and head gasket free of all dirt, water and grease, 2. Install the cylinder head over the dowels on the cylinder block. 3. Insert the push rods in correct order, after applying engine oil to both ends. 4, Mount the rocker arm assembly on the cylinder head, make sure that the push rods interlock with the adjusting screws. NOTE: Always loosen the lock nut and ral the adhusting screws fulty to the top, 5, Tighten the cylinder head bolts little by little in three stages and in the numerical order as shown. Tighten the bolts ¢ 12mm to the specified torque. NOTE: Apply engine oil to the bolt threads and under the bolt head. ‘+ Mark bolts (cylinder head additional bolt): 10 mm (0.39 in) No. 1 —No. 18 Bolts (Gylinder head bolt): 12mm (0.47 in) Special Tool: Wrench (09411-1260)FITTING NUT. CYLINDER HEAD LOWER FACE PROTRUSION SS T364 ENGINE EN-MP4B-13 6. Tighten the cylinder head additional bolts and rocker arm support bolts littie by little in three stages and in the nu: ‘merical order as shown, Tighten the bolts to the specified torque. 7. Retighten the cylinder head bolts. NOTE: Refer to section ENGINE TUNE-UP. INSTALL THE INJECTION NOZZLE HOLDER. 1. Install a new gasket in the nozzle hole. 2. Insert the nozzle and holder assemblies into the nozzle sleeves with their inlet connectors toward the injection pump, NOTE: © Do not let dust fall into the nozzle holder. Fits care fully over the top end of the sleeve, ring parking when installing the If damaged, the entry of oil, and dust maker removing the nozzle difficult. 3, Tighten the nozzle holder fitting nuts gradually and alter- nately. Tightening Torque: 130-190 kg-em {10-13 tb.ft} NOTE: Insufficient tightening torque causes gas leaks and could result in nozale seizure. 4, Inspect the protrusion of the nozzle. Refer to INSPECTION AND REPAIR.EN-MPAB-14 ENGINE INSPECTION AND REPAIR ove: mn ti Inspection Item Standard Inspection Procedure Cylinder Head Flatness ‘Less than 0.06, = | (0.0019) Cylinder Hood Height 870 86,8 | Replace (3.425) (ai Cylinder Head Cracks and Replace, if Damage necessary + Using a Dye Penetrant A= ee SOSSO —— saa Valve Seating Condition ‘There should be good Hand+-top with * Using Red Leed Marking | contact around entire lapping com. Compound circumtrence of valve pound freed. - Valve Seat Angle | Intake 30°-30°30" Rogrind or replace vaive Exhaust | 45°—45"30° and/or valve — | swat Valve Angle Intake 2930-30" [of | Exhaust | 44°30—45° wane | ooausr ‘3-809 Nozzle Protrusion from 2.75-3.25 Replace nozzle Cylinder Head Surface (0.1083-0.1278) sasket swa-091 Intake Valve Sink | WO4D 0.18 ~ -0.45 “055 | Replace valve | gis cyLINDER @ (0.0069 ~ -0.0177) | (-0.0216) | and/or HEAD SURPACE™ woae-T 0.05 - 0.35 ~0.05 | vaveseat (0.0019-0.0137) | (-0.0019), N & Exhaust Valve Sink 0.47 - -0.77 ~087 S {-0.0185 ~ -0.0303) | (-0.0342) sm3.236)(0.0394) ENGINE EN-MP4B-15, Unit: me nd Ingpection Item Limit Remedy Inspection Procedure | tntake Votve Stem Diameter 8.90 | Replace vive (0.3903) | guide and/or Exhaust Valve Stem Diameter a“ (0.3616-0.3524) Intake and ExhaustValve Guide 9.000-9.015 Diameter (0.3544-0.3649) A: 5(0.187) rn 8: 25 (0.984) C: 45 (1.771) Clearance between Vaive Stem 0.036-0.068 and Valve Guide (Intake) (0.0004~0.0026) Clearance between Valve Stem 0.050-0.083 and Valve Guide (Exhaust) {0.0020-0.0032) | 02 (0.0078) 33-835) Rocker Arm Shaft Diameter 18.97-18.98 18.95 | “Replace rocker (0.7469-0.7472) | (0.7461) | arm bushing | and/or shaft CClearanca between Rocker Arm 0.036-0.079 on Shaft and Bushing (0.0015-0.0031) | (0.0039) Inner Valve Spring Setting Load | 8.8 kg (1 8.0kg | Replace 43.0 mm (1.69 (17.61) 274 kg (54.5 ib) at | 25.5 kg ae 45,5 mm (1,79 in) | (66.2 1b) ‘Valve Spring Straightness 2.0 | Replace {inner and Outer) (0.0787) ‘Valve Spring Seat for Wear A: 25 Repalce (0.0984) B: 6.0 7 (0.1968) e: 1.0EN-MP4B-16 ENGINE Unit: ram tind Inspection Item. Standard Limit Remedy Inspection Procedure Nalve Stem Tip Surface for Resurface or ‘Visual Cneck we replace Valve Stem Contact Surface fof Rocker Arm for Wear = ~~ sua ar] Push Rod Bend 0.3 | Replace (0.0118) ‘Tappet Diameter 26.95-26.97 Replace tappet (1.0631-1.0618) ‘Tappet Guide Inside Diameter 27.00-27.02 (1.0630— 1.0637) Cleerance between Tappet and | 0,025-0.071 04 7 ‘Tapper Guide {0.0010-0,0029) | (0.0039) : ‘Teppet for Weer Should not be worn Replace, if unevenly. necessary - Visual CheckENGINE EN-MPQ817 TIMING GEAR, CAMSHAFT AND OIL PAN OVERHAUL T= 190-260 (14-18) ‘T= Tightening Torque: kgm (lb.ft) 1 11, Gaaer 2 12. Connector 2 Cralhet paley 12, Soft water (If s0 equipped) 14, Power steering oil pump 4. Crankset ploy 15, Power searing oi pom 5. Oil eal drier ‘airaour Powe wast Sen trl geal dooneeee STEERING OIL PUMP Bal beaig + Engine mounting ‘8. Retainer ring 18, Oil pan 9. Timing a eover 12, Drain pug 10, Timing gn pte 20, PeeEN-MP4B-18 ENGINE OVERHAUL T= 1,100—1,300 (80-94) T= 190-260 (14-18) T= 190-260 (14-18) T= 1,100-1,300 (80-94) ‘T= 300-350 (22-25) ‘T= Tightening torque: kg-cm (Ib.ft) 1. Camshaft 7. Idler gear thrust plate 13. Injection pump drive gear 2. Key 8. Straight pin 14. Coupling flange 3. Thrust besring 8. Idler gear shaft 16, O-ring ‘4, Camshaft gear 10. Bearing 16. Timer cover ‘5. Thrust washer 11. Idler gear 17. Soft washer 6. Oil pump drive gear 12. Crankshaft gear 18, PlugENGINE EN-MP4B.19 IMPORTANT POINTS — DISASSEMBLY REMOVE THE CRANKSHAFT PULLY. 1, Remove the nut and spacer. 2. Using a special tool, remove the pulley, Special Toot: Crankshaft pulley Puller (09420-1500) DISMOUNT THE INJECTION PUMP ASSEMBLY. Pee coven 1. Rlemove the inspection hole dust cover of the timer, 2, Turn the crankshaft clockwise viewing from the timing gear ‘cover to align the injection timing mark, MaRe\ \ POINTER. guy3eae 3. Lock the automatic timer with a special tool. ‘Special Tool: Timer Setting Too! (09512-2090) for WO4D (09612-2100) for WO4C-T NOTE: Do not loosen the injection pump drive goar fitting bolts. 4, Remove the injection pump assembly. 83.260 REMOVE THE CAMSHAFT WITH GEAR, NOTE: Pull out the camshaft, slowly turning it so a: not damage ‘the bearings. REMOVE THE IDLER GEAR SHAFT. Using a special tool, remove the idler gear shaft. ‘Special Tool: Sliding Hammer (09420-1100)EN-MP4B.20 ENGINE 53-718) ‘CYLINDER BLOCK UPPER SURFACE J OIL HOLE ‘sm3.2030 IF NECESSARY, REMOVE THE CAMSHAFT GEAR. 1. Hold the camshaft with a vice through wooden plates. 2. Remove the bolt and plain washer, then using a gear puller, remove the gear. IMPORTANT POINTS ~ ASSEMBLY IF NECESSARY, REPLACE THE TIMING GEAR CASE COVER ONL SEAL, 1. Using a screwdriver, remove the cil seal. 2. Using a special tool, install the new oil seal Special Tool: Press (09482-1530) IF NECESSARY, REPLACE THE CAMSHAFT BEARING. 1. Remove the old bearing. 2. Set the notch of bearing right above and install the new bearing NOTE: When install the No.3 bearing (with oif holes), make sure ‘that the oil holes of the bearing and oil path in the cylinder block are aligned. ASSEMBLE THE CAMSHAFT GEAR AND SHAFT, Install the camshaft gear with thrust bearing. NOTE: When installing the gear to the camshaft: © Hest the gear in hot water Approx. 100°C (212°F)], ‘then install the gear to the camshaft By using a pres. © When tightening the bolt, apply engine ot to the threads and plate surface of the bolt. INSTALL THE CAMSHAFT. Lubricate all journals of the camshaft and insert the camshaft assembly into the cylinder block. NOTE: © Insert the camshaft, slowly turning whl the bearing will not be damaged. the camshaft, be sure that the match ‘marks of the oil pump drive gear and camshaft gear are aligned correctly. inserting so that2 FcR ANKSHAFT sMs.8a3, sMa-247, ENGINE EN-MPQB-21 INSTALL THE IDLER GEAR SHAFT. Install the idler gear shaft with thrust plate using a plastic hammer. NOTE: Se sure that the oll hole is downward, if installed the wrong way, damage to the idler gear shaft and bushing can result. INSTALL THE IDLER GEAR. NOTE: When installing the idler gear, be sure that the matching marks of the crankshaft gear, oil pump drive gear and idler gear are aligned correctly. INSTALL THE INJECTION PUMP TEMPORARILY. NOTE: When installing the injection pump, be sure that the mately ‘marks of the idler gear and injection pump drive gear are aligned correctly. MEASURE THE GEAR BACKLASH. Measure the backlash of each gear using a dial indicator. Replace the gear if necessary. Refer to INSPECTION AND REPAIR. INSTALL THE TIMING GEAR CASE. 1. Clean the faces. 2. Apply the liquid gasket as shown an ‘cover within 20 minutes, NOTE: If leaving it more than 20 minutes, clean the liquid gasket ‘completely and reapply the liquid gasket. Costing Width (A): 1.5 — 2.5 mm (0.06 — 0.10 in} stall the timing gearEN-MPAR-22 ENGINE INSTALL THE OIL STRAINER. Refer to “O1L PUMP AND OIL STRAINER” in SECTION LUBRICATING SYSTEM, TIMING GEAR PLATE INSTALL THE OIL PAN. 1, Cut the protrusion of the timing gear plate gasket from the oi! CYLINDER ‘pan mounting surface. BLOCK rmncccan (Of Ase s.268] 2, Clean the faces. 3. Apply the liquid gasket as shown and instal the oil pan within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width (A): 3— 4mm (0.12 — 0.15 in) TIGHTEN THE CRANKSHAFT PULLY. swa2eal NOTE: Apply engine oil to the nut threads. INSPECTION AND REPAIR ox ten hn Inspection Item ‘Standard Limit Remedy Inspection Procedure Gear Teeth for Pitting o Wear Roptace, if Visual check necessary Idler Gear Shatt Diameter 49.95-49.97 49.94 | Replace bearing (0.9311-1.9318) | (1.9307) | and/or shaft Idler Gear Bearing Inside '50.00-50.03 50.05 Diameter (1,9685~-1.9696) | (1.9705) imal =| ™~ ‘Oil Clearance between Idler Gear] 0.03-0.08 01 ‘Shaft and Besting {0.0012-0.0031) | (0.039) 5m3.847| ee ma Idler Gear end Pay 0.04—0.10 0.15 | Replace thrust (0.0016—0.0039) | (0.0059) | plate SM3-421ENGINE EN-MP4B23 Unit: men (in) Inspection Item Standord Limit Remedy Camshaft Band 0.05 | Replace (0.0020) ‘Camshaft Cam Height 49.44 48.90 Replace (Intake) (1.9465) (1.9251) Camshate Cam Height 49.50 48.95 (Exhaust) (1,9488) (1.9271) ‘Camshaft end Play 0.10-0.18 03 Replace thrust (0.0040-0.0070) | (0.0118) | plate Camshaft Journal Diametor No.1: 57.0 56.85 Replace shaft Journal No. = (2.2441) (2.2382) | -and/or bearing Noe 668 56.85 (2.2362) (2.2303) No.3: 56.6 56.45 (2.2283) (2.2224) Camshaft Journal Bearing No.1: 57.0 87.15 beside Inside Diameter (2.2441) (2.2500) Journal No.: | No.2: 56.8 86.95 (2.2362) (2.2421) No.3: 56.6 56.75 (2.2283) (2.2342) Oil Clearnace between Camshaft 0.03-0.12 0.15 Sournsl and Bearing (0.0012-0.9047) | (0.0089) Crankshaft Gear — Idler Gear | 0.068-0.194 03 | Replace gear, {0.0027—0.0076) (0.0118) | if necessary ‘| Idler Gear — Oil Pump Gear 0.065—0.182, i {(0.0026—0.007 1) 5 | Idler Gear — Injection Pump 0,065—0.232 i (0.0026-0.0091) f Injection Pump Gear — Air 0.065—0.274 | Compressor Gear (0.0028-0.0107) sma oa Oil Pump Gear — Camshaft 0.065—0.182 I Gear {0.0026—0.007 1)EN-MP4B.24 ENGINE PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING OVERHAUL St e- oP i “2h oe ‘T= 1,220-1,280 (89-92), ‘T= 1,400--1,600 (102-115)/ ‘T= Tightening torque kg-om {ib.ft) 5u5-1284 1. Piston ring 7. Crankshaft gear 13, Crankshaft bearing 2 Piston 8 Key 14, Camshaft besring 3. Piston pin 9. Crankshaft 15. Cylinder liner 4. Retainer ring 10. Connecting rod cap 16. Expansion plug 5. Connecting rod 14. Collar 17. Cylinder block 6. Connecting rod bearing 12. Crankshaft thrust bearing 18. Bearing cap1 { ENGINE EN-MP4B-25 OVERHAUL, Flywheel housing Oil seat . Ring gear Flywheel T= 1,800-2,000 (131-144) T= Tigntening torque kg-em (lb-ft) SMG-1285EN-MP4B-26 R259] ENGINE IMPORTANT POINTS — DISASSEMBLY REMOVE THE PISTONS WITH CONNECTING RODS, 1. Remove the carbon from the upper end of the cylinder liner with a seraper or emery paper (recommended: No. 150) in a circular direction, 2. Extract the piston and connecting rod assembly out through ‘the top of the cylinder. NOTE: © Arrange the piston and connecting rod caps in order. REMOVE THE CRANKSHAFT, NOTE: Arrange the caps, bearings and thrust bearings in order. REMOVE THE CONNECTING ROD. 1. Remove the retainer ring installed on both ends of the piston pin, by means of retainer ring pliers. 2, Apply a metal pad to the pin and strike out the pin with a hammer. NOTE: Warm up the piston first in hot water 80—90°C (176— 194°F) for about 5 minutes before removing the pin. REMOVE THE PISTON RINGS Special Toot: Piston Ring Expander (09442-1180) NOTE: © Handle the piston rings carefully becaure they are made of a special casting which is easily broken. (© Keep the rings for each cylinder separate.ENGINE EN-MP4B.27 REMOVE THE CYLINDER LINER. veY o 1, Place the match marks with a pen on the cylinder block and liner flange, before removing the cylinder liners, NOTE: Do not put the match marks with # punch, MaTcH MARK 5M3.851 2. Using a special tool, remove the cylinder liners. ‘Special Tool: Cylinder Liner Puller (09420-1460) NOTE: After removing the cylinder liners, put numbers on their pperiphory oF arrange them in sequence, IMPORTANT POINTS — ASSEMBLY INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK. +. When a new cylinder liner is used, make sure that the liner has the same mark as the mark on the cylinder block. NOTE: © There are 4 different liner and cylinder block matches. ‘The flange section of each liner has a marking any, W, X, Y, Z, oF indicating the size of the outer diametar Of the liner on which it is stamped. The markings W, X, ¥ and 2, indicating the inner diameter of the cylinder bore supporting the liner on the sides and top of the cylinder block (the bost section for attaching the coot ant gallery cover), are inscribed on each cylinder. Se | 2. When reusing @ finer, insert the liner its original position signing the marking marked before disassembly. sM3-861EN-MP4B-28 SPECIAL my Foot ~ 33-054 Unit: men (ind ‘Under Outside diameter aise ‘Gran ‘Journal ozs | 81-69-8171 7269-7271 . (zazes—24205) | 12.9619-2.6625) oso |, 81.44-61.46. 72.44-72.46. : (2.aiea—24196) | (28620-20527) 075 | 8118-8121 7219-7221 E (zans1—24038) | (2.8422-2.0420) joo | , 80.94-60.98 7194-7196 | tz398z-24000 | (2.823-25530) connect wrong sM3-441 Apply @ small amount of fresh engine ol on the cuter periphery of the liner, and apply pressure on the entire flange section of the Hiner. (f insertion by hand is difficult, use 2 eylinder guide, and the cylinder liner will easily be pushed in. Special Took: Cylinder Liner Guide (09480-1120) NOTE: © Do notuse a liner that has been dropped. © Take extra care when handling the liner since the finer {s easily deformed. MEASURE THE PROJECTION OF THE CYLINDER LINER. Tighten a special too! with a tightening torque of 100 kg:em {7.23 lb-ft) and measure the amount of projection of the top ‘end of the liner from the cylinder block with a dial gauge or Straight edge and a thickness gauge. ‘Special Tool: Cylinder Liner Puller (09420-1460) Tightening Torque: 100 kg-cm (7.23 lb-ft) Assombly Standard: 0.01—0.08 mm (0.0004-0,0031 in) IF NECESSARY, GRIND THE CRANKSHAFT AND USE THE UNDER SIZE BEARINGS. Dimension of Fillet R: Crank pin: 3.50 — 4.00 mm (0.1378 — 0.1574 in) Journal; 3.05 — 3.50 mm (0.1201 — 0.1377 in)sMa.a7a| No.4 TIMING GEAR, eR > ARROW ENGINE EN-MP48.29 INSTALL THE CRANKSHAFT. 1, Install the crankshaft bearings on the cylinder block and bearing cap. NOTE: Apply fresh engine oil to each bearing surface. 2. Install the crankshaft on the cylinder block. 3. Inert the crankshaft thrust bearings along the groove of the cylinder block, 4. Inetall the thrust bearings on the No. 4 bearing cap sides. NOTE: Apply fresh engine oi to each thrust bearing surface. 5. Install the crankshaft bearing caps. Install the bearing caps in numbered order from timing gear side with the arrow point toward the timing gear side, 6. Tighten the cap bolts in three stages following the tightening order. NOTE: Apply ongine oll to the bolt threads and under the bolt head. Tightening order: 3-2—4—1-5 NOTE: © Make sure that the crankshaft rotates smoothly. © Inspect the crankshaft end play.EN-MP4B-30 ENGINE WING NUT quipe PRESS SUB ASSEMBLY sa3-1565] CONNECTING ROD vay 7 PRESS SUB ASSEMBLY sm3-1566] SPINDLE BUSHING CONNECTING Press sus. ‘ASSEMBLY sMa-1567 PRESS SUB $M3-1567A IF NECESSARY, REPLACE THE PISTON PIN BUSHING. Prepre the special tools. ‘Assemble the guide and press sub assembly interting ite pin into the guide, then secure them with the wing nut, Special tools: Guide (09481-1130) Prass sub assembly (09402-1450) Wing mut (9233-10360) NOTE: © Bring leter “W" punched on the guide above the pin. © Make sure to align both supporting surface of the ‘guide and press sub assembly flush on a flat plane. 2. Using a special tool, remove the piston pin bushing. 2, Set the connecting rod assembled withour crank pin bore: bearing on the guide and press sub assembly. b. Sot the spindle on the bushing. Special tool; Spindle (09402-1470) for WO4C-T (09402-1460) for WD NOTE: Align the grooving of the spindle ‘bushing. the oil hole of theCONNECTING ROD, PRESS SPINDLE C.05-C.1.0 mm CONNECTING ROD sus-1589] ‘MODEL WoAD [1 croove ott HOLE: wy ‘OIL HOLE GUIDE: rt BUSHING eer ‘sM3-15708] MODEL WOICT SPINDLE GROOVE om Hote, iw “OL HOLE cue a BUSHING BOLT sMa-1570| J press OIL HOLE (A). OIL PATH, sua-1s71¢] ENGINE EN-MP4B-31 ©. Using a hydraulic press, remove the bushing. NOTE: Always operate the press slowly and smoothly. 3. Assemble the piston pin bushing Chamfer one edge of the bushing hele at the small end of the connecting tod uniformly by C 0.5~1.0 mm (0.0196-0.0393 in, NOTE: © Irregular chamfering can cause out-of-roundness of the pressed bushing, which may result in jamming during insertion, © Remove dust from the inner surface of the tmall-end hole. 4. Mount the bushing on the spindle. 2. Set the bushing and guide on the spindle aligning oll hole (AD in the bushing the grooves on the Both the spindle and guide b. Secure the bushing and guide with the bolt. Special tools: Spindle (09402-1470) for WO4C-T (09402-1460) for WOAD Guide (09481-1140) for Wo4c-T (09481-1120) for WOAD Bott (9191-08252) NOTE: © Be sure to stip the bushing over the spindle in the proper direction so that oil hole (A) will later elign with the oil path in the connseting rod. © Apply fresh engine oil to the bushing and guide. 5. Install the bushing in the connecting rod. Position the bushing-special tool assembly so that oil hole (AP align with the oil path through the connecting rod. NOTE: © Fully coat the bore in the connecting rod with fresh engine oi ‘© Always operate the press slowly and smoothly.EN-MP4B.32 BUSHING CONNECTING ROD ‘sm-1672| sm3-424] MATCH MARKS sua.acy| 6. Inspect the bushing position after instalation, NOTE: (© Make sure that the oil holes of the bushing and connect ing rod are aligned. © Insert a pin of 3 mm (0.1181 in) dia, into an hole ‘the end of the connecting rod, and make sure that the pin fully penetrates. If there is any deviation in the alignment of the oil holes correct it with a drill ot 3 mm (0.1181 in) dia. (© Misalignment of the oil holes can lead to insufficient lubrication, which may result in seizure. © Insert a new piston pin and rotate it slowly to make sure that there is no rattling. ASSEMBLE THE PISTON AND CONNECTING ROD. Make sure that the O:mar ‘at the top of the piston and the connecting rod match marks in opposite directions. NOTE: © Use the new retainer rings. © Heat the piston to abow 80 — 90°C (176 — 194°F) in ‘hot water about 5 minutes,MARK Pre wosc-) St TOP RING SECOND FING — OIL RING (MODEL WOAD) JOINT ‘Rr |5M3-205_$M3-408_$M3-445 MARK OIL RING TOP RING SECOND RING. 63.270] ‘sms.4a4| OMARK MARK. MATCH MARKS ‘3M3-407 ENGINE EN-MPAB-33 INSTALL THE PISTON RING. ae 1, Install the piston rings in the sequence oll ring, second ring and PACE top ring with the identification mark at the top of the ring facing up. NOTE: © Identification mark of second ring and oil ring is applied with gold paint. ‘© Apply oil to the piston rings. ‘Special Tool: Piston Ring Expander (09442-1180) 2. Connect the ends of the coil expander and then fit the coil inside the piston ring after ensuring that the gap af the piston ‘ing is 180° away from the joint of the coil. ‘Arrange the piston rings so that their gaps are equally spaced. INSTALL THE PISTON IN THE CYLINDER LINER. 1. Apply engine oil to the piston, cylinder liner and connecting Tod bearing suctace. 2. Using a special tool, hold the piston rings and push the piston with connecting rod assembly with a wooden rod. NOTE: Check the piston that the O-mark on the top is on the ‘tappet chamber Special Tool: Piston Ring Holder (09441-1260) INSTALL THE CONNECTING ROD CAP, 1, Apply engine oil to the cap bearing surface. ‘Atign the match marks on the connecting rod and cap. Apply engine oil to the bolt threads and under the bolt head. Tighten the cap bolt in three stages. BONEN-MP4B-34 su-2ta| su3.27} TIGHTENING ‘ORDER 513.1698 BOLT 53.1697] INSTALL THE OIL SEAL IN THE FLYWHEEL HOUSING. Using a special tool, press in the oil seal in the flywheel housing, Special Tool: Press (00482-1540) INSTALL THE FLYWHEEL HOUSING. 1. Clean the faces. 2. Apply the fiquid gasket as shown and install the flywheel housing within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the fiquid gasket ‘completely and respply the liquid gasket. Coating Width: 7.5-2.5 mm (0.06-0.10 in} INSTALL THE FLYWHEEL, 1, Install the flywheel and tighten the bolts through several repetitions of the tightening order so as to reach speci torque evenly and gradually, then slacken and tighten them ‘one by one to the specified torque. NOTE: © Align the “O~ mark on the flywheel snd crankshaft collar knock-in. (© When tightening the bolt, apply engine oil to the threads and flywheel surface of the bolts. 2. Install the pilot bearing and stopper.INSPECTION AND REPAIR EN-MPAB-35 Unit: mm (in) Inspection trem Standerd Limit Remedy Inspection Procedure Piston Diameter 103,860~103.876 — [Replace piston (4.0890—4.0896) |and/or liner Cylinder Liner Inside 704.008-104.040 | 104.18 Diameter (4.0849=4.0860) | (4.1003) Clearance between Piston 0.140-0.172 7 aed Cylinder Linar (0.0056—0.0067) Piston Pin Diameter @] 24.989-35.000 | 34.080 | Replace piston 3 | 3776-13779) | (1.3711_| and/or piston | 36.989-37.000 | 3698 |Pin 8] trases—1.4567 | (14580) Piston Pin Hole Inside ‘g | 34987-35003 | s.02 Diameter 3 | 3775-13780) | (1.3787) 5 | s6987-37.003 | 37.02 3 (1.4561—1.4568) | (7.4574) Clearance between Piston oorsT—oora | 0.04 Pin and Piston Pin Hole (0.00062T—0.000881) | (0.0015) T: Tight L: Clearance ‘Crankshaft end Play 0.05-0.22 (04 (Replace thrust (0,0020-0.0088) | (0.0157). bearing Comecivg Red SnallEnd | §] 36.016-a5.098, | 26.060 [Replace bus Bushing Inside Diameter (1.3786—1.3789) | (1.3811) |and/or piston | 37.018-37.025 | 37.080 {Pi 8] (nas7—1.4676) | (15172) Fiston Pin Diameter g| ase ame | 240 (arre—1.3779) | (1.3771) 5] 36980-37000 | 36.98 3) (rases—1ase7) | (1.4559) ‘Clearance between Piston 0.015-0.036 or fin and Connecting Rod too0016-0.0014) | (0.0039) ‘Small End BushingEN-MP4B-36 ENGINE Unit: men (in) Inspection Item Standard Limit Remedy Inspection Procedure ‘Connecting Rod Big end 65.985—66.000 Replace Inside Diameter (25879-25984) = Jeonnecting roc (Without Bearings) assembly sM3.300] ‘Crank Pin Diameter 61.94-61.86 0.20 | Regrind and use | (2.4386-2.4393) | (-0,0078) |undersize besring | 60.76 | Replace crank- (2.3021) | shatt Clearance between Connecting 0.031-0.082 (0:12 — | Replace beating od and Crank Pin (0.0013-0.0032) | (0.0047) 'sM3-300 ‘Connecting Flod End Play 020-052 0.6 | Replace connect: {0.0079-0.0204) | (0.0236) jing rod sua.se2 Connecting Rod Straightness 01 | Replace (0.0099) - Per 200 (0.7874) sus-se1 Connecting Rod Twist 01 | Replace (0.0039) - Par 200 (0.7874)EN-MP4B-37 Unit: mm (in) {Inspection Item Standard Limit Remedy Inspection Procedure ‘Connecting Rod Bearing 67.05-67.55 Roplace Spread Dimension (2.6398-2.6594) 7 (Crankshaft bearing 79,00-79.60 wa spread dimension (3.1102-3.1339) 7 su3.226| ‘Crankshaft Bend 0.04 | Repair or replace (Crankshaft Main Baaring 77.985-78.000 Replace Cap tnside {3.0703-3.0708) Diameter L (Without Bearings) (Crankshaft Journal Diameter 72.94-72.96 0.20 | Regrind and use (28717-28724) _| (-0.0078) | undersize bearing 71.76 | Replace erank- (2.8621) | shate \ ‘sma.860 Clearance between Crankshaft 0.039-0.090 0.13. [Replace bearing Journal and Main Bearing {0.0018-0.0036) | (0.0051) ‘Crankshaft Main Bearing 78.00-78.06 Replace Spread Dimension (3.1103-3.1125) 7 fel an All yer 93-1372 INSPECT THE VACUUM SWITCHING VALVE FUNCTION. 1. Inspect the vacuum switching valve (Type II. 2, Connect the switching valve terminals to the battery terminals as shown, b, Blow air into port B and check that air comes out of port C. ©. Disconnect the battery connections. 4, Blow air port B and check that air comes out of port A. . Inspect the vacuum switching valve (Type 1) 3. Connect the switching valve terminals tothe bettery terminals as shown. b. Blow air nto port A and check that air comes out of port B. ©. Disconnect the battery connections. d. Blow air port A and check that air comes out air filter.ENGINE EN-TUdC4 ENGINE TUNE-UP vA FLYWHEEL sM3-1773| VALVE CLEARANCE INSPECTION AND ADJUSTMENT OF THE VALVE CLEARANCE 1. Set the No. 1 piston to top dead center on compression stroke. 2. With the No. 1 piston positioned at top dead center and of the compression stroke, adjust the No. 1 valve clearance using a thickness gauge. “The thickness gauge should move with avery slight pull Valve Clearance = Unit: mm (in) ‘Model Intake T Exhaust Wo4c-T 0.30 (0.0118) [ 0.45 (0.0177) woaD 0.30(0.0118) | ~—_—0.40 (0.0157) 3. Adjust the other valves. Turn the crankshaft counterclockwise 180° viewed from the flywheel side. Adjust the valve clearance for each cylinder in the firing order. METHODE FOR DETERMINING IF THE NO.1 OR NO.4 PISTON 18 AT THE TOP DEAD CENTER ON COMPRESSION STROKE. Turning the crankshaft, align the mark “14” on the flywheel with the pointer on the flywheel housing. In this position either the No. 1 or No. 4 piston is at the top dead center on compression stroke. 1. If both the No. 1 intake and exhaust rocker arms can be moved easily by hand, the No. 1 piston is at top dead center ‘on compression stroke.EN-TU4C-2 ENGINE TIMER COVER POINTER 'SM3-834) PUSH RODS: STANDING PUSH RODS: MOVE {Overepping sroke) {TDC of eampresion ‘rokel (a0? to w& sM3-713A FLYWHEEL HOUSING FLYWHEEL = ‘TIMER CovER 5M3-8856) mank\, \ pointer sM3.a34| 2, If the injection timing mark is nearly aligned with the pointer, the No. 1 piston is at top dead center of the compression stroke. NOTE: If not, turn the crankshaft one complete revolution and align marks as abow' 3. While looking at the push rod of No. 1 and No. 4 pistons. Turn the flywheel unticlockwise and clockwise about 90° to 40° (see left figure). If the piston whose exhaust and inlet push rads do not move during the interval, it is at the top dead center of the compression stroke. If the piston whose push rods have moved, it is at the completion of the exhaust and begun of the intake stroke (overlapping stroke). TDC: Top Dead Cemer NOTE: Always loosen the lock nut and raise the adjusting sorews fully to the top. If the adjusting screws are too low, the piston and valves may strike each other during valve clearance adjustment. INJECTION TIMING INSPECT THE INJECTION TIMING. 1, Turn the crankshaft counter-clockwise viewed from the fly: ‘wheel side to align the injection timing marks on the flywheel at A® before top dead center for No. 1 cylinder on compres: jon stroke with pointer on the flywheel housing. Injection Timing (A°): Refer to section DATA AND SPECIFICA- TIONS, BTDC: Before Top Dead Center 2. Check that the injection timing mark on the automatic timer is aligned with timer cover pointer. If not, adjust the injection timing. NOTE: When odjusting the injection timing, refer to “FUEL INJECTION PUMP” in sectin ENGINE COMPONENT PARTS for details.sus.ats| THROTTLE GONTROL KNOB S $M3-817] ACCELERATOR PEDAL ‘5M3-1776| ACCELERATOR PEDAL’ FOR LEFT HAND ‘DRIVE "RE" ONLY ‘sms.1779] STOPPER BOLT ENGINE EN-Tu4c-3 INJECTION NOZZLE INSPECT AND ADJUST THE INJECTION PRESSURE. Refer to “INJECTION NOZZLE” in SECTION FUEL SYSTEM. ‘TEST THE SPRAY PROFILE. Refer to “INJECTION NOZZLE" in SECTION FUEL SYSTEM. ‘TEST THE FUEL LEAKAGE. Refer to “INJECTION NOZZLE” in SECTION FUEL SYSTEM. ENGINE CONTROL ADJUST THE ACCELERATOR, 1. Rotate the throttle control knob and set the dimension to “a” mm, Dimension A: Approx. 5 mm (0.20 in) for FB, FC, RB, AB Approx. 8 mm (0.31 in) for KM 2. Check that accelerator pedal height is “8 mm. If not, adjust the control cable adjusting nut. mension B: Right hand drive Right hand drive 131-136 mm (5. 16—5.35 in) for FB, FC, RB, ABTISKA 163—173 mam (6,42~6.81 in) for KM 136~141 mm (6:36~5.58 in) far AB2WGKA. Left hand drive 145—150 mm (5.71-5.90 in) for FB, FC 163-173 mm (6.42~-6.81 in) for KM 60-63 mm (2372.48 inl for RB 3. Adjust the accelerator stopper bolt or plate (for left hand drive RB) so that the distance between the pedal and pedal stopper is “G" mm when the control lever strikes the injection pump stopper. Dimension C: 2-5 mm (0.08-0.20 in) NOTE: Eliminate stack in the cable of the control lever of the injection pump. 4, Confirm the engine idling speed, Engine idting speed: 600-650 rpm.ENTUAC4 ENGINE STOPPER PLATE FOR LEFT HAND, DRIVE “Ra” ONLY sh3-(701 AQJUSTING NUT ENGINE ENGINE STOP RUNNING POSITION POSITION, POSITION / VACUUM GENERATOR vacuun. ACTUATOR ADJUST THE ENGINE STOP. (For madel equipped with manual engine stop system.) ‘Aajust the adjusting nut so that the clearance is to “D" mm. |—3 men (0.04—0.12 in) NOTE: After the adjustment, confirm correct axecution of engine ‘art and stop. Dimension INSPECT THE ENGINE STOP. {For model equipped vacuum type engine stop system.) 1. Disconnect the vacuum hose from the vacuum actuator, then cover open end of the vacuum hose to prevent entry of dirt. 2. Connect the vacuum generator 10 the vacuum actuator. 3. Start the engine and then confirm idling speed. Engine idling speed: Refer to section DATA AND SPECIFICA. TIONS. Do not set the starter key st OFF or ACC position while engine running. 4, Appty vacuum pressure and make sure that engine is stopped. Vacuum pressure: 570-600 mmHg (22.5~23.6 inHg) NoT!“SAMPLE THERMOSTAT STIRRING ROD, ‘THERMOMETER HeaTER sislare: Ty : Valve opening ternperature, 82°C Ty / Vaive opened temperature, 98°C som 93-1133) ENGINE EN-TUAC.5 THERMOSTAT INSPECT THE THERMOSTAT FUNCTION. 1, Place the thermostat in hot water and check the opening ‘temperature and the lift. 19 @ thermometer, check to see the thermostat opens at the specified temperature: BO-B4°C (176-183" F}. 3. Immerse the thermostat in hot water of a temperature of °C (202° F}, and measure the lift of the pellet after a period of 5 minutes using vernier calipers. Measure the position of ‘the bottom of the pellet before and after heating the thermostat. Life: At lwast 10 mm (0.4 in) [95°C (203°F)) 4, Immerse a heated thermostat in water of normal temperature If fz completely closes within 5 minutes itis satisfactory. If it remains even slightly open, it is defective and must be re pla COOLANT FILLER CAP INSPECT THE COOLANT FILLER CAP FUNCTION. Check the filler eap pressure using a cap tester 05 : 0.40.6 kg/em? (9.785 Ib/sq.in) 0.9; 0,75--1.05 kg/em? 110.714. Ibi sq.in) NOTE: © The cap pressure is shown on the coolant filler cap, and it should be confirmed. Of the cap pressure is incorrect, there is a risk of ab- normally high pressure being generated in the cooling system, which may cause the hose to drop off or burst ‘and, in turn, damage the engine. WARNING Do not remove the cap while the engine and cooling system are still hot. If the cap Is removed while the engine ani cooling system ace stil hot, scalding water and steam under pressure can be blown out. This can rewutt in personal injury.EN-TUAC- ENGINE ENGINE TUNE-UP ON TEST BENCH GENERATOR BATTERY + ‘sm3-907| east] cona| sa3-390,] NOTE: © If the engine is started with the power steering oil pump installed, the oil pump may bust or oil may spurt out, 30 ‘the following should be observed: 1. For bett-drive oil pumps, remove the V-belt. 2. For geardrive oil pumps, remove the oil pump from the engine rd install a cover to prevent oil leakage ‘rom the point of removal. © Starting the engine when the generator is not connected to the battery may damage the generator. Always ‘connect to the battery. SET THE ENGINE ASSEMBLY ON A TEST BENCH. 1 2. ‘Add the proper amount of the specified engine oil through the oil fillet cap on the cylinder head cover. ‘Add coolant. Bleed out air from inside the coolant gallery through the cylinder block drain plug. BLEED AIR FROM FUEL SYSTEM. Refer to section FUEL SYSTEM. CHECK THE INJECTION TIMING, Refer to “FUEL INJECTION PUMP" in section ENGINE COMPONENT PARTS DISMOUNTING AND MOUNTING. CHECK THE VALVE CLEARANCE. START THE ENGINE. NOTE: Before starting the engine, make sure that the fuol cut lever 1 b. (of the fuel injection pump is operating normally, CCheck the oil feed to rocker arms. Set the engine speed to 600-650 rpm. Within one minute after starting the engine, oll should flow to the head (Face A) ofall push rods and the head (Face 8) of al valves. If the time required for the oil t0 flow to the rocker arms is long, various troubles such as seizing, abnormal weer }‘CONTACT Face SM3-1782| INTAKE sm3.201| I Loose | aN TiGHT 313-457} ENGINE EN-TUAC7 2. Check the contact of the rocker arm and valve stem caps. After running the engine, a contact of approx. 8 mm (0.315 in) should be obtained at the cap contact face of the rocker arm. | the contact face is one sided, the valve will tlt, resulting in valve selzure, breakage, damage, or wear of the rocker arm stem cap. Rotighten the cylinder head bolts. After tightening cylinder head bolt to specified torque, run the engine for about 30 to 40 minutes at a water temperature ‘of about 80°C. Then loosen cylinder each head bolt 1/8—1/4 turn and retighten, in sequence, to specified torque. Special Tool: Socket wrench (09411-1260) NOTE: © Be sure to loown one bolt at a time, then retighton ‘bafore going on to the next boit. © By rotightoning, face pressure of cylinder heed is re- stored from point B to as shown. (© Retighten at the first 7,000 km (600 miles) following sarvicing which involves the loosening or removal of any ‘ylindor head bolt. Such servicing includes replacement Of the cylinder head gatket, servicing of the valve gear parts, and che fk. RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.ENGINE PIPES ENGINE PROCEDURE FOR INSTALLING JOINTS AND GASKETS OF 11. Gasket seal type (aluminum + rubber, asbestos or copper). 18-1 Toakiolot ounsiaea Tightening torgue chart Clamping srw size vow Shai Tightening torque ome qt eur (Biamete rem to Jot q GASKET dee 310318) 120-170 9-12) 70 10.394) 180230 (79-10) 72 (0.472) 230~280 (1720) | 14 (0.561) "230-280 (17-20), oan cONT 16 (0.630) 300-350 (22-28) aout sour 78 (0.708) ‘400-450 (20-32) 2010787) -400—a50 (20-32) GAsKeT ee 22 (0.866) 530600 (38—43) sont 24 (0.948), 720-800 (62-87) ag 29 (1.102) 71300-1500 (94-108) NUT easKer 2. Metal seal type (Flaras connector type). ‘Location of metal sal Tightening torque chart ‘Clamping serew size lenacker, noi Tightening toraue CONNECTOR FLARENUT mtn keer (te 72 (0.472) 200-220 (1516) 74 (0.557) 330~360 (24-26) 16 (0.630) ‘400—600 (20-36) 78 (0.708) (600-700 (43-511 200.787), ‘650-700 (47-51) BRACKET FLARE NUT RE LOCK WASHEREN-PRII 3. Metal seal type (Nipples connectors type) ee Tiahtening torque chart CASKET wr Clamping srow size ‘bameted) Tightening araue al J ‘mm (in) 7 | 10 (0.394) 100-150 (7-10) _ 20 (0.787) 200-250 (14-18) eonNecron rane GONNECTOR EonNEcTOR ONNECTOR NOTE: © Before installing the joints, ensure that there is no dirt or burrs adhering to the various sat faces (pipe joints, geskets, et.) © Because the pipes can move relatively free during installation and the sont faces are liable to tit, first temporarily ‘tighten the pipes, then tighten them to specification and ensure that there is no leekage from ther, © When tightening two pipes together, be very careful that they do not rotate togethar. (© After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage. ‘© Ensure thet the various tightening torques conform to the above table. (© If a soft washer #4840 FRLN (aluminum + rubber and carbon press fit part) is loosened or removed subsequent ‘to being installed, be sure and replace it with a new one. ‘Thora it no need to replace it, however, for normal retightening Ke)TURBOCHARGER TU TU21E-01 CHAPTER TU TURBOCHARGER DATA AND SPECIFICATIONS..........0ss0ceeceee seers Tu2 DESCRIPTION 10.0... csseceeeeeeceeeecese eee ee eee eeee Tu2 a TROUBLESHOOTING ... +. TUS OVERHAUL CRITERIA .... +. TUS SPECIAL TOOL ..... + TUS TURBOCHARGER 2.22.2... 0000-ceeeeeceeeeeeeeee tees TUSTURBOCHARGER DATA AND SPECIFICATIONS Tyee... Tact alet detealeale RHCE Turbine type . . + Radial flow type Blower type : Centrifugal type Lubricating method. « External lubrication type Bearing type . . . Full floating type Direction of rotation . + Counterclockwise as seen from the turbine side DESCRIPTION ‘sw81983, 1. Turbine case A: Oil inlet 2. Turbine rotor B: Oil outlet 3. Bearing case 4, Blower impeller 5, Blower caseTURBOCHARGER Tua ‘Symptom Dense black smoke TROUBLESHOOTING Possible cause Remedy/Prevention High volume exhaust: Exhaust ges leaking before turbocharger like noise. therefore insufficient revolution. Deformed or blocked exhaust gas li sees Rep ‘White smoke-———— © Air cleaner is choked with dust,.......,.... Disassemble and clean or replace causing greater intake air resistance. the air cleaner element. © Air inletis choked... © Air is leaking from intake menifold . . “Turbochaiger does not rotate smooth ‘© Engine oil impurities deposited on .......:.. Overhaul and clean turbocharger rotor, resulting in heavy rotation and/or change engine oil. + Repair. + Repair. © Insufficient lubrication or blockalga ........, Check lubricating oil system, of lubricating oil fines. and/or repair. © Abnormal wear or damage of seal... » Repai ring caused by wear of journal bearing, due to insufficient lubrication, ‘© Temperature of lubricating oil too high © Unbalanced rotating parts © Incomplers warmingup, failure... - to idle before stopping engine, or jack rabbit starts, ‘Loose or damaged turbine rotor or blower impeller, © Oversotation.... 2... (© Temperature of exhaust gas too high ‘© Foreign matter present .. Check cooling system. = Change rotating parts. = Operate vehicle properly. «Check and adjust the engine. s +++ Check and agjust the engine, ssesess Remove foreign material Inspect the air cleaner and air imake manifold. Repair if necessary. 7 + Overhaul and repair. Le incomplete assembly... 2.6.6. se0e0+2++ Reassemply, © Worn thrust beari + Check and repair connections, therefore insufticient revolution. —Choking defects, or deformation of ........ ... .epair and replace the lines. cil return lines so that oil leaks around blower or turbine sides. L_— Seal ring may be broken or worn due... ‘to abnormal wear of thrust washer. + Replace the thrust washer.Tus TURBOCHARGER Symptom Possible cause Remedy/Pravention Loss of power. Gas leakage from exhaust system ............4 Repair. cesee sees Repair Clean or replace. [— Air leakage from air manifold . }-— Clogged air cleaner element. . L_Turbocharger dirty or damaged + Repair or replace. Poor response of: ‘Carbon accumulation on the turbine .....,.... Change engine oil, clean turbocharger side seal ring and heavy rotation. ‘turbocharger. L-Poor combustion . . cesses Check fuel system and improve ‘combustion. igh pitched noise [ow] and vibration © So called “surging” . . . . . Surging somtimes cco when the aes pasage athe nozze ofthe erbise housing is choked er when compressed Overhaul and clean turbocharger. air does not flow in proper responses to acceleration. © Loosen rotating parts + Replace. br © Joints loose between turbocharger .........- Check the mounting and repair. and intake, exhaust manifold or oil tines. Le» Damaged bearing, loose rotating parts, ....... Repair. imbalanced rotating parts, etc.TURBOCHARGER Tus Prior to starting an turbocharger overhaul, ATTACHMENT FOR MEASURING ‘TURBINE SHAFT RADIAL PLAY. o 09944-1330 OVERHAUL CRITERIA GONDITIONS WHICH DETERMINE WHEN TURBOCHARGER OVERHAUL MAY BE NEEDED. THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS BLACK SMOKE. OTHER FACTORS 1 2 3. 4, Noisy of excessive vibration of the turbocharger. Excessive engine oil consumption. Gas leakage at the turbine end or blower end. Oil leakage from the turbocharger. SPECIAL TOOL ‘necessary to have these special tools.TUS TURBOCHARGER TURBOCHARGER 2 3. 175-85 (55-6.1) . Seal ring . Seal plate 4. Blower impeller 5. Lock nut 6. Lock plate T = Tightening torque: kg-cm (Ib.ft) 7. Blower case 13, Journal bearing 8. Turbine case 14, Retainer ring 4. Lock plate 15. Thrust spacer 10. Turbine shaft 16. Thrust bearing 11, Heat protector 17. Elbow 12, Bearing case 18. Actuator — hoa Sus1.002A) 551-002 IMPORTANT POINT (S) - BEFORE DISASSEMBLY 1. Rotate the blower impeller by hand to see if it turns smoothly, If it does not turn smoothly, clean and inspect the bearing and turbine rotor. (2. Check the turbine rotor for axial play iA}. Mf the axial play is greater than the service limit, replace the thrust bearing and/or thrust spacer. Axial Pt 0.05 — 0.08 mm (0,002 — 0.0031 in) Service Limit: 0.11 mm (0.0043 in}TURBOCHARGER Tu-7 ‘SM51-0028, MATCHING MARK SMB 1.017, sm51.089) 3. Cheek the turbine rotor for radial play using a special tool. If the radial piay is greater than the service limit, replace the bearings and/or turbine rotor. Special Tool: 09444-1330 0.10 — 0,16mm (0,039 — 0.0059 in) 0.19 mm (0.0074 in) IMPORTANT POINT (S) - DISASSEMBLY REMOVE THE BLOWER CASING. NOTE: © Make matching marks on the blower cate and bearing ‘case to aid alignment during reassembly. © If the blower easing cannot easily be removed by hand, it carefully all around using ® plastic hammer and carefully remove it. © Be careful not to damage the blower impeller, REMOVE THE TURBINE CASING, NOTE: © Make matching merks on the turbine case and bearing ‘case to aid alignment during reassembly. (© Because the bolts on the turbine side ara expoted to high temperature, if they hive seized, do no apply an unreasonable force to remove them because they may ‘break, Spray a lubricant onto them, then wait for about 15 minutes and loosen them. © Be careful not to damage the turbine blades. © If the turbine casing cannot eauily be removed by hand, tap it carefully all round using a*plastic hammer 2d carefully remove it. REMOVE THE BLOWER IMPELLER. 1. Remove the blower impeller fitting nut. NOTE: Tum the lock nut clockwise to loosen the nut (lefthand threadst, 2. Remove the blower impeller by hand. REMOVE THE TURBINE ROTOR WITH HEATER PROTECTOR.Tua TURBOCHARGER REMOVE THE BEARING 1. Remove the seal plate. Pull out the seal plate using the two screws, 2. Remove the oil thrower from the seai plate, ‘S§51.061 3. Remove the thrust bearing and thrust spacer. Loosen the bolt, then remove the thrust bushing using 2 10 die. copper rod. NOTE: When removing the thrust bearing and thrust spacer, be careful not to damage the thrust bearing hoie in the bearing case, m51.022| sMa7083] 4. Remove the retainer rings of each bearing. NOTE: When removing the retainer ring, be careful not to damage the front face of the hole in the bearing cate, 5, Remove the bearings. REMOVE THE SEAL RINGS. NOTE: When removing the seal ring, be very careful not to damage the groove of the seal ring. M5104) 5Ms1.025} IMPORTANT POINT (S) — ASSEMBLY CLEAN ALL PARTS, 1. Before cleaning, the disassembled parts should be visually inspected to check for burning, abrasion, carbon deposits, gas and oil leakage. 2. Thoroughly clean all the parts with diesal fuel, using a soft brush, and dry with compressed air, © Never usa a caustic cleaning solution, as it may attack alumioum. © Never use a wire brush,Tua OIL INLET 3 Se TURBINE t ROTOR owourier on inter. 8 TURBINE. BLOWER OL | OW IMPELLER AX vier sno ROTOR 351-026, sMs1.0270| ‘Susi.078| 5M51.024 ED \ OIL INLET SMS1-0058 5Mg1030 ASSEMBLE THE JOURNAL BEARINGS. 1. Install the first retainer ring in the bearing casing. NOTE: © Bevelled edge of the retainer ring should be towards the bearing, © Make sure that the retainer ring is securely fitted in the groove. © Install the retainer ring with the gap facing as shawn in the drawing. 2, Install the bearing in the bearing case. NOTE: Apply clean engine oil. 3. Install the other retainer ring. NOTE: The only nearest turbine side of the retainer ring should be installed according to the figure on the left. 4, Repeat step 1) through 4) to install the second bearing. ASSEMBLE THE THRUST BEARING. 1. Install the thrust spacer on the turbine shaft. NOTE: Lubricate thrust spacer surface. 2. Coat the thrust bearing with clean engine oil and install the thrust bearing, NOTE: Always use new screws and lock washers, INSTALL THE SEAL PLATE, 1, Insert two new seat rings on the oil thrower. 2. Install the oil thrower in the seai plate, NOTE: The openings of seal rings should be positioned ax shown. 3. Install the seal plate in the bearing case. NOTE: © The cil return hola should face the oil outiet side. Apply silicone R.T.V. sealer to the flanged surface of the seal plate, (© Take cara that the silicone sealer dost not protrude from {the flange. 4, Tighten the four screws with lock washers. NOTE: Always use new screws and washers, oyTu.10 SEAL RING 5 Tur INE SHAFT, ot \\_uear protector BEARING CASE SM51-065 ower SEAL RING GAP ‘s€1.066| 5M51-032| TURBOCHARGER ASSEMBLE THE TURBINE ROTOR. 1, instalt_ a: new seal ring in the seal ring groove of the turbine shaft. 2. Position the heat protector an the bearing case. 3. Cost the journals of the turbine rotor with clean engine oii and install the turbine rotor in the bearing case. NOTE: © The gap in the seat ring of the turbine shaft must face towards the oil inlet. © Insert the seat ring cancentrie with the turbine shaft. If it inserted with unreasonable force, it may be damaged. © When inserting the turbine shaft, be vary careful not to damage the journal bewring. FIT THE SLOWER IMPELLER ON THE TURBINE ROTOR AND TIGHTEN THE LOCK NUT, NOTE: Remember that this nuthas left-hand threads. INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING SURE TO ALIGN THE MATCHING MARKS. NOTE: Always use new Jock platss. ASSEMBLE THE BLOWER CASE. 1. Install the blower case to the bearing case referring to the ‘matching marks. NOTE: Coat the flange face of the blower cave with silicone R.T.V. sealant, 2. Tighten the six fitting bolts. ASSEMBLY TEST 1. Rotate the biower impeller by hand to see if it turns smoothly. Refer to page TUS. 2. Check the turbine rotor for axial play (A). Refer to page TUG. 3. Check the turbine rotor for radial play using @ special tool. Refer to page TU-7.TURBOCHARGER Tutt INSPECTION AND REPAIR Unit: ne fi) Inspection Item Standard Remedy Inspection Procedure ‘Turbine Shaft Diameter 7 10.38 | Replace 0.4090) ‘Turbine Shaft Bend 0.011 | Replace 40.0004) Groove Width cE 1.34 | Replace shaft of Turbine Shaft (0.05271 | assembly. y 51-095 Bearing Case Inside — A Replace ff Diameter 13.08 7 f (05153) fe “ 18.10 (05944) 51.006 Journal Bearing imide a 10.45 | Replace Diameter (0.4114) Journaf Bearing Outside a 1488 | Replace Diameter (0.5807) ‘Thrust Spacer Height 7 4.03 | Replace (0.1610) ‘Saal Ring Groove Width Za et: Replace of Oil Thrower 1.52 (0.0598) G2: 5 1.32 J (0.0519) L ee seulTu12 TURBOCHARGER INSPECTION AND REPAIR nit: men tin Inspection Item Standard Limit Remedy, Inspection Procedure Thrust Bearing Thickness 7 3.06 | Replace (0.1566) Sealing Bore of Seal Plate 7 Replace 'SM51-0058 (ky)FUEL INJECTION PUMP Pt 1P-128E.01 CHAPTER IP FUEL INJECTION PUMP DESCRIPTION -........ 2. .eeeeceeeee cess tenant er tees Pp 2 TROUBLESHOOTING SPECIAL TOOLS ... INJECTION PUMP .. FEED PUMP ....FUEL INJECTION PUMP DESCRIPTION swaoes FUEL INJECTION PUMP 1. High pressure pipe 5. Control rod 9. Cam shaft 2. Delivery valve 6. Control sleeve 10. Cam 3. Plunger barrel 7. Plunger spring 11. Fuel feed pump 4, Plunger 8. TapperFUEL INJECTION PUMP WP ‘Symptom Engine does not start TROUBLESHOOTING Porsible couse fion puro Fuel lines clogged or damaged . . Fuel filter clogged Air in fuel caused by improper connections of fuel line between fuel tank and feed pump ter incorporated in inlet side of feed pump clogged Faulty feed pump check valve .. . . Feed pump piston spring broken Feed pump push rod or tappet sticking Fuel reaching injection pump Faulty connection of accelerator . . . wire to pump adjusting lever. Control rack faulty or sticking... , Damaged camshaft bearing .....-. Plunger worn or sticking. . Favity connection of engine... . stop wire to pump stop lever. Nozzle faulty Fuel leakage caused by loosened... nozele holder, Low opening pressure of nozzle... . . Nozzle pressure spring broken... . Nozzle needle sti ing to nozzle body Pump out of timing Improperly retarded injection timing . Incorrect timing caused by improper . Installation of gump. Woodruff key for pump camshaft cut off, Improper pre-stroke adjustment. Remedy /Prevantion Clean or replace fue! fines. ‘Clean or replace the filter element. Repair connections, material. Repair or replace it, Replace it. Repair or replace it. Repair connection, Repair it. Repair it. Correct or replace it. Repair it. Inspect and tighten it Adjust it. Replace it. Correct or replace it, Correct injection timing. Check engine timing and correct, it. Replace i Correct it to obtain specified injection timing.1 FUEL INJECTION PUMP ee ‘Symptom Porsible-cause Ramedy/Pravention Excessive smoke Binet smoke © Excassive fuel delivery caused by . Adjust fuel delivery on test incorrect adjustment of fuelload "stand. stopper screw. © Excessively advanced injection ........... Correctit. ‘tming. © Large spread in fuel delivery .. 2 Adjust it ‘© Bad nozzle fuel spray characteristics ........ Check and correct them. White smoke © Improperiy retarded injection Advance injection timing, timing. © Water in fuel... . an cee heck and clean fuel lines. Low idle speed Improper adjustment of idle button ,....... Correct i irregular 7 }— Bad fuel spray characteristic of 7 Check and repair them, nozzles, [— Incorrect injection timing . 7 Correct it. |— incorrect initial tension serting of Adjust or replace is idling spring or the spring broken, [— Control rack not smoothly move .....,.... Disassemble pump and repair it. }— Large spread in fuel delivery... Adjust it. }— Plunger worn Replace it. |— Governor linkage not smoothly Correct it. move. ‘— Defective feed pump 66.0... Dissssemble and repair it. Engine always runs -— Accelerator cabie sticking... (Check and correct it. at hig speed [— Governor linkage sticking .............., Disassemble and repair the governor. | controt rack sticking ce csevess Cheek and correct it Engine starts and stops ee Clean or replace fue! fines. J— Fuel lines clogged . | pir in fuel caused by damaged fue! tines or improper connection of fuel lines. +++ Repair fusl lines or replace fuel ines and gaskets.FUEL INJECTION PUMP Ps Engine has low power ‘Pump out of timing Loud knocking © Excessive advanced timing, resulting in loud knocking © Excessively retarded timing resulting in black smoke. © Defective injection pump overflow valve. (© Feed pressure too low... © Inproper accelerator cable adjustment... . | {Nozzle faulty © Fuel leakage from nozzle holder © Bad nozzle spray characteristic © Loosened adjusting screw in nozzle... holder, resulting in low opening pressure, ‘© Nozzle pressure spring broken . Pump fauity ‘© Fuol leakage from delivery valve... holder. © Defective seat of de! assembly, ry veive © Delivery valve spring broken © Plunger worn . © Large spread in fuel deiivery © Wear of tappet roller . . © Carmshaft bearing worn or broken... © Improper adjustment of governor... ..« fuel load stopper screw, 7—— Imprlper injection timing |— Bed fuel nozzle spray pattern... - after-dribble. [— High nozzle opening pressure . . — Incorrect fuel deliveries to. 6... some nozzles, Remedy Prevention ‘Check and correct it. (Check and correct it. Repair or repiace Repair the feed pump. Adjust it. ‘Check and repair nozzle holder. Repair or replace it. Adjust it Replace it. Retighten the delivery valve holder if it is loosened or replace O-ring if she O-ring is defective. Repair or replace it. Replace the spring. Replace Adjust it Replace the rotter. Replace it Adjust it. Correct i Check and correct it Adjust the opening pressure, Readjust the fuel deliveriMe Ps FUEL INJECTION PUMP Prior to starting an injection pump overhaul, it is necessary ta have thete special tools. SPECIAL TOOLS COUPLING HOLDING WRENCH ‘TAPPET HOLDER 4 L (09877-2000 (09511-1520 99611-1770 CAMSHAFT END PLAY GAUGE GAUGE ADAPTER ‘TAPPET ROLLER CLAMP a BEARING REMOVER BEARING OUTER RACE PLUNGER (09511-1970 (09511-1610 (Use with 09533-1970) 00511-1750 DELIVERY VALVE HOLDER TAPPET CLAMP PLUNGER CLAMP REMOVER L L (09511-1190 09511-1730 09571-1340 ‘SPRING HOLDER oe CS (09500-1290 (09511-1680 09517-1960FUEL INJECTION PUMP Py ‘TIMER EXTRACTOR a (09811-1990FUEL INJECTION PUMP INJECTION PUMP A-TYPE PUMP 1. Injection pump housing 17. Bearing 2. Valve holder lock plate 18. Garket 3. Delivery valve holder 19, Bearing cover 4. O-ring 20. O-ring 5. Delivery valve stopper 21. Over flow valve 6. Delivery vaive spring 22, Soft washer 7. Gasket 23. Adapter 8. Delivery valve 24, Side cover 9. Injection pump element 25. O-ring 10. Bolt 26. Plunger control pinion 11, Screw plug 27. Plunger control sleeve 32. Control rack 28, Plunger spring upper seat 13. Key 29. Plunger spris 14. Camshaft 30. Plunger spring lower seat 15. Camshaft shim plate and O-ring 31. Shim 16. Shim 32. Tappet sub-assemblyFUEL INJECTION PUMP sa.a78) IMPORTANT POINT (S) — DISASSEMBLY WARNING © Breaking of the lead seals or crimp caps by anyone other ‘than HINO or pump manufacture authorized service stations to make these adjustment will void the warranty. © Mf fuel pump or governor difficulties are suspected, consult ‘only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injection pump lead seals and crimp caps can be reinstalled as required, ‘Measure and record the fuel delivery characteristics of the ‘pump before disassembling it. Keep the parts for each cylinder in separate groups and in ‘an orderly arrangoment. Parts to be replaced and parts to be used again must be kept separately. REMOVE THE TIMER ASSEMBLY. Refer to “TIMER AND COUPLING” REMOVE THE GOVERNOR. Refer to “GOVERNOR”. INSERT THE TAPPET INSERTER IN THE TAPPET HOLE. Turn the camshaft ‘tappet hole when their tappet is at the highest position, ‘Special Tool: Tappet inserter (09511-1770) INSPECT THE END PLAY ON CAMSHAFT. Using a special tool inspect the clearance in the axial direction ‘on a camshaft installation. ‘Assembly Standard: 0,020.06 mm (0.0008-0.002 in) ‘Special Tool: Camshaft End Play Gauge (09511-1970) ‘Gauge Adapter (09511-1610) Pg Ind insert the tappet inserters in eachFUEL INJECTION PUMP REARING coveR ma-140 ‘TAPPET CLAMP. M4206 PLUNGER CLAMP ‘smaz07 BEARING REMOVER If the specification is not met, use appropriate shim plates at the drive end of camshaft until the specification is met. REMOVE THE TAPPET ASSEMBLY. 1, Push the tappet with the tappet roller clamp and remove the tappeter holder. Special Tool: Tappet Roller Clamp (09511-1750) NOTE: To prevent droppingof the plunger and the plunger spring, adjust the pump installation base so that the upper surface of the pump is slightly below the horizontal. 2. Remove the tappet through the camshaft bearing hole. Special Tool: Tappet Clamp (09511-1190) REMOVE THE PLUNGERS, SPRINGS AND CONTROL SLEEVE. 1. Use the plunger clamp hold the lower spring seat and remove it together with the plunger. Special Tool: Plunger Clamp (09511-1730) NOTE: © The plungers may not be damaged. (© Arrange the removed plungers in the order of the cylin- dors in the disassembly box to prevent confusion, © Bring the plunger insertion notch of the lower spring sext to the top, and remove so that the plunger will not drop. REMOVE THE TAPER BEARING FROM THE CAMSHAFT. 1. Remove the taper bearing from the drive end of the camshaft. Special Tool: Bearing Remover (09500-1290)FUEL INJECTION PUMP P41 2. Use the guide to remove the bearing at the governor side. Speciat Tool: Bearing Remover (09500-1290) 3, Use the outer race puller, to tap out the outer race in the bearing cover. ‘Special Tool: Outer Race Puller (09511-1680) outer RACE ye Putten BEARING COVER SS o, 94-126) IMPORTANT POINT (S) — ASSEMBLY WARNING (O Wash all parts with clean diel fuel before installing them, and any defective or damaged parts must be replaced. © Do not allow dust or other forsign matter to enter the pump during assembly. © Apply grease to O-rings and oil seals before installing them. (© Assemble the perts in correct order and to correct tightening torques, assembled dimentions ete. © Assembly takes place in the reverse order of disassembly. 1. Before install the plunger barreis should be inspect the plunger Peel INSTALL THE PLUNGER BARRELS, barrels and plungers for wear, scratches, or discoloration, M4213 2. Tilt the plunger to about 60°. Pull the plunger out approximately 10 to 15 mm (0,39—0.59 in) and release it to see if it slides down smoothly from its own weight. If the plunger slides into the barrel too or does not slides smoothly, replace the plunger assembly. ‘sMa.o67waz FUEL INJECTION PUMP sma258 3. Match the plunger notch with the injection pump housing knock pin. INSTALL THE DELIVERY VALVES, SPRINGS AND HOLDERS. 1. Before install the delivery valves, inspect the delivery valves for scratches on the valve seat or the piston sections, 2. Install the gasket, spring, shim and stopper on the delivery valve. 3. Provisionally tighten the delivery valve holder with a new O-ring by hand. NOTE: Tighten the delivery valve holder after insta a the plung- INSTALL THE CONTROL SLEEVES ON THE BARRELS. NOTE: © Install with the control sleeve part to the front so that the mark tines on both ends of the control rack are ‘equidistant from the body. © Make sure that the control sleeve swings eventy right and loft when the control rack is moved to the right and left. INSTALL THE PLUNGER AND TAPPET. 1. Assembly the plunger and spring lower seat, inserting the driving fece marked with a umber and the lower seat notch art upward (cover plate side). Special Tool: Plunger Clamp (09511-1730)FUEL INJECTION PUMP (P43 sMa.207, DRIVING FACE sMaaaa 2, Install the tappet to the pump housing with the adjusting shim, ‘Special Tool: Tappet Roller Clamp (09511-1760) ‘Tappet Clamp (09511-1190) 3, Using the tappet roller clamp to press in the tappet and hold ith the tappet holder. ‘Tappet Holder (09511-1770) NOTE: © Check that the driving face of the plunger fits to the groove of the control sleeve befora inserting the tappet. © When inserting the tappet, check thet the control rack «slides smoothly and without catching, TIGHTEN THE DELIVERY VALVE HOLDER. When one detivery valve holder is tightened, move the control rack to the right and left and inspect the tightness of the rack. Tightening Torque: 400-450 kg-cm (29-32 tb.ft) INSTALL THE CAMSHAFT WITH CENTER BEARING, Place a smal! mount of oil or grease on the center bearing to hold it to camshaft and the install the camshaft in the pump housing NOTE: A-TYPE 4-cylinder pump ix without center bearing,FUEL INJECTION PUM a OvERFLOW PE MIGH PRESSURE MEASURE THE SLIDING RESISTANCE OF THE CONTROL RACK, ‘Assombly Standard: Less Than 750 g (5.29 oz) NOTE: Make sure that the control rack slider smoothly and withour catching. ADJUSTMENT PREPARATION 1, Mount the injection pumnp correctly on the pump tester, 2. Attach e rack measuring device to the control rack and set to “or. 3. Install calibration nozzles and tines, Nozzles and Lines: Refer to the chart “CALIBRATION.” 4, Install the cover on the Yeed pump mounting surface and fill the pump camshaft chamber with engine oil. ADJUSTING THE INJECTION TIMING 1. Preparation of the pre-stroke, 12) Remove the plate cover. b) Install a pre-strake measuring instrument. Bring the tappet of the first cylinder to its bottom dead ‘center, and set the pointer tip on the tappet. 2. Measure the pre-stroke (No.1 plunger) a) Set the control rack at full-load position. b) Loosen the overflow screw of each nozzle holder, ©) Operate the high-pressure pump of the pump tester andlet fuel run out of the overflow line.FUEL INJECTION PUMP 1P-15 4) Move the angle dial to set the first cylinder of the pump to ‘bottom dead center and adjust the pre-stroke gauge to zero. NOTE: Bottom dead center is the point at which the pointer of the dial gauge does not move even when the angle dial it ‘rotated while fuel is flowing from the overflow line, 2) Turn the camshaft clockwise with the angie dial and read the dial gauge when the fuel stops running out of the overflow fine, This reading is the pre-stroke value of the pump. Refer to the Chart “CALIBRATION”. FUEL yg} —-— PLUNGER PRE-STROKE BARREL eMa-408 f) if the pre-stroke value is not within specification, adjust by ‘changing the tappet adjusting shim, ‘Special Tool: Spring Holder (09511-1960) ADJUST THE INJECTION INTERVAL. 1. Using the No.1 cylinder injection starting point as a base, inspect and adjust the interval in the order of injection. Injection Interval 99°45'—20°15" Injection Order: 1-342 2. If the injection intervals are not within specification, adjust by using the same pracedure as for pre-stroke adjustment,PAB FUEL INJECTION PUMP 3 See the No.t cylinder at the injection starting point, and check ‘that the marks on the timer and the marks on the pump body are aligned, If the timing marks are not aligned, make 2 new mark on che timer and erase the old mark, INTER TIMING Manik M4334} CHECK THE TAPPET TOP CLEARANCE, 1, Set the No.1 cylinder at the injection starting point, then move the tappet with the handle. ‘Tappet Top Clearance: More than 0.2 mm (0,0079 in) 2, Follow the above procedure to check the other cylinders (No.2 through No.6). 3. If the tappet clearance Is less than 0.2 mm (0.0079 in), re TAPRET HANDLE csuy. rep check the pre-stroke.. MEASURING AND ADJUSTING THE INJECTION VOLUME. Measure the injection volume for each control rack position and pump revolution, Injeciton Volume: Refer to the chart “CALIBRATION”. vouume varnaTiGh To adjust the injection vaiume, loosen the pinion screw and Insert the adjusting pin into the hole in the control sleeve, then move the sleeve slightly,FUEL INJECTION PUMP INSPECTION AND REPAIR Inspection tom Standard Remady Inspection Procudure [controt Rack. = — | Repiece, Bert, Wear if rmcesery. Gear Teet. Weer Prossfited bus. = = | Repiece, Wear ‘if necessary. NY smear Conti Score = = | Replace, Visual cheek Weer, Darnge it receary. . auasos Tappet Roller, Bushing 7 = | Repiace, Visual eheck maPin. it racenary. Wear, Damage @® sao Lower Spring Saat. - - Replace, ‘Visual check Wear, Damage if necestary. veo ‘Camshaft. - = Replace, Visual check Wear, Damage if necessary. Camshaft Bearing, = - Replace, ‘Bearing Race and Center ‘if necessary. Bearing. Wear, DamageP18 FUEL INJECTION PUMP FEED PUMP FP/KS-TYPE 814, T= 130-180 (9-10) = 400-450 (28-32) 4 : ‘Comet packing, Copper gasket T=. 800-200 (58-65) 16 2 8 wo ( T= 50-80 13.6-6.7) T= Tightening torque: kgem (ibe) 1. Feed purmp serial No. 12. Tappet 2. Joint bolt 13. Pin 3. Soft wosher 14. Sliding blook 4. Connector 15. Feed pump housing, push rod, & oil seat 5. O-ring 16. Piston 8. Chock valve spring 17. Spring 7. Check valve 18. Gasket 19. Plug 20. Soft washer 10. Tappet assembly 21. Filter 11. RollerFUEL INJECTION PUMI INSPECTION AND REPAIR iP-19 Inspection tram Standerd Limit Remedy Inspection Procedure Valve Seat. - - | Replace, Visual check Wear, Damage If nocestary, L 4 F sm1a.517| Piston, Cylindr and Oil Seal. ~ = | Replace, Vinual cheek Wear, Damage if necessary. [fe Sieore Filter, = = | Green Visual check. Clogged suasie| 1B,P20 SCDM-TYPE TIMER 1, Timer hub 2. Timer weight 3. Timer weight rod 4. Timer spring seat 5, Timer spring 6. Timer spring 7, Shim 8. Shim 8. Timer spring sect 10. Retainer ring FUEL INJECTION PUMP TIMER 1". 12 13, 4. 15. 16. 7. 18 19. Special washer Bolt Timer cam Timer cam Timer drive flange Shim. Retainer ring Shim Timer coverFUEL INJECTION PUMP 1P-24 DISASSEMBLY = REMOVE THE TIMER FROM THE INJECTION PUMP. 1. Install the setting tool. | C| rv ‘Special Tool: Timer Setting Too! (09612-2100) 5M3.250 | 3, Remove the timer from the injection pump, using the timer extractor, Special Tool: Timer Extractor (09611-1980) 4, Remove the injection pump drive gear. smasio| REMOVE THE DRIVE FLANGE. 1, Remove the retainer ring, 2. Remove the shims, 3. Remove the drive flange. REMOVE THE TIMER CAMS, NOTE: Before removing the timer cams, the positions of the large and small cams (cam hole positions) should be re- corded in order to facilitate installation of the drive flange when reassembling. REMOVE THE TIMER COVER. 1. Remove the retainer ring, 2, Remove the shim, 3. Apply a brass rod to the timer cover and tap lightly by hand ‘to remove.1.22 FUEL INJECTION PUMP DISASSEMBLY THE FLYWEIGHT ASSEMBLY. Push the timer spring to compress it, then remove the retainer ring, syte.470] IMPORTANT POINT (S) - ASSEMBLY a ‘ASSEMBLY THE FLYWEIGHT ASSEMBLY. INSTALL THE DRIVE FLANGE. DRIVE FLANGE an 1. Install the drive flange on the timer hub. 2, Install the shim. 3, Install the retainer ring. TIMER HUB RETAINER RING AUB sos 4, Inspect the end play of the drive flange. Push the drive flange all the way towards the timer hub side, ‘then measure the gap between the drive flange and the shim, Assembly Standard: 0,02—0.1 mm (0.0008—-0.0039 in) if the end play is not within the standard value, use the following shims for adjustment. ‘Shim Thickness: 0,10 mm (0.0039 in} 0,90 mm (0.0350 in) 0.12 mm (0.0047 in) 1.10 mm {0.0433 in) 0.14 mm (0.0055 in) 1.30 mm (0.0512 in) 0.16 mm (0.0062 1.50 mm (0,0590in) 0.18 mm (0.0070 in) 1.70 mm (0.0669 in)FUEL INJECTION PUMP M4496 e— +h 6 ona & S : ©) ee Bence _ TIMER COVER DRIVE FLANGE PIN M4496 RETAINER RING ‘SHIM sM4493 INSTALL THE CAMS. Install the large and small cams on the timer hub as shown in the figure (as seen from the side of the timer cover). INSTALL THE FLYWEIGHT ASSEMBLY. Measure the distance (L) between the flyweight pin centers 1 2 3, after the flywelght spring has been installed. Turn the large cam so that the same dimension is obtained fon the left and the right for the distance (L/2) between the large cam hole center and the timer hub rotation centers. Install the flyweight assembiy. To confirm correct installation of the flyweight, check that the right shoulder part of the flyweight is lowered when the ‘two pins of the driving hub are in the vertical axis position, as shown in the figure (as seen from the side of the timer cover) INSTALL THE TIMER COVER. 1 Install the timer cover, shim, and retainer ring. 1P-23 xM4473 FUEL INJECTION PUMP 2. Inspect the end play of the timer cover. Push the timer cover by hand all the way to the timer hub side, then measure the distance between the timer cover and the shim, ‘Assembly Standard: 0,050.2 mm (0.002~-0.00 If the end play is not within the standard value, use the following shims for adjustment, ‘Shim Thicknesses: 0.10 mm (0.0039 in) 0.90 mm (0.0350 in) 0.12 mm (0.0047 in) 1.10 mm (0.0433 in) (0.14 mm (0.0056 in) 1.30 mm (0.0512 in) 0.16 mm (0.0062 in) 1.50 mm (0.0590in) (0.18 mm (0.0070 in) 1.70 mm (0.0669 in} INSTALL THE TIMER ASSEMBLY ON THE INJECTION PUMP. 1, Install the injection pump drive gear, 2. Mount the timer assembly on the injection pump, Tightening Torque: 850--1,000 kg-em (62-72 Ib.ft) ADJUSTMENT OF THE TIMER INSPECT THE TIMER ADVANCE. 1, Seta stroboscope on a pump tester. 2. Check the timer advance. ‘Advance Angle: Reter to the chart “CALIBRATION”. {f the angle in not within specification, adjust with proper shir, Outer Thicknesses: 0.10 mm (0.0039 in) 0.5 mm (0.0196 in) 0.30 mm (0.0118 in) 1.0. mm (0.0393 in) Inner Shim Thicknosses: 0.5 mm (0.0196 in) 1.0. mm (0.0393 in) wrGOVERNOR eva CHAPTER GV INJECTION PUMP GOVERNOR (MODEL: RLD and RLD with BOOST COMPENSATOR) DESCRIPTION SPECIAL TOOL GOVERNOR 22-0... ccc ee cece cee ee cee ee nent een ee tees avsGOVERNOR DESCRIPTION smas70 Representative model RLD 1. Speed control lever 9, Tension lever 17. Rod and spring 2. Supporting lever 10. Idling spring sub-assombly 18, Torque cam ‘3. Maximum-speed setting bolt, 11. Adjusting screw 19. Governor spring 4. Idling-speed setting bolt 32. Shifter 20. Rack connecting link 5, Floating lever 13. Cancel spring 21. Cancel spring 6. Guide lever 14, Tension lever shaft 22. Control lever sheft 7, Guide screw 15, Sleeve sub-assembly 23. Control rack 8. Governor shaft 16. Flyweight assemblyGOVERNOR v3 SPECIAL TOOL Prior to starting an injection pump overhaul, it is necessary to have these special tools, GOVERNOR ROUND NUT COUPLING HOLDING WRENCH WRENCH o 09511-2000 (09511-1520 (09511-1500 FLYWEIGHT EXTRACTOR PLUG PRESS ‘SPECIAL WRENCH SPECIAL WRENCH te (09511-1980Mg ova (Model RLD) GOVERNOR 1. Engine stop lever 2. Spring seat 3. Return spring 4. Shim 5. Oxing 6. Bushing 7. Collar 8. Supporting lever 9. Gasket 10. Adapter 11. Guide plug 12. Full4oad setting bolt 13. Lock nut 14. Woodruff key 18. Governor housing 16. Full4oad setting ki 17, Fulldoad setting lever shaft 1B. Cancel spring 10. U-shape lover 20. Snap ring 21. Sentor lever 22. 23, Spring washer 24. Round nut 26. Start spring eye 26. Start spring 27, Rack connecti 28. Plate 28. Governor shaft 30. Spring seat 31. Governor spring, inner 32, Governor spring, outer 33, Sleeve sub-assembly 34, Shifter 35. Floating tever tub-assambly 36. Speed control lever shaft 37. Supporting lever 38. Floating lever 39. Guide lever 40. Tension lever 41. Pin 42, Tension lever shaft 45. Adjusting nut 46, Inner spring 54, Maximurm-speed setting bolt 55. Idling-speed setting bolt 56. Gasket 57, Plug 58. Cap nut 59. Idina spring sub-assembly 60. Governor cover 61. Control rack coverGOVERNOR {Model RLD with BOOST COMPENSATOR) avs 15230 1 2 3 4 5 6 7 8 1. Engine stop lever 2. Spring seat 3. Return spring 4, Shien 5, O-+ing 6. Bushing 7, Colter ‘8. Supporting lever 9. Gasket 10. Adapter 14. Guide plug 12. Full-load setting bolt 18, Lock nut 14, Woodruff key 18. Governor housing 1G. Fulh-oad setting lover 17. Full-load setting lever shaft 18. Cancel spring 19. Usshape lever 20, Snap ring 21. Sensor tover 22. Flyweight assambly 23. Spring washer 24, Round nut Stare spring eye ‘Start spring Rack connecting link Plate: Governor shaft Spring seat Governor spring, inner Governor spring, outer Sleeve sub-assembly Shifter Floating lever sub-assembly ‘Speed control lever shaft |, Supporting lever . Floating lover Guide fever 40. Tension lever Pin ‘Tonsion lever shaft Plug Lock sorew 45, Adjusting nut 48. Inner spring 47, Outer sping 48. Rod BRSSESSRR S8S8R8 BBRE 49. Torque cam 50. Bracket ‘51, Tube 52, Speed contro! lever 53. Oil seal 54, Maximum-speed setting bolt 55. Idling-speed setting bott ‘56. Gasket 57. Plug 58. Cap nut 59, Idling spring sub-assembly 80. Governor cover 61, Control rack cover 62. Boost compensator assembly 63. Spring 64, Push rod 65. Set screw 66. Boost compensator housing 67. Spacer 68. Diaphragm 89. Screw plug 70. Boost compensator coverove GOVERNOR IMPORTANT POINT (S) — DISASSEMBLY WARNING © Breaking of the lead seals or crimp caps by any other than HINO or pump manufacture authorized service stations to make these adjustmant will void the warranty. (O If fuel pump or governor difficulties are suspected, consutt only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injec- ‘tion pump lead seals and erimp caps can be rainstalted as required. REMOVE THE GOVERNOR COVER FROM PUMP BODY. 1. Remove the return spring from the speed control lever. 2. Remove the cap nut. 3. Using two spanners, remove two lock nuts from the governor shaft, 4, Loosen the lock nut, 5. Remove the acces hole plug. 6, Remove the cap nut, and loosen the lock nut Then remove the idling spring capsule,GOVERNOR v7 sna.526] 7. Using a philips-head screwdriver, remove the bolts to separate ‘the governor cover from the governor housing. Then remove ‘the governor cover. NOTE: Be sure to keep an oil pan under the governor to catch lubricating oi. REMOVE THE GOVERNOR SHAFT TOGETHER WITH THE GOVERNOR SPRINGS AND SPRING SEAT. REMOVE THE RACK CONNECTING LINK. 1. Using fong-nose pliers, remove the start spring from the rack connecting link. 7 2. Using two spanners, unserew the bolt and nut holding the > ‘control rack and the rack conneeting Jink in place. 3, Remove the rack connecting link and bolt together, REMOVE THE SENSOR LEVER. Remove the snap ring from the pin of the Uspaced lever and remove the sensor lever. REMOVE THE FULL-LOAD SETTING LEVER AND RELATED PARTS. 1, Remove the nut, 2, Remove the full toad setting bolt. 3. Remove the full load setting lever and return spring together. ‘Then remove the O-ring and shim.sua.s77A) GOVERNOR REMOVE THE U-SHAPED LEVER. 1, Remove the guide plug. 2, Remove the U-shaped lever. REMOVE THE FULL-LOAD LEVER SHAFT AND SPRING. REMOVE THE ENGINE STOP LEVER AND RELATED PARTS. Remove the bolt, and then remove the stop lever, cap, spring, ‘Oring, and shim, PULL OUT THE SUPPORTING LEVER FROM GOVERNOR HOUSING. REMOVE THE FLYWEIGHT ROUND NUT. 1. Using the special tools, hold the coupling, so that the camshaft witl not turn, Special Tool: Coupling (09511-2000) Holding wrench (09511-1620) 2. Using a special too!, remove the round nut. ‘Special Tool: Round nut wrench (09511-1500)GOVERNOR ava smaseo| REMOVE THE FLYWEIGHT FROM THE GAM SHAFT. Using @ flyweight extractor, remove the flyweight from cam shaft, Special Toot: Flyweight extractor (09511-1900) REMOVE THE GOVERNOR HOUSING FROM THE PUMP BODY, 4, Remove the start spring eye. 2, Remove the governor housing fitting bolt and give the gover- Ror housing a light tap with a mallet to remove the governor housing from the pump body. REMOVE THE TENSION LEVER SHAFT. 1. Using a punch, remove the two plugs press-fitted in the gover. ‘nor cover, 2. Pull out the tension lever shatt. REMOVE THE TENSION LEVER ASSEMBLY. 1. Remove the snap ring, then remove the rod from the torque 2. Remove the tension lever assembly,Gv-10 ‘SOVERNOR sasa70) sye-5e8a| REMOVE THE TORQUE CAM. Remove the snap ring, then remove the torque cam from the press-fitted pin in the governor cover. REMOVE THE SPEED CONTROL LEVER. Remove the nut, and then remove the speed control lever and adjusting shim, REMOVE THE FLOATING LEVER ASSEMBLY FROM THE GOVERNOR COVER. DISASSEMBLE THE SLEEVE SUB-ASSEMBLY FOR INSPEC- TION. 1. Remove the snap ring end pull out the pin. ring pliers, remove the snap ring installed within,GOVERNOR Govt 3. Separate the shifter and the bearing assembly from the sleeve. sma.5a94| 4, Use a press to remove the outer ring of the bearing. t— press GUIDE IMPORTANT POINT (S) - ASSEMBLY WARNING. (© Wash all parts with loan diesel fuel betore installing them, ‘and any defective or damaged parts must be replaced. © Do not allow dust or other forsign matter to enter the Pump during assembly. © Apply grease to Oxings and oil seals before installing them. (© Amembie the parts in correct order and to correct tightening torque assembled dimensions etc. © Astembly takes place in the roverse order of disassembly. NOTE: Once removed, gasket, oil seals, O-rings, and snap rings ‘cannot be reused. New ones must be used in reassembly. FIT THE FLOATING LEVER TO THE SUPPORTING LEVER WITH THE CHAMFERED FORK-GROOVE OF THE FLOATING LEVER FACING DOWN. NOTE: A mark (() is stamped on the side with the chamfered a forkegroove. ‘SUPPORTING LEVER THE SIDE WITH. ‘THE CHAMFERED, FORK-GROOVE FLOATING LEVER! STAMPING MARK PORTION sass] styov-12 saa-saa| GOVERNOR SET THE FLOATING LEVER CANCEL SPRING, INSPECT THE END PLAY OF THE SPEED CONTROL LEVER. Assembly Standard: Less than 0.1 mm (Less than 0.004 in) If the end play is not within the standard value, use the following shims for adjustment, ‘Shim Thickness: 0.20 mm (0.0078 in) 0.40 mm (0.0187 in) 0.25 mm (0.0098 in) 0.50 mm (0.0196 in} 0.30 mm {0.0118 in) INSPECT THE END PLAY OF THE ENGINE STOP LEVER. ‘Assembly Standard: Loss than 0,1 mm (Lets than 0,004 in) If the end play is not within the standard value, use the following shims for adjustment, ‘Shim Thickness: 0.20 mm (0.0078 in} 0,40 mm (0.0157 in) 0.25 mm {0.0098 in} 0,50 mm (0.0196 in) 0.30 mm (0.0118 in) ‘SET THE FULL-LOAD LEVER SHAFT SPRING. INSPECT THE END PLAY OF THE FULL-LOAD SETTING LEVER. ‘Assembly Standard: Less than 0.1 mm (Loss than 0.004 in) If the end play is not within the standard value, use the follow: ing shims for adjustment. ‘Shim Thickness: 0,20 mm (0.0078 in} 0.96 mm (0.0137 in} 0.25 mm (0.0098 in) 0.40 mm (0.0157 in) 0.30 mm (0.0118 in) 0.50 mm (0.0196 in)v.14 GOVERNOR sma-oe7| x ‘swe-557| GoveRNoR: cover FLUSH FACE GUIDE scREW. Leta 205mm NUT SET THE TENSION LEVER CANCEL SPRING. For ease in attaching the cancel spring, a V-notch screwdriver is recommended PRESS FIT THE TENSION LEVER SHAFT PLUGS 1. The governor must be reassembled with new plugs press: fitted into the governor cover, these plugs secure both ends of the tension lever shaft. Press-expand each plug to ensure seating. Special Tool: Plug Press (09511-2130) 2. Apply liquid adhesive to the outside of each plug to prevent leakage of lubrication oil. INSTALL THE START SPRING. ‘The start spring is set in position, with its hook securely fitted from above, in the hook hole of the rack cennecting link. NOTE: If the start spring hook is fitted into place from under- neath, they may catch in a fork groove of the floating lever, and interfere with its motion. ‘ADJUSTMENT OF THE GUIDE SCREW PROTRUSION. Lock the guide screw, using the nut with a distance of 13.5— 145 mm (0.63—0.57 in) maintained between the guide screw tip and the outer face of the governor cover. In this ‘ase, the opposing end of the guide screw is approximately flush with the inner face of the governor cover.M4591 sma.so2 GOVERNOR v5 INSERT THE GOVERNOR SHAFT. NOTE: The spring sost must be mounted on the governor shaft with the governor spring seat facing toward the governor springs (the governor housing side is tevel). GOVERNOR COVER ASSEMBLY INSTALLATION SEQUENCE. 1, First set the spring seat of the tension lever with the step of tho spring saat facing towards the governor springs, and insert ‘the governor shaft into the center hole of the spring seat. Insert the ball joint of the guide lever into the fork-groove in the floating lever. Fit the sleeve into the flyweight holder. Push the control rack toward the governor, and hold. Next, insert the bai! joint of the connecting link into the fork groove of the floating lever, 5, Finally, tighten the seven bolts in diagonal sequence, with a uniform torque applied to each bolt. Tightening Torque: 70-90 kgm (5—6 lb-ft) AFTER INSTALLATION OF THE GOVERNOR COVER ASSEM- BLY. CHECK THE FOLLOWING ITEM. 1. Ensure the governor shaft can be moved smoothly by hand, NOTE: If governor shaft movement is difficult, loosen the seven bolts of the governor cover s0 8s to slide the governor cover until the governor shaft center is aligned with the ‘uide screw hole center, and then reighten these bolts, 2. Check that the controt rack moves smoothly when operating the control lever. NOTE: Should the contro! rack movement be difficult, remove the governor cover assembly, end determine the cause.tet Gv-16 GOVERNOR INSPECTION AND REPAIR Inspection Item Standard Limit Remedy Flyweight Pin Hole and Pin. Wear ot any other damage. Replace Pin and/or Flyweight Rack connecting Link, ‘Wear or any other damage. Fiywoight Slider. = = Replace, Wear or any other damage. it necessary. Each part of the Tension = = Replace, Lover assembly. if necessary. Wear o any other damage. ‘Sleeve, Shifter and Bearing = =| Repiace, Assembly. if necessary. Wear or any other damage. Floating Lever, Supporting = =| Replace, Lover, Control Lever Shaft and if necessary. Wear or any other damage. ‘Sensor Lever and Torque Cam. = = Visual check q sass2| ‘Control Lever, Control Lever = = | Replace, Visual check Shaft and Supporting Lever. if necessary. sua.553|GOVERNOR Gv? INSPECTION AND REPAIR Inspection Itam ‘Standard | Limit Remedy inspection Procedure ‘Springs. = = | Replace, Visual check Wear or any other damage. if necessary.GOVERNOR ADJUSTMENT OF THE GOVERNOR PREPARATION 1, Mount the injection pump correctly on the pump tester. 2. Connect the fuel line, 3. Refill the camshaft chamber and governor chamber with engine oit. Install the angle gauge on the adjusting lever. Remove the idling spring assembly Remove the governor shaft lock nut. Loosen the maximum-speed setting bolt, Loosen the idling speed setting bolt, Loosen the full-load setting bolt. ‘Adjust the torque cam position preliminary. Refer to the chart “CALIBRATION” or “ASSEMBLY OF ‘THE GOVERNOR”. 11, Set the zero position of the control rack, a, Mount the control rack travel measuring device on the end of ‘the control rack. . Lock the contrat iever at the idling position. ©. Push the governor shaft until it comes into contact with the wall of the pump housing, and, keeping the pump speed between 1,000—1,200 rpm, set the control rack at the position where the dial gauge indicates a zero reading. NOTE: The control rack of the RLD type governor-mounted fuel injection pump cannot be set at zero uniess the pump is operated at between 1,000 to 1,200 rpm. If the control rack is pushed to the non-injection position while the injection pump is running at less than 1,000 rpm, the ‘governor links may be damaged. Beexooe ‘CAUTION: © The injection timing adjustment and fuel injection quantity adjustment are excuted before governor adjustment. © Before shifting the control lever to the maximum-speed position, increase the pump speed to 500-600 rpm while ‘the control lever is held at the idling position. ‘Then shift the control lever to the maximum-speed position. Next, set the control rack 3 mm (0.12 in) bayond the full-peed position, using the full-load setting bolt. Various adjustments can now be made with the control rack locked in the specified position.YDLING ' [BLING MAXIMUMSPEED SETTING BOLT BOLT CONTROL LEVER IDLING toraue SPRING s a M4870 FULL-LOAD SETTING BOLT RACK POSITION (en) ai PUMP SPEED (rom) gya.css| GOVERNOR avg STEPS IN GOVERNOR ADJUSTMENT ADJUSTMENT OF THE IDLING SPEED CONTROL. ‘Temporarily setting of the contrat level Adjustment of the outor idiing spring. Adjustment of the inner idling spring. ‘Adjustment of the governor spring. Adjustment of the idling setting bolt gpene ADJUSTMENT OF THE FULL-LOAD RACK POSITION. 1. Temporarily setting the control lever. 2. Temporarily adjustment of the maximum-speed setting bolt 3, Adjustment of the full-load setting bolt. 4. Adjustment of the torque cam position. 5. Measurement of fuel injection quantity. ADJUSTMENT OF THE MAXIMUMSPEED CONTROL. 1. Adjustment of the maximum-speed setting bolt. 2, Checking of the speed droop. ADJUSTMENT OF THE GOVERNOR ADJUSTMENT OF THE IDLING SPEED CONTROL. 3, Temporary setting of the control lever. While keeping the pump speed at Na (80-100 rpm), adjust ling setting bolt so that the control rack-Avill be at 2. Adjustment of the outer idling spring. Screw in the spring capsule until the control rack is set 10 position Rb with the pump speed increased to Nb rpm and then lock the nut. The outer idling spring is now set.Gv.20 GOVERNOR RACK POSITION (mm) PUMP SPEED (rom) syya.565) PUMP SPEED (rpm) saeses Let 2050 GoveRNod, eave sige Ft eu guioe SCREW lal sass =z = 7 3 - 8 na) > 3 z NS Ne PUMP SPEED (rom) swa.565| ‘Adjust screw after increasing the pump speed to Ne rpm so that the control rack will be at Re, and the lock the locking nut. ‘The inner idling spring is then set in position. Fit the gasket and cap to the spring capsule, ‘Adjustment of the governor springs. Recheck that the distance between the tip of the guide screw land the outer face of the governor cover is between 13.5— 14.5 mm (0.53-0.87 in) NOTE: If the distance exceeds 14.5 mm (0.57 in), itis diffieult to adjust the governor spring with the two nuts, Conversely, when the distance is less than 13.5 mm (0.53 in), the spring seat of the tension lever contacts the guide serew. If $0, the flyweight cannot achieve its maximum lift. Lock the control lever at the idling position. Adjust the governor shaft with the pump speed fixe at Nd rpm 30 that the control rack will be at position Rd, and then lock it to the governor shaft with the nut.RACK POSITION (mm) Ne PUMP SPEED (rom smases| ACK POSITLOW imi 32 Ne PUMP SPEED (rom) RACK POSITION (mm) PUMP SPEED (rpmn] NIN sma.sio| GOVERNOR ovat d. Increase the pump speed until the control rack position is 4 Re, and then check that the pump is running at Ne rpm. NOTE: The adjustment sequence may be reversed. {Set to Re mm at Ne rpm, check that Nd rpm at Rd mm). Adjustment of the idling setting bolt. a. Derease the pump speed to Ne rpm, and adjust the idling setting bolt so that the control rack will be at position Rf mm. Then lock the nut, H+: Fast injection volume check point. Refer to the chart “CALIBRATION”. b. Further decrease the pump speed to Na (80-100 rpm, and ensure the control rack is positioned at Ra, ADJUSTMENT OF FULL-LOAD RACK POSITION. 1. Adjustment of the maximum-speed setting bolt. a. Adjust the maximum-speed setting bolt so that the control rack position is at Rh when pump speed is Nh rpm. ‘Then lock the maximum speed setting bolt with the nut, b, Ensure that the control rack begins moving in the fuel decrease direction at a pump speed of Ni rpm.GOVERNOR 2. Adjustment of the ful-load setting bolt. Adjust the full-load setting bolt so that the control rack posi- ton is at Rg mm when the pump speed is Ng rpm. wy RACK POSITION (mm) No. PUMP SPEED ftpm)—gyasig) 3. Adjustment of the torque cam position. Using a special tool, adjust the adjusting nut so that the con ‘rol rack position is at Rj mm when the pump speed is Nj rpm. Lock the adjusting nut with a lock screw. Special Tool: Special Wrench (09511-1980) RACK POSITION Imm? PUMP SPEED (tem) gutasia 4, Measurement of fuel injection quantity. imme ‘Measure the fuel injection quantity at each of adjusting points, e 7 A. B,C, D, E and I (the fuel injection characteristics for full- A 8 load). If the fuel injection quantity is no: correct, adjust the \ fullload setting bolt and the torque cam adjusting nut carefully, Lock the nut and bolt after adjustments, NOTE: If this adjustment is not exoscuted properly, the specified \ fuel injection quantity cannot be obtained, there will be decreased engine output, and black smoke may be pro- PUMP SPEED (om) a duced. Swasi9 Refer to the chart “CALIBRATION”, RACK POSITION (mm?s4-600| RACK POSITION (mm) 2 Ne PUMP SPEED (rom) suesig. + soosr COMPENSATOR, ft Se [7 stro len, a3 BE A FE Bo T eer Be a We ok soost paeseune| PUMP SPEED (rem) (mmHa) GOVERNOR GV.23 ADJUSTMENT OF THE MAXIMUM SPEED CONTROL. 1. Lock the control lever where it contacts the maximum-speed setting bolt. 2. Adjustment of the maximum -speed setting bolt. a. Adjust the maximum-speed setting bolt so that the control rack position becomes Rh when pump speed is Nh rpm. ‘Then lock the maximum speed setting bolt with the nut. b. Ensure that the contro! rack bagins moving in the fuel decrease direction at a pump speed of Ni rpm. ©. Increase the pump speed further to ensure that the control rack reaches 0 mm. ADJUSTMENT OF BOOST COMPENSATOR |. Spacer 8. Adjusting screw . Gasket 9. Cap nut 10. Cover 11. Plug 12. Washer 13, Push rod 14. Spring washer MegPene 1. Install the spacer on the governor cover, and ensure the push rod can move smoothly. 2. Measure the protrusion (L) of push tod fram the end face of the spacer. L = 19.4-19.6 mm (0.764-0.771 in) 3. Boost compensator stroke adjustment. 2. Maintain the pump speed at Np rpm.Gv24 GOVERNOR b. Fully foosen the adjusting screw with the wrench, and then ‘confirm that the control rack position Ry mm can be obtained. If the rack position Ry mm is not as specified, readjust the full-load setting bolt and torque cam. ‘Special Tool: Special Wrench (09511-1820) c. Shift the control rack position from Ry to Ry using the adjusting serew, and then lock it with the nut. NOTE: During boost compesstor stroke adjustment it is not ‘necessary to supply compressed air. 4, Setting the boost compensator spring force. a. With the pump speed maintained at Np rpm, gradually increase the boost pressure. b. Adjust the screw so that the control rack begins moving from t FR, mm in the fuel increase direction when the boost pressure y PUMP SPEED: Np rom reaches Py mmHg. Se a ————__y—_—_ Lock the screw with the nut. aE 38 Be at 88 BOOST PRESSURE {romg) —— c._Increase the boost pressure, and ensure it reaches P; mmHg when the control rack is at Ry mm. If the boost pressure is not as specified, replace the boost ‘compensator spring, PUMP SPEED: Np mm CONTROL RACK POSITION (rom). BOOST PRESSURE fmmlig)——CONTROL RACK POSITIONImm) | — Jusuue RACK LIMIT PUMP SPEED(Tom) = s4a.n7s] sha.726. GOVERNOR v.25 d. Recheck the boost compensator stroke, and if not as specified readjust the screw. ADJUSTING THE CONTROL RACK STROKE LIMIT. 1. Remove the rack guide screw from the pump housing. 2. Lock the control rack at the position given with the chart “CALIBRATION”, keeping the pump speed at 0 rpm. 3. Measure the depth 2" of the rack cap, nd of the control rack. 5. Adjust the bolt so that the distance between the end face of the pump housing and the bolt top is "2", the rack eap depth. Now tighten the nut to lock the bolt, and install the rack cap.Gv-25 GOVERNOR INSTALL THE GOVERNOR EXTERNAL CRIMP CAPS AND LEAD SEALS. NOTE: All adjusting devices on the fuel injection pump governor, ‘except the low idle adjustment screw, are sealed with ‘crimp caps as a protection for the customer. This is to Prevent unauthorized readjustment which may cause ‘engine malfunction and/or engine failure. Periodically check to insure that these soals are not broken, as this will void the warranty. sm4-602 sma.2e2 (wryGENERATOR Ge GE-A2E-05 CHAPTER GE GENERATOR (24V,30A) DATA AND SPECIFICATIONS...............0-0200005 GE. 2 DESCRIPTION ........ 2-0... cceceee eee ceee ee eee eee GE. 2 TROUBLESHOOTING ....2. 0.0... 00 eee cece ee neers GE. 4 GENERATOR ........ 020002. e ces ee settee cee ee eee GE. 5 anyGENERATOR GE2 DATA AND SPECIFICATIONS MODEL 27050-1081 2750-1350 | 27040-1290 GENERATOR Type. Alternator Output 24V, 304 Normal voltage 2av Charging rotation and voltage . 900 r.p.m., 27V_ Direction of rotation - Right (From the pulley side) Allowable max. speed 7,200 r.p.m. [ Max. output . 2BV, 30A at 5,000 mam DESCRIPTION 7050081 27060.1350, 1 2 3 5 | 4 \ iS + o fy q a it + GENERATOR WITH VACUUM PUMP 3, Stator 1. Brush 4 2. 1.C, Regulator 8. Rotor ‘Vacuum pump asrembly SMGE-132GENERATOR GES 27040-1290 SMGE.N15 GENERATOR WITHOUT VACUUM PUMP 1. Brush 4, Rotor 2. LC. Regulator 5. Pulley 3. Stator SMGE-116 CHARGING SYSTEM CIRCUIT 1. Alternator 4. Starter switch 7. Fuse 2. LC. regulator ‘8, Charging warning lamp 8 Load 3. Field coil 6. BatteryGes GENERATOR TROUBLESHOOTING Symptom Possible cause Remedy/Prevention Charging warning lamp does- Fuse blown . . ciceseeeeeeee sss + Determine cause and replace not light with starter fuse serie G1 ond erine off [— Lamp burned out + Replzce iamp «Tighten loose connections = Check relay = Replace IC regulator |—Wiring connection hose . [Charge ‘amp relay faulty Lic reguiator faulty. Charge warning lm dove Drie beteiot or wor A or coplse deve bet cee wat arane not aut wh rg Betty ebie loom, corded of wom... Repair or repace abe (Battery requires frequent Fuse blown . . Ida 7 . Determine cause and replace recharging) fuse, Fusible link blown... 0. ee see eee ee eee Replace fusible link Charge lamp relay, IC regulator oF... 2... Check charging system generator faulty Wiring faulty fete ee eee eee Repair wiringGENERATOR GENERATOR GENERATOR WITH VACUUM PUMP 1, Through bolt 2. Front bracket asiembly 3, Nut H exams ef Bs g 9. Bearing retainer 10. Retainer plate 11, Ball bearing 12. Felt cover 13, Felt 14. From bracket 15, Rear bracket assembly 16. Cover 17. Regulator assembly 18, Torminal with leed wire 19, Brush holder ossermbly 20. Brush holder 21, Brush 22. Brush spring 23. Stator coil 24, Condenser T= 33-45 (2.4~3.2 J t ) y PP ; a I 7 | = 990-1,300 (71-84) T= Tightening torque: kg-em (lb-ft) 25. Insulator 26, Connector with lead wire 27. Rectifier 2B. Insulator 29. Gasket 30. Bail bearing 31. O-ring 32, Insulator ‘33. Rear bracket 34. Vacuum pump ansembly $5. Through boltGES GENERATOR 8 ‘T= 19-25 (1.4-1.8) NS 4 Lo = 33-45 (2.4-3.2) a oe, ‘T= 980--1,300 (71-94) GENERATOR WITHOUT VACUUM PUMP ‘T= Tightaning torque: kg-em (lb-ft) 1. Through bolt 13, Flt 25. insulstor 2. Front bracket essembly 14, Front bracket 26. Connector with lead wire 3. Nut 5. Rear bracket atsembly 27. Rectifier 4. Rotor Cover 28. Insulator 5, Pulley Regulator assembly 29, Gasket 6. Fun Terminal with lead wire 30. Bal! bearing 7. Collar ‘Brush holder assembly 31. O-ring 8. Bolt Brush holder 32. Insulator 9. Bearing retainer Brush ‘33. Rear bracket 10. Retainer . Brush spring 34. Cover 11, Ball bearing Stator coil 12. Fett cover CondenserGENERATOR GET SMGE-117 SMGE19 IMPORTANT POINT (S) — OISASSEMBLY* REMOVE THE REGULATOR AND THE BRUSH HOLDER. 1. Unsolder the lead wire from the regulator. 2. Remove the regulator and brush holder atsembly REMOVE THE ROTOR. Using a press, remove the rotor. REMOVE THE FRONT AND REAR BEARINGS. 1. Using a press, remove the front ball bearing. 2. Using a puller, remove the rear ball bearing. REMOVE THE STATOR ASSEMBLY. 1. Unsolder the regulator lead wire,GENERATOR 2, Unsolder the each terminal of stator coil then remove the stator coil assembly, IMPORTANT POINT (S) — TESTING RECTIFIER. ‘Tost the each positive side recttier eonditian. Connect the circuit tester @) ead to the rectifier holder and the lead tothe rectifier tarminal. @ toad to the rectitior terminal and ©) lead to the recttier holder. ‘Test the each negative rectifier condition, Connect the circuit tester G@) lead to the rectifier terminat and the ©) lead to the rectifier holder. BAD © lead to the rectifier holder and ©) lead to the rect terminal. 521.0128]GENERATOR GES SMGe21 SMGE123, SMGE-125| IMPORTANT POINT (S) — ASSEMBLY INSTALL THE STARTOR COIL ASSEMBLY. 1, Install the stator coil assembly, and then solder the each terminal of stator 2, Solder the regulator lead wire, INSTALL THE FRONT AND REAR BALL BEARINGS. 1. Using a press, install the rear ball bearing, 2, Using a press, instalt the front ball bearing. 3. Using a press, install the rotor into the front bracket.GEA0 GENERATOR INSTALL THE REGULATOR AND THE BRUSH HOLDER ASSEMBLY. 1. __ Install the brush holder assembly and reguiator. 2. Solder the lead wire to the regulator. S0ce-117 Rn AFTER ASSEMBLING THE GENERATOR, MEASURE THE RESISTANCE BETWEEN EACH TERMINAL. Tester | Resiswnce [Terr [Resistance +Lead | —Lead (a) + Lead | — Lead ta) B R 2 N E 7-10 B N 7-10 N B o R L 400-500 — Rg - c N Rg E o E u eo SiGe 128 ce = ae a PERFORMANCE TEST NOTE: © Note the battery polarity carefully $0 as not te make reverse connections, {f the connections are reversed, the diodes will short the circuit and allow large current to flow through and damage the diodes and 1C regulator as well as bum up ‘the wiring harness. j © Use care not to make wrong connections of terminals. | (© When charging the battery with a quick charge. { Disconnect the battery terminals, ! © Do not perform tests with high voltage insulation resistance tester. ‘© When in operation, never disconnect the battery. GENERATOR PERFORMANCE TEST. 1, Turn on switch SW, and off SW; ‘the alternator slowly. increase the rotation of sM2vorea| 2, When voltage reaches 28V, turn on switch SW; regulate load resistance, Increase the rotation of the rotor keeping voltage at 2BV. Generator Spaed: 5,000 rpm at 28V, 308 621.0148GENERATOR GET VOLTAGE REGULATION TEST. ‘Tur on switch SW; and off SW, to increase the rotation of rotor to 8,000 rpm. Standard Voltage: 28.5-29.5V Sv21-014a, INSPECTION AND REPAIR Inspection Item Standard Limit Remedy Inspection Procedure Brush length. 16mm 7.0mm} Reptece {0.630 in) SNGE-127 Function of the brush holder. bal = Replace, ‘Visual check if necessary. ‘ SMGE-128 ‘Conductance of the rotor About 12.62 Lessthan | Replace. coil, 112 or infinity <2 ) SMGE1298 More than Less than | Replace. 1.0 Mo 0.5 M2 SMGE-130] Diameter of the slip ring. 345mm 33.5mm | Replace. (1.3583 in) (1.3188in)| *, suce.131A|GENERATOR Inspection Item Standard Limit Remedy Conductance of the #tatar call = Replace (UVM. terminal) N-u About N-V | 30 nw Tnulation of the stator coil. | More than Lem then | Replace 1.0 Mo. 0.5Ma ‘Condenser capecity 05 uF = Replace. 5 SMGE-114 Wear or damage of the = — | Replace, Visual check. bearings. if necessary. o 021-083 ‘Wear or damage of the oll seal - | Replace, Visa check, and O-ring, if necessary. = Resistance between each — | Replace, ‘arminal of connector. + Lsad Tertor | — Leed Tester R L 400 — 5002 L Support = ‘Support L 9-120 7 Support N = sm21o76GENERATOR Ge43 Inspection Item ‘Standard Limit Remedy Inspection Procedure Resistance between each ‘terminal of 1.C. regulator. ‘+ Lead Tester [ — Lead Tester [® t ‘About 10 2 R F ‘About 10 2 a c = R E About 15 K 2 L F ‘About 10% F t c About 90% a e t E ‘About 100 2 ~ | Reptac F ¢ About 10 F = ‘About 180 u © c E ‘About 40% 9121-038 L R = F f = c R = E R = F L ‘About 2K c t = E a ‘About 1.5K 2 c F E F € ¢ KdGENERATOR GE CHAPTER GE GENERATOR (24V, 70A} DATA AND SPECIFICATIONS ......0.. 0006.0 cc eee beeee GE2 DESCRIPTION 1.0.00 ec sceeeeee tenet sect een eee teases GE2 TROUBLESHOOTING .....-0....c bec ceceeeee eee eee ees GE3 GENERATOR 00.0060 0 eee ee eece cence eeeeeeteet teens GE-4GE2 GENERATOR DATA AND SPECIFICATIONS MODEL 27080-1210 (GENERATOR Type... Alternator Rated voltage .. 2av Rated output... 708 Operating output end speed . TOA, 28V wt 5,000 rpm Rotating direction --..--+.+e eee eee e ees Clockwise (Seen from pulley side) REGULATOR Se LG. Regulator (Built-in) DESCRIPTION SMGE-177 GENERATOR 41. Rotor shaft 4, Stator assembly 7. Rear bracket assembly 2. Ball bearing 5. Diode assembly 8. Front bracket assembly 3. Rotor assembly 6. Rear coverGENERATOR 6E3 SMGE-178 CHARGING SYSTEM CIRCUIT 4. Altemator 4 Battery 2. Le regulator 8. Earth 3. Coupter TROUBLESHOOTING Symptom Ponte couse Remedy /Prevention Ammeter does not move to Fuse blown... aes «++ Determine cause and replace ‘negative side (remained at fuse tenes ey an Wiring connection loose . . see ves Tighten loose connections starter switch on and engine off Ammeter indicate the negative side with starter ‘witch on and engine running \— iC regulator faulty... — Drive bolt loose or worn . [- Battery cable loose, corroded or worn }— Fuse blown ....-. +... [— Fusible link blown. : [— IC regulator or generator faulty . 1— Wiring faulty . . Replace IC regulator ‘Adjust or replace drive belt +... Repair or replace cables +. Determine cause and replace fuse = Replace fusible link «Check charging system «Repair wiringGes GENERATOR GENERATOR 18236 INO. 21 = 7 ‘T= 24-36 (18-26) | “6 T= 60-90 (4.4-6.5) Aa T® Tightening torque: kgem (Ib.ft) 1. Fan with pulley 12, Field coil 2. Front bracket 13. Rear bracket a Felt 14. Insulator 4. Felt cover 15. Condenser 5. Ball bearing 18. 1.C. regulator 6. Retainer plate 17. Connector 7. Packing 18. O-ring & Retainer plate 19, Bearing cover ‘8. Stator assembly 20. Cover 10. Rotor assembly 21, Rectifier assembly 11, Retainer plateSMGE-179] SMGE-123) smae-174) suce-118a] GENERATOR GES IMPORTANT (S) - DISASSEMBLY REMOVE THE I.C, REGULATOR, CONNECTOR AND COUPLER. 1, Unsolder the 1.C. regulator lead wire. 2. Remove the connector lead wire, NOTE: Protect rectifier from heat. BEMOVE THE REAR BALL BEARING. Using a press, remove the ball bearing. REMOVE THE ROTOR. 1. Place the pulley in a soft jaw vice. Remove the fan and pulley. NOTE: Do not hold the rotor assembly in a vice when disassemble the far and pulley. 2. Remove the rotor. Using a press, remove the rotor and collar. REMOVE THE FRONT BALL BEARING. 1. Remove the retainer plate. 2. Using a press, remove the front ball bearing. 3. Remove the plata and felt.GES GENERATOR IMPORTANT POINT (8) — TESTING SMGE.120) ‘SMGE-179] smae-124] RECTIFIER ‘Test the esch positive side rectifier condition, Rectifier Tran Terminal Holder sivance © Led eed ‘About 7=10 @ lead O Lead =o GREEN MARK (-) sucess} Seep, TEOMA aol ‘Test the each negative rectifier condition. fae Rectifier ae Terminal Holder re © Lead @ Leod =a mane) @ Lead ‘Olea ‘About 7—19 IMPORTANT POINTS (S) — ASSEMBLY INSTALL THE REAR BALL BEARING. 1. Using a press, install the bait bearing. 2 Install the O-ring and bearing cover. NOTE: Apply the bearing grease to bearing. INSTALL THE ILC. REGULATOR, CONNECTOR AND COUPLER, 1. Solder the 1.C. regulator lead wire. 2. Install the connector lead wire. NOTE: Protect rectifier from heat. INSTALL THE FRONT BALL BEARING 1. tastall the felt and felt cover, 2. Using a press, install the front ball bearing, 3. Install the retainer plate. NOTE: Apply the bearing grease to bearing and cil yeal tip.GENERATOR GE? INSTALL THE ROTOR, 1. Instat the rotor. Using a press, install the rotor and collar SMGE-12 2. Place the pulley in a soft jaw vice. Install the fan and pulley. NOTE: Do not hold the rotor assembly in a vice when assemble the fon and pulley. SMGE-174| AFTER ASSEMBLING THE GENERATOR, MEASURE THE RESISTANCE BETWEEN EACH TERMINAL. Tester Resistance + teed [= (ay R 2k 2K. 300 1K 1K SMGE-1516| wl|o|a|= [mp lalate! stalste e [2 |o/m|z]o/e | m| en] 20/23GES GENERATOR PERFORMANCE TEST NOTE: © Note the battery polarity carefully 30 as not to make reverse connections JF the connections are reversed, the diodes will ahort the cireuit and allow large current to flow through snd damage the diodes and 1C regulator as well as burn up ‘the wiring harness, © Use care not to make wrong connections of terminals. © When cherging the battery with a quick charge. Disconnect the bartery terminals. © Do not perform tests with high voltage insulation resistance tester, (© When in operation, never disconnect the battery. — — ot GENERATOR PERFORMANCE TEST. 1, Turn on switch SW, and off SW; to increase the revolution ‘of the generator slowly. SM21.0148, When voltage reaches 28V, turn on switch SW; regulate toad resistance, Increase the revolution of the rotor keeping voltage at 28V. Generator Speed | Less than §,000 rpm 28V, 708, | su21-o145| VOLTAGE REGULATOR TEST Turn on switch SW, and off SW, to increase the revolution of rotor to 5,000 tpn. Standard Voltate: 28.6-28.5V 8M21-0148)GENERATOR INSPECTION AND REPAIR Unit: mm tin) Inspection Item Standard Limit Remedy Inspection Procedure Resistance of field coll, ‘About 109 - Replace (at 20°C) F nce.tsa| Irwulation resistance of field | More than 1M | Lessthan | Replace coil o5ma Resistance of stator coll (at 20°C) eo - UW | About 0.139 Replece vw Insulation resistance of stator | More then 1M | Less then | Replace coil os Ma. ‘Condenser capacity OS uF = Replace = ‘SMGE-114] Outside diameter — | Front | 25.0 (0,984) 24.95 ‘of rotor shaft (0.982) t— Replace Rear | 17.0 (0.669) 16.98 (0.668)GE-10 GENERATOR {nspaction Iam Standard Limit Remedy ‘Wear or damage of front ball Replace, bearing if necessary. y ie zig ‘Weer or damage of O-ring, Replace, ‘Visual check seat and ft. if necessary a «rdSTARTER sta CHAPTER ST STARTER (24V, 4.5 KW) DATA AND SPECIFICATIONS... DESCRIPTION TROUBLESHOOTING STARTERSTARTER ST2 DATA AND SPECIFICATIONS Hon. ares lesen /tateem Steer vm setae Rated output . Module... 02.0.0. Rotating direction Number of teeth of pinion . 2av,45 KW 1 3 Clockwise (Seen from pinion side) DESCRIPTION Brush Commutator Field coil Armature |. Magnetic switch ‘The starter parts number is engraved at the commutator lend frame Pinion shift tever Reduction gear Clutch and pinion Pivion stopper SMST.1240,STARTER sta TROUBLESHOOTING “Symptom Possible cause Remedy/Pravention Engine does not crank, —Key switct] or cranks slowly. © Poor contact, cess eevee esses Polish oF replace contacts © Discharged battery 6... ee eee ee es Charge © Short circuited between electrodes. , - Replace battery © Poor contact at battery terminal .....,...., Plish or retighten © Improper viscosity oil. Change oil jagnetic awitch] © Poor contact caused by burnt contact plate . . . . Polish or replace contact plate © Contact plate worn out. Repair Holdin coil disconnected . ss se sree Replace field coil {Overrunning clutch moves back and forth) © Pull.in coil disconnected or short circuited .... Replace Starter relay] © Defective or poor contact........-++++++ Repair or replace | feet] Brush worn out. . . Commutator burnt out Replace Correct on lathe + Correct by undercutting Rewind er replace . . © Commutator worn out... see © Field winding shorted or grounded . . . ‘Armature winding shorted or grounded . Replace armature Insufficient brush spring tension... . Replace brush spring Poor contact between magnetic switch . Repair and field windings © Armature contacts pole core because of worn... Replace bearing brush or armature bearing bush or bent armature shaft © Overrunning clutch mutfunction ........... Replace Engine does not crank while starter is running 7 Hoh, © Overrunning clutch mulfunction ........... Replace © Pinion teeth worn Out 0.0... 0-2. s+. Replace © Poor sliding of spline teeth .............., Remove foreign materials, dirt, or replist4 STARTER ‘Symptom Ponsible couse Romedy/Prevention Starter does not stop. Key switen] running, © Contacts keep closing ..... veeees es Replace © Key swinch sticks seser esses Replace © Overrunning clutch sticks to armature ....... Repair or replace overrunning clutch or armature Starter relay] © Contacts keep closing... 6... 6s. e s+. Repair or replaceSTARTER sts STARTER “TYPE I for 28100-1900 only ‘TYPE I for 28100-2010 only T= 140-160 (10.2-11.5) 211 = 140-160 (10.2-11.5) \\ 24 ‘T= Tightening torque: kg-em (Ib.ft) 1. Yoke assembly 15. Shim 28, Bushing 2 Brush 16. Bearing housing 30. Plug 3. Commutator end frame 17. Clutch and pinion assembly «31. Magnetic switch assembly 4, Brush holder assembly 18. Pinion stopper 32. Contactor with terminal 5. Brush 19. Hook ‘cover assembly 6, Brush spring 20. Clip 33, Terminal assembly 7, Set bolt 21. Set bolt 34, Contactor assembly 8, Armature assembly 22. Gasket 35, Moving core assembly 8, Ball beering 3. Drive pinion lever 36. O-ring 10. Ball bearing 24. Lever pin 37. Contactor spring 11, Sot bott 25. Lever holder 38, Bolt 12. Gear housing 25. Holder spring 39. Plote 13. Shim 27. Insert 40. Harness 14. Drive shaft assembly 28. Drive houting atsemblyST SMST-139 sMST-131 sMST-138) SMST-141 a STARTER IMPORTANT POINT(S) ~ DISASSEMBLY When disassembling the starter, pregare a work stand as shown in the figure, D: Diameter = 110 mm (4.331 in) T: Thickness = 10 mm (0.994 in) Hs Hight = 120 mm (4,724 in) REMOVE THE MOVING CORE. Remove the moving core in the direction of the marked arrow in the order @ and @ REMOVE THE ARMATURE ASSEMBLY. Using 2 press, remove the erraature assembly. REMOVE THE PLUG Remove the drive housing plug using a press. D: Diameter = 16 mm (0.620 in) REMOVE THE MAGNETIC SWITCH. Unsolder the “COIL” terminal andSMST-158 SMST-149] SMST-155| STARTER 87 IMPORTANT POINT(S) — ASSEMBLY LUBRICATION Before reassembling, apply the recommended grease as follows and replace the O-ring with new one. Bushing Clutch and pinion assembly Bushing and shim Drive shaft Gear housing and stim Bearing Drive pinion lever Moving core Lever holder and pin GOVOHHOOHO: REPLACEMENT OF BUSHING @_ Remove the bushing using a pres. @® _ Replace the bushing with a new one using a press. NOTE: In the case of the bearing housing bushing, also replace the bearing housing bushing. INSTALL THE MAGNETIC SWITCH. Solder the "COIL" terminal and “C” terminal,sTa STARTER SMST-165| sst-160| BRUSH HOLDER, ;OSITIONING INSTALL THE ARMATURE ASSEMBLY. Using a press, install the armature assembly. TO REASSEMBLE, FOLLOW THE DISASSEMBLY PROCEDURE IN REVERSE ORDER. NOTE: When assembling the starter, pay attention to the following Points. 1. When installing the drive pinion lever on the shaft, pay attention to the direction in which the lever is installed. 2, Match the positioning of the brush holder with the "M" lead. 3. Match the end trame positioning guide with the notch of the brush holder positioning guide. MEASURE THE THRUST GAP. ‘After assembling the starter (without the magnetic switch), use 2 dial gauge to measure the thrust gap as you move the drive shaft in and out by hand. Standard: 0.1 — 0.5 mm {0,004 — 010196 in) AFTER MEASURE THE NO-LOAD TEST OF THE STARTER, INSTALL THE DRIVE HOUSING PLUG. NOTE: Use anew plug.STARTER STS INSTALL THE MOVING CORE. {install the moving core in the direction of the marked arrow in the order @ and @). AFTER ASSEMBLING THE STARTER, MEASURE THE TIMING GaP. © Arrange the circuit. © Close switches SW1 and SW2. 2 Open SW2 alone when the pinion pops out. © In the above condition, push the pinion back to measure the ap. Standard: 0.5 — 3,0 mm (0,020 ~ 0.118 in} If the gap exceeds the standard, check the following parts and, if necessary, replace them. Lever holder Lever pin Drive pinion lever Gasket inert @®000 522.113] TEST MAGNETIC SWITCH TEST. The following test should be performed with the starter ‘assembled without the “M" terminal lead with specified voltage applied. NOTE: Each test should be performed a short time (3 to 5 sec.) to prevent the magnetic switch winding from burning.sT40 STARTER 1, Pulbin test Connect the test leads as shown. When the switch is closed, the pinion should jump out, SMST.163 2. Holding test With the same procedure as the pullin test, disconnect the “"B” terminal, ‘The pinion should remai in th “jumped out” position, 3. Return-test the same procedure as in the hold-in test, disconnect the “EARTH” jumper wire. The pinion should return immediately. PERFORMANCE TEST The following test should be carried out after reassembling the starter. If suitable equipment is not available, at least the no-load test should be carried out. No-oad test (© With the starter securely clamped in a vice. (© Using a battery and suitable ammeter. © Connect the positive lead to the ammeter, terminal. (© Connect the negative lead to the starter body. ‘The starter should show smooth and steady rotation immediately after jumping out of the pinion and should draw less than the specified current. and "C" Revolution ‘More than 4,000 rpm Current Loss than 1004 SMST.-04A,STARTER ST INSPECTION AND REPAIR ise i) Anepection Item Standard Limit Remedy Inspection Procedure ‘Armature Short Circuit - Weheiron | Repalce Test place is not vibrated, the armatur good ‘Armature Insulation More than 1M | Less than | Replace 0.5Ma | Distortion the Commutator 0.08 0.1 | Replace 0.0020) (0.0039) Outside Diameter of the 36.0 34.0 | Replace ‘Commutator (a (1.339) Depth of Under Cut of 05-08 02 | Replace Peet the Mies (0.0197-0.0315) | (0.0078) sMs7"126 ‘Conductance berween the - Should be | Replace Brush and the Yoke Body conducted Insulation between the Brush More than 1M | Lessthan | Replace and the “M” Terminal 05 M2st42 STARTER Unit: ene Ui — Inspection item Standard Limit Remedy Inspection Procedur Bend of he Drive Shaft 0.05 01 | Replace (0.0019) (0.0039) sustoae | Weat or Damage of the - ae er ee ca Internal Gear and the Spline acetal y a sust29) Drive Housing Bushing 17.0 17.2 | Replace Inside Diameter (0.9699) (oe772) Bearing Housing Inside 28.0 28.2 Replace Diameter. (1.1024) (41,1102) sMsr-149 : VISUAL CHECK ‘or Damage of the - - Replace, if 7 Bearing necessary Insulation between the More than 1M Less than | Replace Brush Holder and Bracket oma sMsv-15t Brush Length 18.0 12.0 Replace (0.709) (0.472) ‘sMst-150]STARTER ST43 Uni: em find Inspection Item Standard Limit Remedy Inspection Procedure Tension of the Brush 14 Kp 10kg | Replace I Springs (3.010) (20 1b) sust-117 Wear or Damage of the - - Replace, if Moving Core, Spring, necessary visuat cHECK Stal Rubber and Seat ‘Damage of the Contactor - ~ Replace, it VISUAL CHECK Point necessary Conductance between 05-202 ‘Should be | Repalce the C Terminal and the Body conducted {Holding Coil) ‘Conductance between 01-032 Should be | Replace the € Terminal and conducted the Coil Terminal {Pulling Coil) SMsT-153 Damage af the Pinion 5 7 Replace, if VISUAL CHECK Teeth necessary 4 smst-188] Rotating Toruge of 4-6 kgem - Rreptace, if it . Pinion (03-04 Ib.AY turns both side or does not turn at all. suay.oa1sT414 STARTER Unit: re tint Inspection Item ‘Standard Limit Remedy Inspection Procedure Wear or Damage of the - - Replace, if VISUAL CHECK Pinion Shift Lever necessary a ‘sMsT-108 Damage of the O-rings - - Replace, of aia VISUAL CHECK Commutater End Frame 28.0 281 | Replace Inside Diameter. (1.1024) (1.1063) \ SMST-159) (ky)CALIBRATION CHAPTER C INJECTION PUMP CALIBRATIONcz CALIBRATION Eine WoT 7 section. |_Inieetion pump part number 22000-5660, 22080-1390, 220005280 PUMP net z PUMP a. [inition pump type NP-PESAAEC 3278 Ton ‘Governor type FLO with boost compensator (Allapeed governor Timer type NP-EP/SCOM Feed pump type NP-FPIKSA Test nozzle type 105780-6140 Test nozzle opening prewure 175 kg/em? (2489 po) Outer diameter 6.0mm (0:24 in} Test Injection pipe Taner diameter 2.0 mm (0.08 in) CONDITION Length 1200 mm (23.6 in) Cafioraion Ot ne Siero Oil tempersture 40-45" (1041157 F) Fuel feed pressure 1.6 Kafer? (228 pd Rotation Clockwise viewed from dive side insecrion | Iniection order 34-2 TIMING” [injection interval re Prestroke 3:17-8:23 mm (0:12460,1272 in) Rack position | Pump | Measuring | Injection volume Boost pressure mn (in) speed | strokes oe (euin} roma (inks) fom 107 oss | 200 38,25-~40.25 (2.23-2.46) ° “About 0.68 7 H{aotostso| 300 378-6.25 (023-03 | (0081) ° 107, : A} (oars) | 900 38,75~39.7 (2.96-2.42) = 102 | (a4o2 | 1600 41.25-43.25 (2.52-2.64) 7 More than O45 1606.30) ce} sin | 1300 40.15-42.15 (245-257) - INJECTION VOLUME 102 500 o| sia | 650 3038-92.35 (1,85-1.97) - ef - 400 24,0-26.0 (1.46-1.59) = ° About 1 |143105630| 100 50,0-60.0 (3.05-3.66) - {Rack tit) 10.9 F| 42 | 500 95.3 (2.18) 7 s| - 400 37.3 (228) = Fy 190 k | tosses) | 650 18.65-2065 (1.14-1.26) - °‘Adjusting | “Adjusting Pump speed Control rack position — | ‘ , item [lever position (com) mm (in) Adjusting position Na :80—100 Ra : 11.5 (0.453) Setting of the control lever. Nb : 105-205 Rb : 1110433) Outer idling spring {dle speed a Ne :300 Re :8 (0.315) Inet idling sp control Nd: 360 Rd 17.4 (0.201) Governor spring Ne :1,100-1,300 | Re : 2.5 (0.098) Confirmation Ne $300 Rf_: About 8 (0.315) Icing setting bolt Ng 900 Ro :10.7 (0.421) Setting of the control lever 7 Nh: Less than Rh : 6.7 (0.264) Temporarily adjustment of the & | Furiosd | Fulltoad 1,875 maximum speed setting bolt B |eack position| position 1,650 Should start to be pulled | Confirmation é 900 10,7 (0.421) Fullload setting bolt 8 500 0.9 (0.428) Torque cam position 3 | Maximum |” Fulllosd NK Lass ihan Rh : 6.7 (0.264) ‘Maximum-speed setting bolt speed position 1,875 = | controt 31,850 Ri_: Should start to be pulled_| Confirm the speed droop z Ry + 102 (0.402) Confirmation & {Fully loosened adjusting screw) 3 Ry :8.9-9.1 (0.350-0.358) | Adjusting screw 8 When boost pressus Is at P, mmHg, Control rack begins | t0 move from Ry mm in the Bode fuel increase direction, Jcompensator Np +650 When control rack returns to | Confirmation position Ry, the available pressure corresponds to P, mmlg. ‘Adjusting lever position Pump speed (rom) ‘Advance angle TIMER en Fulllowd [Loss than 1,200—1,360 © 1,600 32-38 Adjusting position GONTROL LEVER IDLING SETTING, sOLT MAXINUMSPEED- SETTING BOLT TORQUE CAM GOVERNOR ADJUSTMENT] GOVERNOR IDLING sPAING sw6570ca CALIBRATION CONTROL RACK POSITION (rnmj———pe BOOST COMPENSATOR ADJUSTMENT Governor characteristic diagram FULL-LOAD ADJUSTMENT ul 7 {Boor compensator stroke) = (Rj) 10.9, 3 (9) 10.7 2 4046 3 102 5 80 2 (nn 67) 8 PUMP SPEED om) ——e IDLE ADJUSTMENT ans s (wy ihe ted aE Un About 33 (rei8) E nave 33 (re) 25 (Ne) 1,001,200 >= — PUMP SPEED (rpm) a 8 a Boost | (Vn) Low than 13375} 54.774 PRESSURE (mmHg) —~o> M778 C-aBE-04 OP)RECOMMENDED LUBRICANTS FOR ALL HINO VEHICLES Wee lel alalalaletaleatal las dddalddld/dldldldld diblddala ddd 3 g | z lelsslls oletgel ep as wal4 ¥ [epee leySet) sete) fs, | bs, | 2 i fil, is + 3 CHG MH Hee RUA A a AAA Ae | PURURUHG Ee tee EUR UE jhe L iil tHaldlelale! | Peele EE Eg, . lial Gl} BT a Abe tt ep eng AU EE sla] al dlae| sel eel eels neg ag ag ee alate A ell stad that lag : Wedd ge bla a lililese IRIE aulmu canal LEEW Ut eg HE IE EAL lala la #iaal TGR RE RW ei ele hlflilal gal dillé 3s ale| else # | , Jing a | iad 3 dap a] 5 i a Bay ad : i | a ‘hoo T + 7 i £ 3 é = i | asa Sa au Bi ' 2 3gd || laidlida | |) dldldila aly mi ai dla) a). leeale cclelelacleesa fH) dlate[ Wala agp alii Bae EEG a EE ! ij i lie Qk alk ER RVR PER aaa Wade alllalaladel ll ig WEE GE (WE tie | fi L i | i, kilt us|! u th hi ih I hii He lelA{HIE TE Lt fe ala} 1] ita Bait eel ag] Hi ]Ah teh He in a Ha] Bd i? eladlidtulia alt ial a Htlicic a a Aol Asli ol Gs] EE Te Be f 2 2 | gal | al bi betes POSITIONS | | T 1 ht: ca se nd dg aren yA ton Pace LUBRICANTS. 21 | suicone crease 23 | suicone on,Hino Motors.Ltd. 4-1.HINODA S-CHOME HINC SH, TOKYO 191-8560 JAPAN PRINTED IN JAPAN PubNo S5:WO4E04DHino Motors,Ltd. 1. MINODAL SOME, NO-54, TOXVO. 197-860 APM

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