DAEWOO SERVICE MANUAL DIESEL ENGINE D1146 D1146T D2366 D2366T FOREWORD ‘This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of the com: ponents of the models titled, The Section Index on the contents page enables the user to ‘quickly locate any desired section. At the beginning of each section containing more than one major subject is a Table of Contents, which gives the page number on which each major subject begins. An index is placed at the beginning of each major subject within the section, Any reference to brand names in this manual is intended merely asan example of the types of lubricants, tools, materials, etc. recommended for use in servicing Daewoo Engine. In all cases, an equivalent may be used, ‘This manual should be kept in a handy place for ready refer- ence. If properly used, it will enable the technician to better serve the owners of Daewoo Engine, All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice, Wg DAEWOO Seoul KOREA SECTION INDEX SECTION] NAME 1 GENERAL INFORMATION PREVENTIVE MAINTENANCE ENGINE ASSEMBLY 4 |coouine system 5 | vusricatine system 6 | Fuevsystem ENGINE ELECTRICAL TURBOCHARGER SUPPLEMENT1 GENERAL INFORMATION Section 1 GENERAL INFORMATION CONTENTS PAGE 1, General Repair Instructions. 2 2. General Description ........s06eee008 a 2:1 Engine Characteristics +3 2.2 Main Data and Specification .. -3 2-3. Engine Performance Curve .. 5 3, External View of Engine . . 7 31 DIV46 Engine ......eeeeeee eee 32 D1146T Engine .. : 9 3-3. D2366 Engine ... 34 D2366T Engine .. 4, Sectional View of Engine 4-1, Engine Section .. 4-2 Fuel System . 4-3 Lubricating System 44 Cooling System WORLDWIDE NETWORKGENERAL INFORMATION |. GENERAL REPAIR INSTRUCTIONS . The use of proper tools and special tools ‘where specified, is important to efficient and ‘reliable service operation. Use genuine Daewoo parts. Used cotter pins, gaskets, O-rings, oil seals, lock washers and self lock nuts should be discarded and new ones should be prepared for installation at normal function of the parts can not be maintained if these parts are reused. . To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important as they vary in hhardness and design depending on position of installation. Clean the parts before inspection or re- assembly. Also clean oil ports, ete. using compressed air to make certain they are free from restrictions. 6, Lubricate rotating and sliding faces of the parts with oil or grease before instalation, 7, When necessary, use a sealer on gaskets to prevent leakage. 8. Carefully observe all specifications for bolt and nut torques. 8. When service operation is completed, make a final check to be sure service has been done Property. 2, GENERAL DESCRIPTION Models 01146 and 02366 are Goylinder, 4- cycle, insine, vertical type engines. They are water-cooled and use Toroidal combustion system, Both engine models are ‘and construction. It may be assumed that the information and values contained in this manual is applicable to both engine type unless otherwise noted. ilar in appearance1 GENERAL INFORMATION 2-1. Engine Characteristics ‘The engine operates according to the Toroidal combustion system developed by Daewoo Heavy Industrial Co. of Korea and AVL Co. of Austria. The main design features of this systern are ‘the combustion chamber arranged in the center of the piston and the swirling passage in the cylinder head, Due to the swirling passage, the air entering the feylinder through the helical port designed specially during intake stroke is imparted a strong rotary motion in the combustion ‘chamber and the complicated turbulence motion created by the swirl produced during compression stroke and strong squish flow makes the fuel be mixed more sufficiently with air During power stroke the fuel injected from 2 ‘multiorifice nozzle is mixed sufficiently with air for complete combustion, so that the Improvement of performance is achieved. Engines with the Toroidal combustion system are characterized by their quiet running, high flexibility and very low specific fuel and oil consumption. 2-2. Main Data and Specification | | Engine pe See ee ee |e | vertical | | combunion chamber | Trae | | type combustion ~~ | ~ | _ Combustion type Direct injection | _ _ . | type | |GEIVERAL_ INFORMATION Engine Models | ae 1146 o1n4eT 2366 023667 Deschiptions | No. of Cylinders 6.111 «139 _ 6-123 x 155 a Bore x Storke (mm) | Total displacement (cc) | 8,071 = 11,051 _- Compression ratio 176: 1724 178: 165:1 ‘Max. power (PS/rpm) | -187/2,500 2738/2300 240/2,200 '305/2,200 Max. torque (kg-mv/rpm) | 98/1600 80/1,400 84.2/1,400 | 108/1,400 Fuel injection timing BTDc 18° Broc 17 sroc 14° | toc 14° Fuel injection order 1536-24 _ _ = Injection pump type Np-pe6aD95 | NP-PEGP 120/ | NP-PEGP 120/ | gai2Rs2s 721 RS 3000 | 721283000 = Governor type | p.ep/RFD 200 | NP-EP/RFD200 | NP-EP/RFD200| NP-EP/RFD200 11650 AF9 CHL | /1650PF 9CZR | /1350 PF 7C HAI /1650 PF BCWR, Timer type INP-EP/SP700 NP.EP/SP 960 | NP-EP/SPEOO- | NP-EP/SD 700- 1250 BAR 1180248 | 110028.5R | 11002 30A Injection nozzle type DLLA 1505 312 | OLA 1505 1064 |DLLA 150 308 | DLLA 1505 310 | Feed pump type | NP-FP/KE ADS | NP-FP/K-P NP-FPIK-P — Intake valve open at | BTDC 16° _ BTDc 18° a Close at| ABDC 36° _ ABDC 34° _ Exhaust valve openat apc 46° _ ppc 46° — Close at TOC 14 _ ATOG 14° _ il Pump type | Gear type _ — _ it cooler type | _aer cooled — _ _ aa Sate eage | Sof Slement il capacity (2) | 155 _ 20 an Cooling water capacity n _ 19 ~~ @ Thermostat type | Waxpelter , o7 _ ad Starter motor | Voltageoutput (V-kw) | 244.5" ; oo sa | Alternator | | Voltage-capacity (V-A) | 24.25" | _ 24-62" jo * Specification may vary depend on the vehicle models1 GENERAL INFORMATION 2-3. Engine Performance Curve 2.3.1, D1146 engine ‘SAE 80kg-m/1,400 RPM 3. Fuel Consumption ratio, 1S4g/ps.h + 596 wl 4 & s a .e z - i 8 ve 1, Mas, power zg ‘SAE 187 PS/2,500 RPM 8 2. Max true z SAE 58.5 kgim/1,600 RPM . . 3. Furl eonsumptan eta C 158 ofan 8 eee Engine revolution(rpm) D1146T engi ™ t a ¢ g ce t 2 e 2 & 2 . ‘4 1. Max, power i SAE 238 79/2300 APM i 2. Max tore 3 Engine revolution(rpm)1 GENERAL INFORMATION 3. 2366 engine TToraque(kg-m)> Fuel Consumption Ratio(g/ps-h)-» Engine ravolution(epm) 2.3.4, D2366T engine Toxque(kg-m)+ coutput(ps) ‘ Fuel Consumption Ratio(g/ps-h)—+ Engine revotution(rpm) 1, Max, power SAE 240 PS/2,200 RPM 2. Max. torque SAE 84.2 kgm/1,400 rpm 3. Fuel consumption ratio 157 g/ps.h + 8% 1. Max. power ‘SAE 305 PS/2,200 RPM 2, Max. torque SAE. 108 kgm/1,400 RPM 3. Fuel consumption ratio 153 g/ps.h + 5%1 GENERAL INFORMATION 3. EXTERNAL VIEW OF ENGINE 341 D1146 Engine Fuel Filter Intake Manifold Fuel Pipe Air Compressor Thermostat Water Pump Cooling Fan V-Bett Idle Pulley Mounting Bracket Vibration Damper Oil Level Gauge Timing Gear Case Cover i! Pan Timer Oil Fitter Injection Pump Bracket Fly Wheel Housing Fuel Hose 1. Fuel Injection Pump Exhaust Manifold Cylinder h Head Cover il Filler Cap Cylinder Head Fly Whee! Starter 7. Cylinder Block Gil Cooter Cooling Water Pipe Breather Pipe Alternator1 GENERAL INFORMATION3-2, DI146T Engine n 12, 13, 14 16. 16. 17 18, 19, 20. 21 22, 23. 24, 26. 27. 28. 29. 30, 31 32, 1 GENERAL_INFORMATION Fuel Filter Intake Manifold Fuel Pipe Air Compressor ii Filler Cap Water Pump Cooling Fan V-Belt Idle Pulley Mounting Bracket Vibration Damper Timing Gear Case Cover it Pan Oil Level Gauge Timer oil Filter liection Pump Bracket Fly Wheel Housing Fuel Injection Pump Fuel Hose Exhaust Manifold Cylinder Head Cover Cylinder Head Preheater Plug Fly Whee! Turbo Charger starter Cylinder Block Oil Cooler ‘Cooling Water Pipe Breather Pipe Alternator1 GENERAL INFORMATION -10-1 GENERAL INFORMATION 3-3, D2366 Engine 1. Fuel Pipe 2. Water Pipe 3. Intake Manifold 4. Alternator 5. Water Hose 6. Cooling Fan 7. Water Pump 8 V-Belt 9, Water Pipe 10. Vibration Damper 11, Oil Pan 12. Oil Level Gauge 13, Timer 14, Oil Fitter | 16, Injection Pump Bracket 16. Oil Cooler 17. Fuel Injection Pump | 18, Fuel Filter | 19. Preheater Plug 20. Air Compressor 21. Thermostat 22. il Filler Neck 23. Cylinder Head Cover 26, Ex-Manifold 25. Cylinder Block 26. Cylinder Head 27. Fly Whee! 28. Fly Wheel Housing | 29, Starter 30. Breather Pipe 31. Power Steering Pump | 32, Air Compressor Bracket -H-1_GENERAL INFORMATION ~12-1 GENERAL_INFORVATION 3-4, D2366T Engine 1. Fuel Pipe 2. Water Pipe 3. Intake Manifold 4, Alternator 5. Water Hose 6. Cooling Fan 7. Water Pump 8. V-Belt 9. Vibration Damper 10. Oil Pan’ 11, Oil Level Gauge 12, Timer 13, Oil Fitter 14, Fuel Injection Pump 16, Oil Cooler 16. Water Pipe 17, Fuel Filter 18. Preheater Plug 19. Injection Nozzle 20. Thermostat 21. Oil Filler neck 22, ExManifold 23. Cylinder Head Cover 24. Turbo Charger 25. Cylinder Head 26. Fly Wheel 27. Fly Wheel Housing 28. Oil Hose 29. Starter 30. Gylinder Block 31. Oil Drain Plug 22, Breather Pipe 33. Air Compressor Bracket 34. Air Compressor i 3230 29 28 27 -B-1 GENERAL INFORMATION, =| =e1 GENERAL INFORMATION 4, SECTIONAL VIEW OF ENGINE 4-1. Engine Section -15-1 GENERAL INFORMATION 4-2. Fuel System -17-1 GENERAL INFORMATION 4-3. Lubricating System4-4, Cooling System2 PREVENTIVE MAINTENANCE Section2 PREVENTIVE MAINTENANCE CONTENTS 1. Servicing of Engine. 1-1 General....... sees 1-2. Inspection and Maintenance Procedure 2. Trouble Shooting . . 2:1 Hard-Starting ..... we 2-2. Engine Runs Rough ..... 2-3. Engine Lacks Power . 24 Engine Noisy ........ 2-5 Fuel Consumption Excessive .. . 26 Oil Consumption Excessive .. 2-7 Exhaust Smoke Excessive2 PREVENTIVE MAINTENANCE 1. SERVICING OF ENGINE 1-1, General Regular inspection and maintenance is the key to more efficient operation of the vehicle. It is advisable to make judement as to which components are in need of service attention by taking the following inspection anc maitenance procedures into consideration before removing the engine from the vehicle for overhauling. 1-2. Inspection and Maintenance Procedure 1.24, Coolant ‘© Check the level of coolant in radiator by removing the radiator filler cap and replenish coolant if necessary. © Check the pressure valve opening pressure using 2 radiator cap tester. Replace the radiator filler cap if the measured value deviates from the specified value. Pressure val opening pressure (ke/em?] | 0.5 © Flush the cooling system using rain water or city water with cleanser. © With begin of the cold weather season the ‘coolant must be checked with a calibrated hydrometer for sufficient freeze protection and if necessary, antifreeze must be added as described below. ‘Antifreeze solution (14) Freezing Ponit(“c} ~22- 122. Fan belt © Check the belt for fraying or damage and replace with new one as necessary. © Check the amount of fan belt deflection by applying a good finger pressure to the belt between the fan pulley and generator pulley. If the fan belt deflection is incorrect, adjust by pivotting the generator. [___ Fan bet detection fmm] | About 10-15] Ac compressor Water pump pulley Press pulley rank pulley | 1.23. Engine oil © Pull out the oil level gauge rod (oil dipstick), wipe clean and reinsert it. Again pull it out and check the oil level against the level mark If the oll level is too low, replenish with specified engine oil © Check engine oil for deterioration, If engine oil is found to be deteriorated with coolant ‘or fuel, check the cooling or fuel system to establish the cause of deterioration and give necessary service attention. © Replace engine oil at specified intervals or when found to be fouled considerably. To drain, remove the drain plug fom the oil pan while the engine is hot. Also drain the oil filter by removing the drain plug. ; Treva creates tent | CoN see© Lubricants should be carefully selected according to the recommendation. It is also important to select viscosity of lubricants according to the atmospheric temperature by referring to the following chart. ———— ‘Atmospheric temperature | SAE No, -30°¢ ~0°C SAE 10W oc ~30°C SAE 30 30°C ~ 30°C SAE 10W30 1-2-4, Oil filter ‘© Cheok the oil filter for leakage and correct as necessary. © Replace the oil filter element at specified intervals. To replace the element, drain the oil filter ‘through the drain plug hole while the engine is hot, turn loose the center bolt, then remove the filter together with the body. i iter element replacement intervals Gem ‘Same as engine oi! Change intervals 1-25, Fuel filter The fuel filter system is of the two-stage type with a felt element as a primary filter and a paper ‘lement as a secondary element. © Paper element is noncleanable type and should be replaced at every engine oil chang: ing intervals. © Felt element should be cleaned every 5,000 km and be replaced after 3 times of cleaning. 3. Air cleaner © Check the element for distortion or damage and air cleaner body for cracks distortion fr broken seal, Clean, correct or replace parts as necessary. © Clean and replace the air cleaner element according to element manufacturer's intruc- tions. 2 PREVENTIVE MAINTENANCE 1-27. Valve clearance adjustment © After removing the cylinder head cover to measure the valve clearance, No. 6 cylinder valve should be completely opened by turing the crankshaft, Then, the piston in No. 1 cylinder is at the top dead center on com- pression stroke, and adjust the valve clearance of No. 1 cylinder. © After releasing the lock nut to adjust the valve clearance, insert a feeler gauge of specified thickness into the clearance between the valve stem end and rocker arm, and adjust the clearance with the adjusting serew. Fully tighten the lock nut when a correct adjustment is obtained. Leck nut ‘Valve stem Rocker a ‘Adjusting serew ‘© When adjustment of the valves on the No. 1 Js completed, turn the crankshaft 1 full turn ‘and adjust the clearances of the valves on remaining cylinders. Grinder | + [2 ]a]*|s|e Vane elle elsfe arrangemenn || * | aavsment | ole lole Jel olel| ender | | Nore: E.. Exhaust valve2 PREVENTIVE MAINTENANCE © Adjust the clearance of the velves marked with © in the table when the piston in the No. 1 cylinder is held at the top dead center ‘on compression stroke. Conversely, adjust the clearance of the valves marked with @ in the table when the piston in the No. 6 cylinder is held at she top dead center on compression stroke. 1.28. Cylinder compression pressure © Remove the entire nozzle holders after engine warmed up, '# Mount the compression yauge adapter in position of nozzle holder and install the com: pression gauge. © Measure the compression presure in the cylinders with operating the starter motor. ‘Standard value 24 ~ 28Kg/Cm Limit for use 2AKg/Ce? or tess Difference between | +199 or less each cylinder _ Condition: Coolant temperature, 20°C Engine rpm: 200 ¢.p.m. 1-29. Fuel injection nozzle © Check the nozzle injection pressure and spray ing condition and make necessary adjustment at specified intervals. © To make adjustment on the injection pressure, check the pressure with a nozze tester and adjust the injection starting pressure to the specification (214 + § kglem®) with the adjusting shim. =24— 1.2.10, Air bleeding If air is in the fuel system or after the fuel system service has been done, bleeding of the fuel system should be performed, The bleeding ‘operations are as follows, © Turn loose the air bleeder screws on the fuel fitters, and manually operate the fuel priming pump on the fuel feed pump to bleed the air ‘through the bleeder screw. © After checking to make sure that the fuel system is completely bled, securely tighten the air bleeder screw of the first fuel filter and repeat the same procedure for the secondary fuel filter © After bleeding operation, make sure to screw in the fuel feed pump handle,2 PREVENTIVE MAINTENANCE 2. TROUBLE SHOOTING 2-1, Hard-Starting Complaint Cause Correction Trouble in starter circuit Magnetic switch does not work Magnetic switch operates but pinion does not come into ‘engagement with ring gear. Pinion engages ring gear but ‘Trouble in fuel system Fuel not being pumped out from feed pump. ‘when starter switch is turned on. starter motor does not turn over. (1) Wrong connections, wire broken or loosely connected (2) Starter switch points defective (3) Magnetic switch coil open or ‘burned out (4) Plunger shaft bent or binding. (5) Pinion sticking (1) Atmature shaft bearings defective (2) Pinion o ring gear teeth worn excessively or distorted (3) Battery under charged (4) Movement of pinion on shaft tunsmooth (5) Plunger or contactor shaft sticking (1) Pinion eluteh stipping (2) Armature field coil burned out (3) Brushes in poor contact with commutator (4) Battery under-charged (5) Starter motor circuit poorly ‘grounded (1) Fuel tank empty (2) Fuel tank strainer clogged (3) Fuel pipes clogged or aie in fuel line (4) Feed pump valves defective (5) Feed pump piston or push-rod sticking (6) Feed pump strainer clogged Correct Replace Replace Correct or replace Correct or replace Correct or replace Replace Recharge or replace Clean Correct or replace Replace Replace Correct or replace Recharge or replace Correct icon Clean Correct Replace Correct or replace Clean =25-2 PREVENTIVE MAINTENANCE ‘Complaint Cause Correction Fuel not being injected from (1) Fuel filter element clogged injection pump. (2) Fuel filter overflow valve | remaining open | ©) Arintut tite ortat pune | Bed (4) Plunger or detivery valves Corrector replace | sticking Fuel injection timing | (1) Injection pump not properly Correct incorrect. Installed (2) Injection timing ineoreet Correct (3) Cams or camshaft worn Replace \ excessively Injection nozzles not working | (1) Needle valves sticking Corrector replace | (@) Fuel teaking past clearance Correct or replace between nozzle needle valve (@) Injection pressure incorcect Adjust | . _ Compression pressure | (1) Cylinder head gasket broken Replace insufficient (2) Piston, piston rings or eylinder | Replace | tiners worn |G) Piston ings seized up Replace | (4) Valve clearances incorrect Adjust (5) Valves not properly seated Lap valves and | valve seats | (6) Valve stem seized up Replace. | (7) Valve springs) weskened or | Replace | broken 2-2, Engine Runs Rough T Complaint Cause [conection Rough engine idling (1) Inpetion timing incorrect | dust | (2) Injection pipes loosened | Tighten | (3) Injection nozzle defective Correct or replace (4) Volume of fuel injection unequal | Correct (5) Movement of contrl rack Corrector replace sluggish | (8) Operation of plungers Corrector replace | unsmoath |2 PREVENTIVE MAINTENANCE Cause Correction Complaint I | (7) Control pinions not engaged Correct or replace | 7 th contr rack correc | (8) Airin injection pump Bleed Engine runs rough attow and | (1) Governor idling spring binding | Corrector replace medium speed furious) | (2) Gono rng weaning Corrector replace Engine rune at high speed (1) Linkage or cable between Correct and does not stop accelerator pedal and injection pump binding (2) Injection pump control Correct | rack binding 2-3, Engine Lacks Power | Complaint, | Couse _ ____Conreetion Engine lacks power (1) Valve clearances incorrect Adjust continuity | (2) Valve poorly seated Corrector replace (3) Cylinder head gasket defective | Replace | (4) Piston rings worn or sticking Replace | (8) Injection timing incorrect Adjust (6) Volume of fuel delivery Adjust insufficient | (2) Nozze injection pressure | Adis or Replace incorrect or nozzle seized | (8) Feed pump defective | corrector replace (9) Restretions in fuel pipes | Correct (10) Volume of intake air | Service air cleaner insufficient | (11) Cluteh sipping | Adjust or replace (12) Brake deagged just or replace Engine lacks power on | (1) Compression pressure Engine overhaul acceleration insufficient | 2) Injection timing incorrect Adjust (3) Injection pump timer out Corrector replace of funetion (4) Nozzle injection pressure or Adjust or replace spray angle incorrect | (5) Feed pump defective Corrector replace (6) Volume of intake air | Serviee sir cleaner sufficient -27-2 PREVENTIVE MAINTENANCE Complaint Cause Correction Engine overheating (1) Cooling water level too low | ‘Replenish and check for leakage (2) Radiator cap pressure valve Replace spring weakened (3) Restrictions in radiator core (4) Restrictions in oil cooler | | Corract or replace | | (8) Fan bat loosened worn | | | Correct or replace Adjust or replace or broken (6) Thermostat defective Replace (7) Water pump defective Replace (8) Injection timing incorrect Adjust (9) Cylinder head gasket Replace | aetective 2.4, Engine Noisy {tis important to check the engine components systematically to pinpoint the true cause of abnormal engine noise at it generally consists of various noises that arginate in rotating parts, sliding parts ete Complaint Cause Correction (1) Oit elearnaceexceissve due Replace or grind Others (2) Grankshate thrust bearing worn (2) Camshaft end play excessive Replace thrust bearings Crankshaft bearings toworn bearing or erankshatt | crankshaft |) Grankshatt worn out-ofround | Replace or grind | | crankshaft | (3) Restrictions in oil ports | Clean | (4) Bearings seized up | Replace and grind crankshaft Connecting rods o (1) Connecting rod bearings worn | Replace connecting-od bearings (2) Crankpins worn out-ofround | Replace o grind | (3) Conneeting-rd bent Replace Bearings sezied up Replace or grind Pistons, piston pins and (1) Piston clearance excessive due | Replace piston rings | to worn piston and piston } | rings | 2) Piston or piston pin worn Replace |) Piston seized up Replace | (4) Piston rings broken Replace - ___|_# ~~ |S —__§_ | Replace —28-2 PREVENTIVE MAINTENANCE Complaint Cause Correction TG) lle gear end play excessive Replace thrust collar (4) Timing gear backlash excessive | Replace (5) Valve clearances incorrect Adjust (6) Valve seized up within Replace valve gui (7) Valve spring(s) broken Replace (8) Valve seat insert defective Correct (9) Tappets and cams worn Replace (10), Rocker arms and rocker Replace armshaft bent 2-5. Fuel Consumption Excessive Complaint Cause Correction Trouble in fuel syste {1) Injection timing incorrect Adjust (2) Volume of fuel injection Adjust excessive Others (1) Clutch slipping Correct or replace (2) Brake(s) dragging Correct or replace (3) Tire under inflated Correct (4) Gear selection inadequate Select goers according to load 2.6. Oil Consumption Excessive Complaint Cause Correction Oil leakage (1) Clamping parts loosened Tighten (2) Gaskets defective | Replace |) Oit seals defective Replace il leaking past cylinder head (1) Oit plugs defective Replace (2) Valve stems or valve guides Replace worn excessively (3) Cylinder head gasket defective | Replace il leaking into (1) Clearance between piston and Replace ‘combustion chambers Cylinder walls excessive (2) Piston rings and ring grooves Replace worn excessively | (2) Pieton rings broken, worn | Roptace ‘on sticking (4) Piston rings gaps set incorrectly | Correct (5) Piston rings not correctly Correct installed ~29-2 PREVENTIVE MAINTENANCE Complaint Cause | (6) Oil return hates in oi Replace | controt ring ctogged (7)_Air breather clogged Clean 2:7. Exhaust Smoke Excessive Complaint Cause Correction ‘Amount of white smoke (1) Injection timing too late Adjust exhausted excessive (2) Lack of compression pressure | Refer to “HARD | STARTING” |) ater in fet | Replace fuel (4) Oit leaking into combustion | Refer to “OIL | chambers: | consumption EXCESSIVE” | (6) Engine runs coot Correct | (6) Volume of fuet injection Adjust | excessive | (7) Volume of fuel injection Adjust | unequal + ~ ‘Amount of dark smoke Jom Clean or replace ae ae | (2) Glow plug processing defective | Correct or replace (3) Intake hose sharply kinked or | Correct or replace fattened (4) Compression pressure Refer to “ENGINE insufficient LACKS POWER” (5) Fuel injection timing too fast ‘Adjust (6) Volume of fue injection Adjust or overhaul excessive (7) Fuel spray patterns of Adjust or replace ‘nozzles poor (8) Valve clearance incorrect Adjust (9) Use of wrong fuel Replace3 ENGINE ASSEMBLY Section3 ENGINE ASSEMBLY CONTENTS 1. Removal and Installation Steps .........-.6..0 05 1-1 Trucks... 1-2 Front Engine Buses... . 1-3 Rear Engine Buses. . 2. Major Servicing... 241 Disassembly of Engine .... 2-2. Inspection of Major Component Parts .......... 2:3. Reassembly of Engine .....3 ENGINE ASSEMBLY 1. REMOVAL AND INSTALLATION STEPS, 4-1, Trucks 12, Front Engine Buses 1-3, Rear Engine Buses Removal steps 1 2 3. 4, 6. 6. 7, cab tilt Mini-pack 41st propeller shaft, Transmission Cooling fan Engine ‘Clutch Installation stops To install, follow the removal procedure in reverse order. Removal steps 1 2 3. 4 5. 6. 7 8. Bumper Front cross member Radiator grille Radiator Mini-pack 1st propeller shaft Engine with transmission ‘Transmission and clutch Installation stops To install, follow the removal procedure in reverse order. Removal steps Bumper Rear cross member Mini-pack Propeller shaft Engine with transmission Transmission and clutch Installation steps To install, follow the removal procedure in reverse order.3 ENGINE ASSEMBLY 2. MAJOR SERVICING 2-1, Disassembly of Engine 24-1, Oi level gauge © Take out the oil level gauge. 24-2, Engine Oil © Remove the drain plug from the oil pan and drain the engine oil © Also drain the oil filter by removing the drain plug. 2.4.3, Cooling water © Remove the radiator filler cap and the drain plug from the engine block and drain the cooling water completely. 21.4, Cooling fan © Remove fan attaching bolts. © Take off fan and flange. 245, Vibe 146, Engine 1 Loosen the tension adjusting bolts atached on the alternator and idle pulley, and take oft the V-tek [serine J «Lass the ton adusing ol ata fon the air compressor bracket and take off the V-belt ~33- 24.8. Thermostat ‘© Remove the thermostat. ‘© Remove the by-pass and rubber hoses. 24-7, Starter motor © Screw out the starter attaching must and remove the starter. 248, Fudl filter. ‘© Remove fuel hoses, Screw out the filter attaching bolts ard take off the filter.ENGINE ASSEMBLY 21.9, Breather Pipe 02366 Engine — ‘© Loosen the clamp screw of breather pipe. © Remove the breather pipe. 24-10. Alternator © Screw off oil cooler attaching nuts and take off the oil cooler. ‘© Remove the alternator attching bolts and take off alternator. 24-11. Oil Cooter, and oil fitter ‘© Release the pipe clamp on the rubber joint from water pump to oil cooler and from oil cooler to thermostat © Screw out the oil filter attaching bolt and remove the oil filter assembly. __] [02366 Enel © Remove the oil filter from the oil cooler assombly,3 ENGINE ASSEMBLY [(Tozsee ence J3 ENGINE ASSEMBLY a are 7 © Unscrew the cylinder head cover(s) bolts and remove the cover(sh. 24-416. Injection nozzle © Unscrew the fuel pressure pipes at nozzle holders and remove the pipes. ‘© Remove the injection nozzle assembly using special tool ‘© Remove the seal from nozzle holder hole of cylinder head and discard it. 24-46. Turbo charger [ 11467, 02806 T Engine only | \ ae Remove the inlet and outlet ol pipes between erlinder block and turbo charger Loosen. the clamp screw of rubber hose connected to intake manifold Unscrew the turbo charger attaching bolts and remove the turbo charger from the exhaust manifold 2.4.47. Exhaust manifold © Unscrew the exhaust manifold attaching bolts and remove the exhaust manifold from the cylinder head © Remove the exhaust manifold gasket and discard it,24-18. Intake manifold © Unscrew the intake manifold attaching bolts and remove the intake manifold from the cylinder head, '® Remove the intake manifold gasket and discard it 21-19, Cooling water pipe © Unscrew the cooling water pipe attaching bolts and remove from the cylinder head. © Remove the cooling water pipe gasket and Clean the surface using a suitable scraper. 244-20, Rocker arm © Remove attaching bolts for rocker arm brackets and take out locker arm assembly (© Take out push rods upwards. 3 ENGINE ASSEMBLY 24.21. Cylinder head ‘© Remove the cylinder head bolts by loosening them in sequence in two steps, Note: Always loosen bolts in progression and avoid loosening bolts in localized area, or cylinder head distortion may result © Take off cylinder heads) and gasket). © Unscrew the oil pan attaching bolts and remove the oil pan ‘@ Remove the oil pan gasket and discard it -37-3 ENGINE ASSEMBLY 24-23. Vibration damper ‘© Unscrew the vibration damper attaching bolts in reverse sequence of installing order and ‘remove the vibration damper assembly. 24-24, Timing gear case cover © Unscrew the timing gear case cover attaching bolts, and remove the timing gear case cover 24-26. Oil pump =38- © Unscrew oll suction pipe bracket fixing bolts ‘© Unscrew the bolts fixing oil suction pipe and remove the oil suction pipe, © Unscrew the bolts mounting the oil pump, then take off the oil pump assembly. 24.26. Piston © Unscrew the bolts clamping the connecting rod bearing cap in reverse sequence of installing order. © Take off connectingod bearing caps with bearing shells. © Remove combustion residue from upper edge of cylinder liner to facilitate smooth with drawed of the piston, © Remove the piston and connecting-rod assembly toward cylinder head side by pushing on the connecting-rad big-end with 2 hammer handle. © Remove the bearing from the connecting od and bearing cap, then apply @ cylinder ‘number mark to the rear face of the bearings‘Note: Remove connecting rod in parallel with cylinder bore to prevent scratching liner wall in contact with connecting rod. 21.27. Cylinder Liner ‘© Pull out the cylinder liner using the cylinder finer extractor or by hand carefully so as not to damage the cylinder bore. ‘© Number cylinder liners-according to installed position 24-28. Gear and idle gear pin ‘© Unscrew two bolts fixing the idle gear, then remove the idle gear with thrust washer. © Unscrew the bolts mouting the camshaft ‘gear, then remove the camshaft. © Take off the idle gear pin. 2:1-29. Fuel Injection pump, © Remove the joint bolt and nut on the Injection pump oil pipe, then remove the clip and oil pipe, 3 ENGINE ASSEMBLY © Unscrew the coupling flange attaching bolts and nuts using two wrenches. © Remove the bolts mounting the injection pump, then remove the injection pump upwards © Unscrew the injection pump bracket attaching bolts, then remove the bracket tapping the ‘upper and lower edge of bracket with a plastic hammer, 21-30. Injection pump drive gear. -39-3 ENGINE ASSEMBLY ‘© Unserew the bolts fixing the injection pump drive gear housing and remove the drive gear assembly. 2-41.31, Timing gear case ‘© Unscrew the bolts fixing the timing gear case, ‘© Remove the timing gear case tapping the rear side of ease with a plastic hammer. 2.1.32. Cooling water chamber cover ‘© Unscrew the chamber cover attaching bolts and remove the chamber cover. © Remove gasket residue on the both side of cylinder block and chamber cover using 2 scraper. —40- 2433, Flywheel © Remove the bolts fixing the flywheel by Joosening them in diagonal sequence. ‘@ Remove the flywheel. 21-34, Flywhee! housing '* Remove the bolts attaching the flywheel housing, then remove the flywheel housing by tapping lightly with @ copper or plastic hammer. © Remove the oll seal retainer in the flywheel housing, then remove the oil seal.24.35. Bearing cap, '® Remove the crankshaft bearing cap bolts by loosening then in sequence commencing with the outer ones, then remove the bearing caps together with the bearing. '® Number bearing caps. 24.36, Crankshaft., ‘© Tighten bolts temporarily on the both side of crankshaft © Carefully tft out crankshaft with a rope. © Take bearing shells out of cylinder block and ‘mark ther. 2.4.37. Camshaft & tappet ‘© Romove camshaft by carefully siding it out the front of the engine. Do not force shaft ‘as damage can occur to camshaft bearings. 1 Take the tappets out of cylinder block. 21-38. Oil spray nozzle [011467 02366T Engine Only 3 ENGINE ASSEMBLY © Spread retaining washer of the bolts flxing oil spray nozzle. © Unscrew the bolts and remove the oil spray nozzle. 2-2. Inspection of Major Component Parts 22-1, General precautions © Prior to inspection, correction and adjust ‘ment, wash clean the parts to remove dust, carbon, oil, grease, rust, scales, ete © Remove carbon from the pistors, cylinder head, valves, etc. using care not tosseratch the parts particularly aluminum alloy parts © Clean the oil ports with compressed air and check that they are free from restr ctions. © Apply a cylinder number mark to ‘he valves, bearings, pistons and connectingrods from each cylinder and keep them separate to prevent interchanging 22:2. Cylinder block © Check the cylinder block for cracks or damage visually or by using a magnetic flaw detector for by making a hydraulic test. Correct or replace the cylinder block as necessary. 22:3, Cylinder head assembly (1) Removal of vaives and valve springs © Apply cylinder number mark to the head of each valve.ENGINE ASSEMBLY © Install special tool, valve spring compressor on the cylindér head. © Compress the valve springs and remove the cotter pin, valve spring, valve spring seat and valve, ‘© Remove the valve stem seal © Place tool on the upper side of valve guide and drive out valve guide by hammering. (2) Inspection of cylinder head, © Carefully remove carbon from lower face of the cylinder head to prevent scratching of valve seat faces. © Check the entire cylinder head for cracks and damage using a magnetic flaw detector. When necessary test for water leaks with a hhydrautic tester by applying a pressure, r a 7 Hydraulic test on evinder , | nas (1 minute) (eglem?) | © Check the lower face of the cylinder head for distortion in six directions using a straight ‘edge and a feeler guage as shown in figure. If the amount of distortion is beyond the standard value, correct with a surface grinder. If the amount of distortion is beyond the limit of 0.3 mm, replace the cylinder head. [Ton eheome Toor [Smorionaraye [Voie ndesting [Sama | ated or avin ae for | inde ted tower | face fmt |_| o2ormore | 005 -42~ a * Check the joining face of the intake and ex: haust manifolds for distortion in the same manner as used for checking cylinder head lower face for distortion. If the amount of distortion is beyond the standard value, cor rect with a surface grinder. Distartion ot | Value indicating | Standerd ‘manifold joining | need for | val for face of eylinger’ | Servicing | sorb head ‘Trl | o4ormore | 0.08 or | ‘ (3) Inspection and correction of valve | ‘© Replace the valve if reduction in diameter of the valve stem due to wear, is beyond the specified limit. Slight step wear in the valve stem can be corrected with an oil stone or valve refacer. Replace the valve together with the valve guide. Vive storm wear Nominal amt diameter | Limit for use — " 011468 |inake valve) 8.95897 | 8.93 ENG TExhaut | gaas.e.ss | eet intake valve 0.960.10,870] 10.87 2366 ENG ExhaustStem end Position of measurement © Measure the thickness of the valve head, Replace the valve if the amount of wear is beyond the specified limit. | engine | Hompinal | Limit for use | tctoss [orras|im. | 22 | 10 feed imi] ENG fen] 2a | 10 ozae6]im. | 15 | 10 ENG acs © Check the inner wall of the valve guides for wear. Compare the measured velve gi inside diameter with the valve stem diameter to determine the amount of wea If the clearance is beyond the specified limit, replace the valve guide together with the valve. Giearance between valve guide | value inacating | stendard value 208 em [vl |r OF vig] Torey A6.or more_ 068 | 0.15 or more [0.088 ~0.080 onrss: ENG. | 02366 | inteke [0.15 0rmore | 0.030 ~0.065 ene Exnaut [0.18 or more | 0.048 ~0.080 Le [OB ormore 10.045 ~0.08) | 3 ENGINE ASSEMBLY (4) Inspection and correction of valve seats Depression Projection © Install the valve into the cylinder head and check the amount of projection of the valve from the cylinder head fitting surface using 4 dial gage. If the amount of projection is beyond the specified limint, replace the valve seat insert. Projection (mm)) for assembly use Exhaust | 003 ‘© In order to remove the valve seat, apply are: welding work to two points of valve seat insertJLENGINE ASSCMDLY Ccvinder hea Welding bead Pull out valve seat insert with inner extractor. © Wipe clean the valve seat mounting face on the cylinder head, © Undercoo! new seat with dry ice for about 2 hours and press the valve seat insert into position with a bench press by applying a pressure, © Apply valve lapping compound to tre seating face of the valve and Jap the valve seat using ‘valve lapper with suction head, Continue lapping operation until standarc contact width is obtained and impression of uniform contact is well centered on the valve seat. {5) Inspection of valve spring ‘© Visually check the valve springs for damage and replace as necessary. | | | ) © Measure free length of the valve springs with vernier calipers and replace the spring it measured value is beyond the limit. _ _ ‘Standard valve Limit for use ‘Valve Springs: _ for assembly. . | Remark 1146 L 02366 D146 02366 | | "yoies [ite | omar | | Freeiengts mm) = | gg | 58 | 4 set length) | | 02366: 37mm _ : fo | Les aor | Deviation trom ‘vertical (men) ~ - re | outer | inom compressed 627 oe 1146: 41 men ‘Spring th) ~63.9 83 | 67.7 oa 02366: 34 mm vive Awhen free) — | al Free length (mm 0 | 6175 Z | tener (when comprestes.co | 27.2 aoa | 1146: 38 mm pe ft lenth of 38 mm) 262 36102366. 37 mm | {end bnren tee) al =44-(6) Reassembly of cylinder head assembly. © Clean cylinder head. © Press in new valve stem seal in valve guide using special tool © Apply engine oil to valve stem and valve guide, ‘© Install valves in their respective guides carfully 0 as not to damage the valve stem seal 3 ENGINE ASSEMBLY Install the valve spring lower seat in position fon the valve gulde of cylinder head. Install the valve springs and valve spring ‘upper seat Install and fix special tool, valve spring compressor on the cylinder head, then compress the valve springs and install valve cotters. ‘Check valves and valve springs to be sure they are properly seated by tapping slightly with a plastic hammer. 2-2-4, Rocker arm shaft assembly (1) Disassembly of rocker arm shaft assembly © Remove snap rings from the both sides of rocker arm shaft. © Remove the washer, rocker arm, bracket and spiing from the rocker arm shaft in the order. ~45- ‘© Press out the rocker arm bush as necessary.ENGINE ASSEMBLY (2) Inspection and correction of rocker arm shaft assembly, ‘© Support the rocker arm shaft on V~ blocks at its ends and check the amount of run-out at the center part using a dial indicator. If a slight amount of run-out is noticeable, correct with a bench press without applying heat. Replace the rocker arm shaft ifthe amount of run-out is beyond the specified limit. — Rocker arm shaft run-out (mm) value indicating nged for servicing [omer | | 02366 ENG = © With an outside micrometer, measure the rocker arm shaft diameter at 12 portions on which rocker arms are installed, Replace the rocker arm shaft if the amount of wear is beyond the specified limit, ~46- —Rocker shaft wear Limit for Standard valve 01146 ENG | for assembiy se as | 02268 ENG [3 og a 23978 ~ 23959 © Visually check the face of the rocker arms in contact with the valve stem end for scores and step wear and correct with an oil stone as necessary. Rocker arm with a considerable ‘amount of step wear should be replaced (© Measure the inside diameter of the rocker arm ‘bushing and compare the measured value with the rocker arm shaft diameter to determine the clearance. If the amount of clearance is beyond the value indicating need for servicing, replace either the rocker arm shaft or the bushings. Clearance between rocker arm shaft and bushing (mm) ‘Standerd valve] Value indicating for assembly | need for sevricing 1146 ENG 2366 ENG | G99 ~0.089 Abnormal contact ‘© Visually check the face of the tappets in con tact with the eam for pitting, scores or cracks and replace as necessary.© Measure the diameter of the tappets with an outside micrometer. If the amount of wear is beyond the specified limit, replace the tappets. Standard value | Limit for Tappet wear | for eszembiy use (mm) | 1.9¢4~19,965| 19.75 ‘© Check each end of the push-rods for wear or damage and replace as necessary. © Roll each pushrod on a surface plate and check for bending using a feeler gauge Replace the pushrod if the amount of bending is beyond the value indicating need for servicing, Bending of value indicating push rod for servicing (eam) 03 3 ENGINE ASSEMBLY (3) Reassembly of rocker arm shaft assembly. © To reassemble, follow the disassembly procedure in reverse order and note the following points: Note:1. Clean oil ports in the rocker arms and rocker arm shaft and check that they are free from restrictions. 2 Apply engine oil to rocker arm bush: ings before installation. 3 Install the rocker arm shaft brackets in ‘correct position. 2.25. Camshaft Assembly (1) Measurement of camshaft end play. ‘© Hold the thrust plate depressed against the camshaft gear. © Measure the clearance between the thrust plate and side face of the journal © Replace the thrust plate if the clearance is ‘beyond the limit. ‘Camshaft end] —Standerd value | Limit or play (mm) | for ssimbiy the orasenc | 0.28~o3 os 02366 ENG | 0.13 ~0.27 03 (2) Inspection and correction of camshaft. © Visually check the journals, and cams for wear or damage and replace the camshaft as necessary, -47-3 ENGINE ASSEMBLY (© ‘Slight step wear or damage on the cam face may be corcected with an oil stone, © Measure the cam height with a micrometer and replace the camshaft if the measured value is beyond the specified limit, © With an outside micrometer measure the journal diameter of camshaft. (© Measure the inside diameter of the bush on the cylinder block with a cylinder bore gauge and compare the measured value with ‘the journal diameter to determine the clearance. ‘© Replace the camshaft bush if the clearance is beyond the limit, Beweed Seanga Tum) rma and bam] Standard waive [Limit tor Team” | for assy [[oasee sno [oeso~orse | om] © Support the camshaft on V— blocks at its ends and check for runout using a dial indicator. Small amount of run-out may bbe corrected with a bench press without applying heat. Replace the camshaft if the amount of run-out is beyond the value indicating need for servicing Camshaft run-out (mm) 0.1 oF more. 2:26. Crankshaft (1) Inspection and measurement of crankshatt. ‘© Check the crankshaft journals an erank pins for wear or damage. © Check the crankshaft for cracks using a magnetic flaw dotector or red check as necessary, ‘© With an outside micrometer measure the diameter of the crankshaft journals and crankspins in 2 directions A and B at the frontand rear portions | and il ard compare ‘measured values to determine the amount of wear. If amount of wear is beyond the limit, have the crankshaft groune and install tundersize bearings. ‘rank sat juroal and Standard value pinelameter Imm) | far asembly ; i | sourna! | 82,966 ~23.988 1146 enc} —— [ein | 70.971 ~70.990 bt | Uneven wear tmp | Wasinating | is + 4 ed for servicing |" piv a 1 aoe | oar wzus ene | sow | gy | -49- 3 ENGINE ASSEMBLY Note: 1. When reworking crankshaft to under- size, the fillet section R should be finished correctly. If R is too small the crankshaft may break and if too large, interference may be caused to the crankshaft bearing. Standard value oR Pin 48. Journal 40 abnormal 2 Whenever @ new or reconditioned crankshaft is installed, new connecting rod bearings and main bearings should be installed. fF |_ll ‘© Support the crankshaft at its ends on the crankshaft aligner or on V— blocks at the No. 1 and No. 7 journals. Turn the erank- shaft slowly in one direction with the probe of a dial indicator resting on the No. 4 journal and take the highest reading of the indicator. When amount of run-out is beyond the value Indicating need for servicing, correct or replace the crankshaft. | Standara volve | Limit for run-out 1146 ENG 102366 ENG.3 ENGINE ASSEMBLY (2) Inspection and measurement of crankshaft bearing and connecting rod bearing. © Check the contact surface of crankshaft bearing and connecting rod surface for scoring unever wear or damage. © Install the bearing on the cylinder body ‘and on the bearing cap and tighten the bolts to specified torque, then measure the inside diameter with a cylinder bore indicator. © Install the bearing on the connecting-rod big: tend and tighten the connecting-rod cap bolts to the specified torque then measure the inside diameter with a cylinder bore indicator. © Compare the values obtained through meas ‘urement of bearing inside diameter and out: side diameter of crankshaft jounals and ccrankpins to determine the clearance, {f the clearance deviates from the range specified, hhave the erankshaft ground and install under- size bearings. [Citcewace ore! Stondord vai [ Value indicating] tmecankeuat'nd | for asombly_| fr servicing een Be | 01146 ene | 0.052 ~0.122 025 2366 ENG | 0.072 ~0.142 0.25 —_| Note When installing undersize bearings, have the crankshaft journals and erankpins ground to size indicated in the following table: Dias ENGINE a Bearing | of crank journals | of crankpins after grinding | after grinding on) 83.966 ~85:988 | >9971 ~70.980 83.716 ~83.738 | 70.721 ~70.740 70.471 ~70.490 S050 | 3.466 ~89.480 | is0.75 | 63.216 ~83.238 | 70.221 ~70.240 COutsice diameter | Oustside diameter of crane journals | of erantpins Steergringing | after genaing tenn! rm Bearing 95.966 ~95.088 | 92.966 ~82.988 | [_uso.2s | 95.716 ~98.738 | 62.716 ~82.738 | |_uisoso | 95.455 ~95.088 | 92.456 ~82.488 | 180.75 | 96216 ~96256 | ez2ve “e208, vis 1.00 | 94.966 ~94.988 | 81.868 ~81.988(3) Measurement of bearing clearance with a Plastigauge Position the cylinder body with the erank: shaft side up, Wipe clean the crankshaft journals and inner and outer faces of the bearings to remove all oil. © Install the bearings on the cylinder body and position crankshaft over the bearings care fully. © Turn the crankshaft about 30 degrees to bring the crank journals into good contact with the bearings. © Position a Plastigauge (PG-1) over the crank journal to cover the full width of the bearing © Install the bearings in the bearing cap and tighten the bearing cap bolts to specified torque. ‘© Remove the bearing cap and remove flattened Plastigauge. Check Plastigauge width against the scale printed on container. Kinds of Pastignuge | Clerance measurable | timmy | |_ type Pat beat 0.981 ~0.152 | type P61 tive) 0102~0229 [vee Po lreend 0.025 ~.075 3. ENGINE ASSEMBLY (4) Inspection of bearing spread and crush © Check to see if the bearing had a slight spread, If itis necessary to force the bearing into the bearing bore, the bearing is normal © Install the bearings into their housings and the bearing caps. © Tighten the bearing cap retaining bolts to the specified torque, then loosen the bolts on one side completely. © Insert a thickness gauge between cap and housing on loosened side. © If an appropriate crush is not provided, replace the bearings.S_ENGINE ASSEMBLY | Bearing Crush (mm) Standard valve | Crankshaft 0.19 ~0.22 bearing | ores enc [2 con roa e | ae 03 ~05 | — Crankshott | | eee 0.15~0.25 2366 ENG |} | Con Roa | Bearing 03 ~05 Crankshaft bearing Connesting-roa Bearing Besring (5) Inspection of crankshaft end play © Install the crankshaft on the cylinder body. '* Measure the end play at the end of cranks! using a dia indicator. © If the clearance deviates from the specified range, replace the thrust bearing. [crank Shate [semezr | Limit for use ft End Play (mmi] for assembly | 1148 eng | 0.15 ~025 os | 02366 ena | 0.15 ~0.228 os | 22-7. Piston assembly (1) Disassembly of piston assembiv '® Remove the piston pin snap rings using snap. ring pliers ‘is © Heat the piston using an electric heater, then take out the piston pin from the piston using 2 brass bar. Note Keep piston, piston pin and connecting rod from each cylinder separate to prevent interchanging.© Remove the piston rings using a piston ring ‘expander. © Throughly clean the pistons. (2) Inspection of Pistons ‘© Check the pistons for cracks, scuff and wear, paying particular attention to the riston skirt. Replace the pistons as necessary, ‘> With an outside micrometer measure the piston diameter at a point 18,0 mm away from the end of piston skiet in cirection at aright angle to the piston pin hole. — ‘© Measure the bore diameter of the cylinder liner at 3 portions such as top ring contact area, center area and oil ring contact area when the piston reachs bottom dead center in 45° directions respectively. ‘Among the obtained values, omitt the largest value and the smallest value and take an average value. © Compare the average value with the piston diameter to determine the clearance Replace the pistons or cylinder liners, if the clearance is beyond the specitied rarge. 3 ENGINE ASSEMBLY — Clearance between piston and cylinder Hiner wall, | stendara value | Limit for for assembly se 01146 ENG | 0.051 ~0.294 2368 ENG | 0.041 ~0.221 03 (3) Inspection of piston rings © Replace the piston rings with new ones when found to be worn or broken or when the engine is overhauled, a —____} Insert the piston ring into the cylinder liner bore and push it to the upper portion of cylinder liner, so that itis held ata right angle to the cylinder liner wall ‘© Measure the piston ring gap with a fecler gauge and replace the piston rings with new Cones if the gap is beyond the limit. Standard valve Limit for Piston ring gap (mm) | Henaera wlee Line 11146 ENG 1° com: pressionring 240068 | 16 2nd com 2966 ENG pression rng ___Jouens—[ o4o~o0s| 15 030~o60| 153 ENGINE ASSEMBLY © Clean the piston ring groove throughly, and place the thickness gauge on the surface of the ring and insert the two together into the groove. © Take measurement at several portions around the circumference of the piston, © If the clearance is beyond the limit or if the faces of the ring grooves are roughened, preventing normal ring to groove face contact, replace the piston, © Pay close attention to the oil ring groove when checking the ring grooves in the pistons. Clearance between piston fing 208 ring 9004 (mm) Standard waive] i for asiembly | for use i T | pitas eng "st eo" an | erersion ring | paces eng 2ndcom | 9.97~0.102| 0.18 | | | tring 0.07 ~0.085| 0.18 | (4) Inspection of piston pin, © with an outside micrometer, measure the dia meter of the piston pins at several portions Replace the piston pin if measured value is beyond the limit [Piston pin diameter] Vaive indicating mead im forwvcirg | ore ENG 0.08 | 02266 ENG Measure the inside diameter of the bushing 005 with a cylinder bore indicator and compare measured value with the piston pin diameter to determine the clearance. If the clearance is beyond the limit, replace either the connecting-rod bushing or the piston pin. — Clearance between connecting rod small TI fend bushing and piston pin (mm) Standard vale Lint foruse 01146 ENG | 0.08 or mare 0.05 ~o081 The piston pin fitting interference may be regarded as normal when it can be fitted into the piston with finger pressure after heating the piston to about 120°C with piston heater.(5) Inspection of connecting rod. © Check the connecting-rod for distortion between the smallend and bigend using ‘connecting-rod aligner. Ifa rod is twisted or bent, a new rod must be installed, no attempt should be made to straighten connecting rods, © Install the connecting-rod on the crankshaft and check clearance between the bigend side face and crankpin side face using a feeler gauge. If the clearance is beyond the limit, replace the connecting-rod, — Clearance between connecting rad big end side face and crank pin (ram) ee Limit for use DIAS ENG, D2366ENG 0.5 ‘© With the connectingrod assembled to the piston, check the end play between the piston bboss and connecting-rod small-end side face using a feeler gauge. If the clearance is excessive, replace either the connecting-rod or the piston, — Clearance between connecting-rod small end and piston boss. (mm) ‘Standard value | Limit for for assembly use | 01146 enc | 0.17 ~o.248 [os ozesenc|o22~os19 | 0s (6) Reassembly of piston and connecting rod assembly ‘© Heat the piston to about 120 ~ 150°C with a piston heater. 3 ENGINE ASSEMBLY Apply engine oil to pin hole and pin, then set piston to connecting rod and insert piston pin into piston, © Secure the piston with the snap ring ‘© Install the oil ring, second ring and top ring fon the piston in the order described using a piston ring expander, o that their faces with ‘TOP mark are tunred up. ‘© When the rings are installed, apply engine oil to the entire faces and check that each ring turns freely within the ring groove. ‘© Measure weight of each piston and connec tingrod assembly and compare measured values to see that variance in weight is within the specified limit. — Variance in weight of piston and connecting od assemblies (8) Standord vale for erly 01146 ENG, 02068 ENG | Less han 56 2:3, Reassembly of Engine 2-3-1. Engine reassembly precautions ‘© Wash clean disassembled parts, particularly oil ports using compressed air, then check that they are free from restrictions. ‘© Apply new engine oil to the inner wall of the cylinder liners, sliding and rotating faces of the pistons and bearings before installation. © Discard used gaskets and seal rings and install new ones at assembly Use liquid gasket as needed to prevent leakage of oil and water. Do not use liquid gasket on asbestos beater sheet gaskets. © Check clearances as the parts are assembled. —55-2 ENGINE ASSEMBLY © Use only the specified torque for bolts and studs clamping aluminum alloy parts and avoid over-tightening. © Use a torque wrench for tightening parts for which torque value is specified. Where specific torque value is not indicated, the parts should be tightened according to the torque specification table. 23-2. Oil spray nozzle [_ 011467, 023667 Engine only © Instalt the oil spray nozzle in position on the cylinder block and tighten the bolts. © Bend the retaining washer down using a plier, Note Alnays.use a new retaining washer. 23:3. Camshaft and tappet. When replacing the camshaft bush cool new bbush in dry ice for 2 hours, then press the new bush in place of cylinder block. © After installing new bush measure the inside diameter of the bush. If any, discrepancy is found replace the bush again. © Apply engine oil to the tappet holes and the tappets, then install the tappets in cylinder block. ~56- © Apply engine oll to the cams and journals of camshaft and the camshaft bush, then install ‘the camshaft in position on the cylinder block. Note When installing camshaft, exercise care not to scratch camshaft bearings. © When the camshaft is installed, check that the camshaft turns smoothly. 23.4, Crankshaft. © Install the bearing cap locating rings in position on the cylinder block, block and front and rear faces of the bearing © Position upper half of main besrings in cylinder block and lubricate with engine ol © Install the crankshaft in position on the cylinder block carefully. © Place bearing shell and thrust washer in bearing cap. © Install caps with lower half of bearing lubricated with engine ol© Lubricate cap bolts with engine oil and Install, but do not tighten. © Tighten cap bolts in following manner in sequence of bearing cap number, 4:3-5-2.6-1-7 commencing with outer ones. Tighten the entive bolts evenly to a torque of 15 kgm, then retighten them to a torque of 25 kg-m Finally tighten the cap bolts to the specified torque. [swim cote ton [a] 2:35. Flywheel housing © Press new crankshaft rear oil seal lubricated with engine oil in the flywheel housing, then instal oll seal retainer with gasket and tighten the nuts | the circular groove is found on the oil seal contact surtace of crankshaft install an 1mm thickness shim in front of oil seal and measure it then instal the oil seal ‘© Position the fly wheel housing gasket on the cylinder block. © Position the flywheel housing gasket on the cylinder block. © Install the flywheel housing on the cylinder block by aligning with 2 guide bar, then install and tighten the bolts to the specified torque. 23.6. Flywheel 3_ENGINE ASSEMBLY © Install the flywheel on the crankshaft by aligning it with a guide bar. © Coat the flywheel attaching bolts with #271 Locktite and install the bolts. © Tighten the flywheel attaching bolts to the specified torque in diagonal sequence as shown on the figure Flywheel bolt torque (kom) | 21.8 —___| 23-7. Cooling water chamber cov © Apply sealer to the gasket sealing surface of the water chamber cover and install the gasket on the water chamber cover. © Install the water chamber cover with gasket fon the cylinder block tighten the bolts to the specified torque, 2:38. Cooling water pipe [ba868 ENG ony © Install the cooling water pipe between the water pump and oil cooler with pipe clamps, and tighten the bolts © Install the cooling water pipe between oll cooler and water chamber cover, and tighten the bolts.3 ENGINE ASSEMBLY Install the rubber hoses to the pipes with clamps, 2.3.9. Timing gear case. © Install_new timing gear case gasket on the cylinder block. Install the timing gear case by aligning it with locating pin and hole, then tap the timing gear case with a plastic hammer Tighten the bolts to the specified torque. 23-10. Injection pump drive gear © Install new drive gear housing gasket on the drive gear housing, then Install the drive gear hhousing on the timing gear case with nuts. © Install the drive gear by tapping lightly with a plastic hammer. ‘© Install the nut with lock washer and tighten the nut to the specified torque. © Insert the key to the groove of the injection pump drive shaft 23-11. Timing gear and idle gear pin, © Install the idle gear pin with the oil port pointed towards the oil pan using a guide ber. © Install the camshaft thrust washer on the timing gear case, then Install the cam gear by tapping with a plastic hammer. © Tighten the attaching bolts in diagonal sequence to the specified torque. - aw LoS ~(O\ ((Uswertar® 97 Ngee om) NS AL ae” OY) Crankehat goer‘© Install the idle gear, so that the marks on the idle gear are aligned with marks on the camshaft gear and the crankshaft gear respectively © Install the thrust washer on the idle gear and install and tighten the bolt to the specified torque. ‘© When installing the timing gears in position, chock the amount of backlash between gears using a thickness gauge. If the amount of backlash is beyond the specified value correct iv — Amount of backlash (mm) Cam gear and ie gear 016 ~0.28 1146 | Crank gear and o16~o28 ENG bees — a Injection pump drive | 0,16~0.28 | ser na te gear ‘cam gear and a | aman 015 ~0.25 Crank gear and late gear I 02366 015 ~0.25 ENG Injection pump drive | sear nd al pe oss~o25 | 3 ENGINE ASSEMBLY 2:3-12, Injection pump. © Install the injection pump mounting bracket with shim between bracket and cylinder block and tighten the bolts. If the thickness of the original shim is not correct, determine which ‘new thrust washer is to be used, There ace 4 kinds of shim for adjusting the horizontal alignment such as 0.1mm, 018mm, 0.2mm and 0.6mm and 3 kinds of shim for adjusting ‘the vertical alignment such as 0.1mm, 0.2mm ‘and 0.3mm in thickness. ‘© Position the injection pump on the bracket, then install and tighten the bolts to the specified torque. © Rotate the flywheel in direction of rotation until the mark on the Vibration damper to cated at the front of engine aligns the pointer. ‘© Align the pointer on injection pump with the line on timer and couple the injection pump to the coupling drive shaft. @ Then check the alignment of coupling drive3 ENGINE ASSEMBLY shaft and injection pump. Hf the alignment is incorrect remove the Injection pump and the injection pump mounting bracket again, then replace the shim with correct one and reinstall the ‘mounting bracket and the injection pump. © Install and tighten the coupling joint bolt Using two wrenches. 2.3.13, Cylinder liner © Throughly clean the cylinder liners and blow away dust and water by applying compressed air. © Insert the cylinder finer into cylinder block and push the cylinder liner applying pressure by hand. © Apply engine oil to the inside of cylinder liner. Note Be careful that the foreign matter is entered under the Cylinder liner flange, ~60~ 23-14, Piston © Apply engine oil to pistons and connecting rod bearings. ‘install piston ring compressing tool on piston, then install each piston and rod in its respective cylinder bore. Note ‘Make sure that rings are installed with “Y” mark turned up. © The gap of each piston ring should be Positioned so that it is 120° opposite that of the preceding ring, as shown on the figure. Too ring ooo OOS | I) Piston oi | oitringooe YE ~ Piston \ 2nd ving we | * Push the piston, into the cylinder until the connecting-rod bearing is brought into contact with the crankpin using care not to scratch the cylinder Liner wall © Push further in on the piston and turn the erankshaft while the connectingrod big-end ‘ides on the crankpin. Continue to push in on the piston head until the crankshaft pin is in the bottom most position, corresponding to the bottom dead center of the piston,© Align the mark on the connecting-rod bearing ap with that on the connecting-rod, oil and install the bearing cap bolts, and then tighten the bolts to a torque of 10 kgm, then fetighten them to a torque of 15 kgm. Finally tighten the bolts to the specified torque. re | Con-rod bearing 1146 ENG capbott kom) | 5096 ENG I ns Ranenniennnes nae ‘© When the connecting rod bearing cap bolts are tightened, check the connecting rod bearing end play with hand. If no end play is found, remove and reinstall the connecting rod bearing cap. 2.3.18. Oil pump © Install the oil pump assembly in position on #7 bearing cap, by tapping’ slightly with a plastic hammer 3 ENGINE ASSEMBLY ‘@ Install the oi! pump mounting bolts with locking washers and tighten the bolts to the specified torque. ‘© Bend the locking washer towards the bolt 10 prevent from loosening ‘© Connect the ol pipes to the oil pump. 02366 ENG Only | "Install oil pipe bracket on the eylinder block and bearing cap. 2.3.16, Water pump. © Apply a thin coat of sealant evenly to both ‘aces of the gasket, then fix it to water pump. © Install the water pump on the eylinder block ‘and tighten the bolts to the specified torque. 2.3.17. Timing gear case cover © Apply engine oil to the oil seal bore of the timing gear case cover using a brush.3 ENGINE ASSEMBLY © Install the vibration damper on the crankshaft, then tighten the bolts in numerical sequence shown on the figure to the specified torque. © Press new oil seal in place of timing gear case carefully, 23-19. Oil pan ‘© Fix new timing gear case gasket to the timing ‘© Remove gasket residue on the fixing surface gear case. of timing gear case, case cover, flywheel housing and cylinder block, using a scraper. © Coat the gasket fixing surface with silicon arease and position new oil pan gasket. © Install the timing gear case cover by topping slightly with a plastic hammer. 23-18. Vibration damper © Install the oll pan on the cylinder block and a! tighten the bolts to the specified torque. D1146 ENG Only ] 2:3-20. Oil filter, and oil cooler. D1146 ENGINE ~62-© Install the oil filter on the cylinder block Using new gasket and tighten the bolts in diagonal sequence to the specified torque. © Install the o-ring coated with grease in the cil port of the oil cooler housing, Note ‘Make sure that the o-ring does not spring out of the groove. ‘© Install the oil cooler assembly on the cylinder block and tighten the nuts to the specified torque. © Connect the cooling water pipe between oil cooler and water pump, and tighten the clamps securely. 02366 ENGINE © Replace the oil filter element © Install new o-ring in the groove of the oi! cooler housing and Install the oil filter housing on the oil cooler by tightening the center bolt 3 ENGINE ASSEMBLY Note Make sure that the oil filter housing does not turn together with the center bolt when tightening the center bolts. If it does, the O- ‘ing is at to spring out of the groove. © Install the O-ring coated with grease in the oll port of the oil cooler housing, © Install oi! cooler assembly on the cylinder block and tighten the bolts in diagonal sequence to the specified torque. 23-21. Starter © Mount the starter assembly on the flywheel housing and cylinder block, then tighten the starter mouting bolts to the specified torque. 23-22. Cylinder head © Clean the bolt hole with compressed ai ‘© Throughly clean the upper face of the cylinder block: (on the cylinder block3 ENGINE ASSEMBLY Tighten the entire bolts evenly to a torque of 10 kgm, then retighten them to a torque of 18 kgm Finally tighten them to the specified torque of 22.0kgim. 2366 ENGINE © Install new cylinder head gasket(s) on the cylinder block by aligning the holes with the dowels. oe © Tighten the entire bolts evenly to a torque of 15 km-m, then retighten them to a torque 20 kgm, Finally tighten them to the specified torque of 24.5 kgm 23:23 Rocker arm © Install the push-rods coated with engine oil in the cylinder head. © Install the cylinder head assembly on the cylinder block by aligning it with dowels. © Clean the cylinder head bolts and dip in engine oil, then install them on the cylinder head. ‘© Tighten the cylinder head bolts in following ‘manner as shown in figure. D146 ENGINE 7 © Install the rocker arm shaft assembly and align the end of the racker arm adjust screw with the push rod, then tighten the bracket ‘bolts in diagonal sequence to the specified torque. —64-3 ENGINE ASSEMBLY © Adjust valve clearance as following procedure; 1) Bring the TOC mark on the crankshaft pulley into alignment with the gear case by turning the crankshaft, then check the state of the rocker arms on No, 1 cylinder to see in which cylinder the piston is at the top dead center on compression stroke. Note When both the intake and exhaust valve rocker arms are in free state, it indicates that the piston in that cylinder is at the top dead center on compression stroke. 2) Perform valve clearance adjustment oper: ation commencing with the valves on the Cylinder in which the piston is at the top dead center on compression stroke. Insert 2 feeler gauge of specified thickness into the clearance between the valve stem end and rocker arm and adjust the clearance with the adjust screw. Fully tighten the rock nut when a correct adjustment is obtained. || intake [0.3 Valve clearance (Cola) | |_| (een) Exhaust | 03 | 3) When adjustment of the valve on the No. 1 cylinder is completed, turn the crankshaft fone full turn and adjust the clearances of the valve on remaining cylinders | Cylinder! 4 [fel Number E: Exhaust valve. 1: Intake valve Note Adjust the clearance of the valves marked with O in the table when the piston in No, 1 cylinder is held at the top deed center on compression stroke. Conversely, adjust the clearance of the valves ‘marked with @ in the table when the piston in No, 6 cylinder is held at the top dead center on compression stroke. 23:24. Intake manifold, © Install the manifold gasket on the eylinder head by aligning its openings with the intake Port in the cylinder head. © Install the intake manifold on the eylinder head using bolts and tighten the bolts to the specified torque,3 ENGINE ASSEMBLY 23-25. Exhaust manifold, © Check the seal ring on the jointing face of the exhaust manifold and replace it if found to be defective. © Fix the new manifold gasket on the eylinder head, and install the exhaust manifold and tighten the fixing nuts to the specified torque. 23:26. Turbo charger [iaer. crest enemy © Install the turbo charger to exhaust manifold flange with new gasket. © Tighten the nuts in diagonal sequence to the specified torque. © Align the air inlet port of turbo charger to the intake, manifold and assemble the air hose. ¢ Assemble the oil supply pipe and return pipe, © Check all connecting parts. 2:3-27. Cooling Water Pipe Se ‘ Me oe a ab © Install new gasket on ae head. Ree) © Install the cooling water pipe using the fixing bolts. 23-28, Idle Pulley 1146, ENG Only © Install the air compressor mounting bracket to the timing gear case. ee [ois ene) ‘© Assemble th’ power steering oil pump to the air compressor with aligning driving dog,3 ENGINE ASSEMBLY © Apply grease to Oxing, then insert Oving Into the oil outlet port of air compressor. ‘© Position the air compressor assembly on the mounting bracket carfully and tighten the fixing bolts to the specified torque. Note When installing the air compressor assembly, exercise care not to damage Oving. © Assemble the oil supply pipe, © Assemble the mounting bracket to the air compressor. © Install the air compressor assembly to timing gear case using fixing bolts and tighten the bolts to the specified torque. ‘© Assemble the oil supply hose and the return hose. 23:30. Alternator Install mounting bracket and supporter to cylinder block using the bolts. Install the alternator assembly to the mount: ing bracket and supporter using the fixing bolts 02366, ENG. © Install the mounting bracket to the water pump housing using the fixing bolts. © Assemble the supporter to the mounting bracket using the bolts © Install the alternator assembly to the mounting bracket and supporter.3ENGINE ASSEMBLY 2.3.31. Breather pipe 1D1146, ENG. - —] © Apply engine oil to orring, then insert o-ring into the groove of breather pipe © Apply engine oil to the oil cooler pipe, then assemble the breather assembly to the oil cooler. © Install pipe clamp and tighten it 02366, ENG. © Assemble the breather baffle into the breather housing and fix the new gasket. © Install the breather housing to the cylinder block and tighten the bolts to the specified torque. ‘© Apply engine oil to O-ring, then insert O-ring into the groove of breather pipe, re © Apply engine oil to the breather housing pipe, thon assemble the breather pipe assembly to the housing ‘© Install pipe clamp and tighten it. 2332. Fuel filter © Lostal-the fuel filter assembly to the intake manifold and tighten the bolts to the specified torque. © Connect the fuel inlet hose and outlet hose to the fuel filter respectively using hollow screw. Note Excercise care not to damage the connector due 1 tight’ ing the hollow screw excessively.ENGINE ASSEMBLY 23-33, Nozzle © Install the new seal ring in the nozzle hole of cylinder head. ‘© Connect the fuel injection pipes. © Connect the fuel over flow pipe assembly to the nozzle holder assembly. © Connect the injection pump lubricating oil hoses using hollow screw. Note Excercise care not to demage the connector due to tightening the hollow screw excessively. 2.3.34, Cylinder head cover © Fix the new gasket to the jointing face of the cylinder head cover. © Position the cylinder head cover on the cylinder head, then tighten the bolts, 23-35, Thermostat © Connect two rubber hoses to the thermostat housing respectively and tighten the hose clamp. © Connect the rubber hose together with the thermostat housing to the cooling water pipe and the by-pass pipe respectively, then tighten ‘the hose clamp, 23:36. Cooling fan ‘© Install the flange to the water pump pulley. © Install the cooling fan using fixing bolts and tighten the bolts to the specified torque Jn diagonal sequence 23.37. Vobett © Check the belt for fraying or damage and replace with new one as necessary. © Install the V-belt. © Check the amount of fan belt deflection by appling @ good finger pressure to the belt between the fan pulley and alternator pulley (D1146 ENG), or the fan pulley and air compressor pulley (02366 ENG). crank (01146, D1146T ENG) crank pulley (02366, 023667 ENG.)3 ENGINE ASSEMBLY 23-38, Oil level gauge ‘© Install the oil level gauge into the guide tube. © Connect all the rest of pipe and hose, 2:3-39, Injection timing adjustment © Bring the piston in the No. 1 eylinder into the top dead center on the compression stroke. © Then turn the crankshaft 60 degrees. toward the apposite direction of engine turning, ‘© Remove the injection pipe in No. 1 cylinder. © Remove the delivery valve holder, spring and valve from the injection pump, © Put only the delivery valve holder back in place, then assemble the U-shaped pipe to the valve holder. Feed fuel by manually operating the priming pump of the feed pump, looking at the fuel outlet port of the U-shaped pipe, © Keep on feeding fuel while rotating the crankshaft clockwise slowly until the fuel dropping from the outlet port of the U- shaped pipe every 6-8 seconds. ‘This point is the injection timing, © In this condition, read the timing mark stamped on the ‘flywheel which is aligned With the pointer on the inspection hole of the flywheel housing © If the injection timing is incorrect, the adjustment should be performed as follow. 1) Aligne the timing mark on the flywheel with the pointer on the inspection hole of the flywheel housing by turning the crankshaft 2) Loosen the fixing bolts and nuts of the injection pump coupling, 3) Rotate .the injection pump coupling slowly until the fuel dropping from the Usshaped pipe every 68 seconds, then tighten the coupling fixing bolts and nuts. '® Remove the U-shaped pipe and assemble the delivery valve and spring. ~70-4 COOLING SYSTEM Section4 COOLING SYSTEM CONTENTS. 1. General Description 2. Main data and Specification . Disassembled View of Cooling System 3-1, Water Pump Assembly and Cooling Fan... . 3-2. Cooling Water Chamber Cover and Cooling Water Pipe ............4. 4, Servicing of Component. ... 6 4-1 Water Pump........ 75 42. Thermostat... 76 43 Radiator... “77 5. Trouble Shooting ... 784 COOLING SYSTEM 1. GENERAL DESCRIPTION The coolant is pressure-circulated within the engine cooling system by the water pump installed on the front part of the eylinder body. After being cooled in the radiator tne coolant is. pumped up and fed into the cylinder block. After the coolant serves as a heat exchange medium for the lubricating oil at the oil cooler, it is distributed equally to each cylinder. ‘A portion of the coolant is pumped up to the cylinder head where it cools the exhaust ports and precombustion chambers. The coolant is then returned to the radiator ‘through the water outlet pipe. The thermostat is installed within the water ontlet pipe to control engine coolant temperature. When coolant temperature is below the thermostat valve opening temperature, the thermostat remains closed and the coolant is by-passed into the engine. }{_ thermostat ]-—{ coolant nine |--[Thermonat ]-—| Coatant Pipe i oylinder Hoos ‘ylinder Block }-Loit Cooter py Water Pump Cylinder Head —— Cynder Block Radiator |~[ water Pump |-—=[ oit Cooter (01146/01146T ENG) 2. MAIN DATA AND SPECIFICATION (02366/02366T ENG) ire [___bivas(on46T 'D2366/02366T 7. Water pump T - _ — Type | Centrifugal impeller type _— = Delivery (¢/min) 190 (at pump 280 (at pump pone Speed of 2300 rpm) Speed of 2700 rpm) ~ Type | Wax pellet = Valve opening temperature | 7° 82°C = Temperature at which i, | thermostat valve opens wide o’c | 94° = Valve lit (mm) 8 | a 3. Cooling fen = Diameter of fan (mm) 528 590 = Number of blades 6 6 4. Radiator Tube and corrugated fin, = Type down flow. _ -2-4 COOLING SYSTEM 3, DISASSEMBLED VIEW OF COOLING SYSTEM COMPONENT 3-1. Water Pump Assembly and Cooling Fan 3-1-2, D2366/D2366 T engi 1. A ‘CaaS : ene . 6 * a ; Gal 12, 17. 18, 19, -73- n Re a 16, Outer gasket 13. Inner gasket Hex. bolt M&x40 ‘14, Water pump cover 3. Hex. bolt M8x70 +18, Bolt MEx14 Spring washer 16. Key Water pump shaft ass'y 17. Spring washer Mechanical seat 18. Hex. bolt M16x1.5, . Ball bearing 19, Pulley ‘Snap cing 20. Flange 1. Spacer 21. Cooling fan Ball bearing 22. Spring washer |. Dust cover 23, Hex. bolt M&x70 Water pump housing |. O-ring 20. Hex. bolt M&x50 Spring washer 21. Key Hex. bolt M10x70 22. Spring washer Hex. bolt M10x65 23. Hex. nut M16x1.5 3. Hex. bolt M10x45 24. Pulley Water pump Housing 25. Gasket (suction) 26. Cooling water pipe ass'y . Snap ring 21. Spring washer Nilos ring 28. Washer Spacer 29. Hex. bolt Ball bearing 30. Connection pipe ass'y Spacer 31, Seal ring Mechanical seal 32. Gasket Spring 33. Connection pipe ass'y Shaft 34. Spring washer Impetter 35, Hex. bolt M6x16 Inner gasket 36. Fan Water pump housing 37. Flange (Delivery) 38. Spring washer Spring washer 39. Hex. bolt MBx70 Hex, bolt MBx224 COOLING SYSTEM 3-2. Cooling Water Chamber Cover and Cooling Water Pipe 3:21, D1146/D1146 T engine 9. 10. n 12. 13. 4, 16. 16. 7, 18. 19. ~14- Water chamber cover Gasket Washer Spring washer 5 Hex. bolt MBx20 Spacer bolt /. Cooling water pipe Gasket . Washer 1. Spring washer |. Hex, bolt MEx55 Hex. bolt M&x70 Gasket . Water chamber cover Washer - Spring washer 5. Hex, bolt MBx25 Cooling water pipe . Gasket . Washer Spring washer Hex bolt Seal ring Plug screw Seal ring Plug sorew ‘Thermostat Rubber hose Hose clamp Hose clamp Rubber hose 13, Plug screw 14, Seal ring 15. Plug screw 16. Seal ring 17. Hose clamp 18. Rubber hose 19. Thermostat 20. Hose clamp 21. Rubber hose 22. Hose clamp 23. Pipe 24. Rubber hose 20. Hose clamp 21. By-pass pipe 22. Cooling water pipe 23. Stud bolt 24. Pipe clamp 28. Spacer 26. Spring washer 27. Hex nut 28. Rubber hose 29, Hose clamp 30. Gasket 31. Cooling water pipe 32. Spring washer 33. Stud bolt 34. Rubber hose 35. Hose clamp 36. Seal ring 37. Union nipple 38, Hex. nut MB4, SERVICING OF COMPONENT 41, Water Pump 4-4-1, Disassembly ‘Remove the screws fixing the water pump cover, then remove the rear cover from the pump housing, ‘© Uncrew the pulley attaching nut. '® Remove the pulley using an suitable extractor and then remove the Nios The pulley isheld on the shaft by @ thrust bearing. ‘© Press out the water pump shaft and remove the ball bearing and spacer. But the cir should not be removed, (© Wash clean disassembled parts. 2. Inspection. © Check the bearings for wear and scores. © Turn the bearing with hand and see if they ‘otate smoothly without making noise ‘© Check the bearings for play. Replace the bearing if there exists a play of 4 COOLING SYSTEM more than 0.2 mm between the inner and outer races. © Check the impeller and shaft for wear, bending and damage paying special attention to the seal unit fitting face for wear or ‘corrosion and replace as necessary. 4.4.3, Reassembly © Use the plane washer and spring washer with ‘S"install the counter ring together with seal ring and secure them in position with the snap ring4 COOLING SYSTEM © Install housing gland, rubber ring, and washer con the shaft © install the spring. L © Measure the clearance between the impeller fan and the pump body, with a feeler gauge. The clearance can be adjusted by pushing with 2 bench press or by pulling with a puller when the measured value is beyond the limit (0.35 mm. 42, Thermostat 4241. Removal © Drain the cooling system about 1/3 of its capacity by opening the drain cock on the radiator. © Disconnect the water hose at both side of thermostat housing. ‘© Remove the thermostat. ‘© instal) the oil deflector ring after installing the Nilds ring on the water pump body. ‘© Apply liquid adhesive to the face of the spring plate collar and install the seal unit. © Pross the water pump shaft from the suction part side. Insert the Nilos ring to seal the front ball bearing © Insert the spring on the waterpump shaft, Install the washer, and tighten and lock the ut. -16- 7° sebetorn Bypass value from eaolant PP Pra by na LD NitLs 4-22. Inspection © Replace the thermostat assombly if its valve remains open at normal room temperature. © Check valve lift and valve opening temper- ature by submerging the thermostat in water and increasing water temperature gradually. Replace the thermostat assembly if the valve opening temperature and/or valve lift deviates from the specified range.‘Thermometer 2 Aiating Ros 1. It is to be noted that thermostat valve is not so sensitive and a certain period of time (3-5 minutes) is taken before it works in response to a change in coolant temperature. 2. When making a test, hold the thermo- stat in suspension in water or use @ piece of wood or equivalent under the thermostat to avoid heating thermo- stat directly. 3. During the test, stir water constantly t0 even out temperature. 4-23. General precautions © Since the wax type thermostat is relatively high in heat capacity, a certain period of time is taken before the valve works in response to varying temperature, It is therefore always advisable to throughly warm up the engine land avoid increasing the coolant temperature abruptly by overloading the engine or by speeding immediately after cold engine starting. When draining and refilling the cooling system pour in coolant gradually to remove ai completely from the water jacket thereby to insure that the cooling system is refilled, start and let the engine run at idle for a few minutes. Recheck the level of water in the radiator and replenish, if necessary. 4-2-4, Replacement intervals © The waxpellet type thermostat contains, as its name implies, wax to attain smooth con trolling of the valve operation but when 2 leakage has developed the valve is closed by -1- 4 COOLING SYSTEM the action of the spring and the entire coolant is bypassed for circulation within the engine and can cause engine overheating. {tis therefore, recommended that the thermostat bbe replaced with a new one periodically according to the conditions under which the engine is operated. (If is recommended that the thermostat assembly be replaced every {50,000-70,000 km}. It is also advisable to remove the thermostat assembly and check for trouble when the engine is running hot ‘and a thermostat failure is suspected,5 LUBRICATING SYSTEM 1. GENERAL DESCRIPTION The lubricating system of D1146 AND 02366 Engine consists of the various components such as the oll pump, oil cooler, full-flow filter, the relief valve and by-pass valves. The lubricating oil is circulated by a gear type pressure pump mounted on lower side of crankease. Al the oil leaving the pump is forced through the cil cooler to the full flow oil filter, and then ‘nto the oil gallery in the cylinder Block from where it is distributed to the various engine bearings. The drain from the cylinder head and (02366/02366T ENG) -g0- other engine parts leads back to the oil pan. A spring loaded integral plunger type relief valve, located in the oll pump body, by-passes excess oil from the discharge to the intake side of the pump when the pressure in the engine Coil gallery exceeds approximately 10 kg/cm? (142 psi. Clean engine ol is assured at all times by the use of @ replaceable element type full flow oil filter incroporated in the engine lubrication system. With this type filter, which is installed in the Jubricating system between the pump and the: main oil gallery, all the oil is filtered before centering the engine. - Oil pipe (Injection pump) Oil pipe (Timing-Idle gear) Oil pipe (Con-rod bearing) Oil pipe (Oi filter) - Oil cooler Oi pump Oil suction pipe i filter Strainer Oil pipe (Air compressor) Oil pipe (Rocker arm shaft) Oil main gallery Oil pressure gauge Oil pipe (Camshaft bearing) il spray nozzle (Piston) Oil pipe (Crankshaft bearing) " 12 13. 4, 16. 16. toe gear it gallery {Main bearing) Oil galery (Crankshaft) Oil gallery (Camshatt bearing) i pump . Oil pipe (Suction) Oil pipe (Delivery) Oit galery (Cylinder block) . Oil sprary nozzle (D2366T only} Oil gatery it pipe for turbo charger (023667 only) Oit pipe (Oil pressure switch Oit galery 15. Oil cooler 16. Oil filter Oil gallery (Cylinder head) Injection pump 19. Coupting it pipe (injection pump} 10. " 12, 4 17, 18,5 LUBRICATING SYSTEM 2, MAIN DATA AND SPECIFICATION Dinas (02366 re a Biiser [pastor Lubricating system Forced pressure circulation =— it pump type Gear type Jz Oil iter pe | Full-fow ,o- Opening pressure of relief valve (kg/m?) | wri | Opening pressure of the by-pass valve for oil filter, (kg/em?) | 40~48 _ Opening pressure ofthe by-pass vlve for filter element (kg/am?) 1e~23 | Opening pressure of the by-pass valve for oil cooler ({kg/em?) ser | Opening pressure of the adjusting valve for say nozzle (ka/em?) | 18~18 = 3. DISASSEMBLED VIEW OF LUBRICATING SYSTEM COMPONENT 3-1. Oil Pump and Oil Pipes |. Idle gear 32, Lock nut 9. Ball bearing 33. Washer |. Snaprring 34. Hex. bolt |. Idle gear pin 35. Gasket - Spiral lock pin 36, Oil pipe 5. Snap ring 37. Gasket Socket head bolt 38. Spring Washer Oil pump drive gear 39, Hex. bolt Oil pump housing 40. Gasket |. Pump gear 41. Connecting flange |. Pump gear 42, Washer . Rear cover 43. Spring washer Front cover 44, Socket head bolt - Dowel pin 45. Oil pipe 5. Hex. bolt 46. Washer Lock nut 47. Spring washer . Wood ruff key 48. Socket head bolt Lock wahser 49. Oil pan ass'y Hex nut 50. Oil pan gasket Dowel pin 51. Spring washer |. Lock washer 52. Socket head bolt M8x20 . Hex. bolt 53. Socket head bolt MBx25 Valve plunger 5A. Seal ring |. Spring 55. Drain plug Pag screw 56. Oil level gauge 3. Oil suction pipe ass'y 57, Guide tube . Suction pipe holder §8. Holder |. Spring washer 59. Hex. bolt Hex. bolt 60. Washer Washer 61. Spring washer (1146/0146 T ENG) 31. Hex. bolt 62. Hex. nut -81-5 LUBRICATING SYSTEM 1. lle gear 31. Hex. bolt MBx35 2. Ball bearing 32. Spring washer 3. Snap ring 33. Spacer ring 4. Idle gear pin 34. Oil level gage tube 5. Spiral lock pin 35. Oil level gage 6. Snap ring 36, Oil suction pipe 7. Socket head bolt 37. Stud bolt M8x20 8. Oil pump drive gear 38. Spring washer 9. Oil pump housing 39. Hex. nut 10. Pump gear 40. Bracket 11, Pump gear 42. Hex. bolt MBx25 12, Rear cover 43. Spring washer 13. Front cover 44. Lock nut 14, Dowel 45, Hex. bolt 15. Hex. bolt 46. Spring washer 17, Woodruff key 47. Oil pipe 18. Lock washer 48, Hex. bolt M&x30_ 19, Hex nut 49. Washer 20. Dowel pin 50. Spring washer 21. Lock washer 51. Bracket 22. Hex. bolt 52. Clamp 23. Valve plunger 53. Hex. bolt MBx25 24. Compression spring 54. Washer 25. Plug screw 55. Lock nut 26. Oil pan 56. Hex. bolt 27. Drain plug 87. Spring washer 28. Seal ring 58. Hex. bolt 29, Oil pan gasket 59. Washer 30. Hex. bolt M&x30 Oil cooler 1. Gasket 15, By-pass ball 2. Oil cooler housing 16. Spring 3. Washer 17. Pin 4. Spring washer 18, Seal ring 5. Socket head bolt 19. Plug screw 6. 7. 8 9 5. Gasket 20. Oil cooler cover tube Oil cooler element 21. Oil cooler cover tube Oil cooler cover 22. Stud bolt . Gasket 23. Washer 10. Washer 24. Spring washer 11. Spring washer 25. Hex Nut M10 12, Hex. bolt M8x75 26. Oving 13. Seal ring 27. Breather ass'y 14. Plug screw (01146/01146T ENG) ~82-5 LUBRICATING SYSTEM Oil Fitter Fitter head 18. Tension spring Gasket 16. Packing Sealing cap 17. Retainer plate Socket head bolt 18. Retainer spring Oring 19. Element paper Valve cone 20. Fitter housing Valve spring 21, Seal ring Seal ring 22. Drain plug Plug screw 23. Seat ring Valve plunger 24, Center bolt Valve spring 25. Gasket Seal ring 26. Hex. bolt M&x35 Plug screw 27. Hex. bolt M&x105 . Seal ring 28. Spring washer Oil Cooter and Fitter, Bracket 17. Owing . Baffle 18. Oving . Scoket head bolt MGx12 19. Seating plate . Spring washer 20. Spring Oil cooler insert 21. Filter housing Gasket 22. O-ring Hex. bolt M&x60 23. Canter bolt Washer 24. Seal ring Spring washer 25, Plug screw Gasket 26. Filter element Oil cooler cover 27. Water tube Plug screw 28. Water tube Seal ring 29. Oxing Hox. bolt MBx90 30. Washer Washer 31. Spring washer Spring washer 32. Hex. bolt 33. Spacer bolt5 LUBRICATING SYSTEM 4, SERVICING OF COMPONENT 4.1, Oil Pump 4.1.1 Disassembly © Unscrew the plug and remove the oil relief valve from pump body. Unlock the lock plate of the pump gear attaching nut and unscrew the attaching nut \ \ AGS \ sc VAS ‘© Pross of the pump gear with two serew-drivers The gpar is hold with a woodruff key. © Take off oil pump cover. Cover is fixed with two locating pins farrows). © Remove the drive and driven gear. 4-1-2 Inspection and Correction ‘© Measure the clearance between gear side face and cover using a square and feeler gauge. ‘© In the clearance is beyond the standard valve, replace either the gear or the cover — 01146, 02366 ENG. | Standard value Clearance between pump cover | Yor | ane gear sige face Imm) Lo | 0.025 ~o.08 (© Measure the back-lash with a feeler gauge. © If the back-lash is beyond the standard valve, replace either drive gear or driven gear 1146, 02366 ENG - ] Standard voue | Backlash between drive geor | for astembly snd driven gear mm 4 0.50 ~0.65 ‘© Measure the outside diameter of the drive and driven shaft using an outside micrometer. If the measured value is beyond the limit, replace the shaft—D1146, D236 ENG Nomina | Value indicating ‘ameter | need for servicing Drive and driven shaft diameters, Imm] 16.950 ~ ‘© With a cylinder bore gauge, measure the inside diameter of oil pump cover hole. Compare ‘the measured value with the shaft diameter to determine the clearance. If the clearance is beyond the standard value for assembly, replace shaft ar all pump cover —D1146, 02365 ENG Standard value for assembly ‘Clearance betwoen drive shaft 8nd pump cover Role (ram | o0s2~o077 Clearance botween driven shaft Bnd pump cover he 0.040 ~0.096 4.1.3, Reassembly © Insert the driven gear assembly into the pump body, © Insert the drive gear assembly into the pump body applying with a engine oil. © Install the oit pump cover. © Install the oi pump gear with the lock plate, 42. Oil Filter 4-2-1. Oil filter on D1146 engine 5 LUBRICATING SYSTEM 1, Packing 11, Filter cover 2. Spring 12, Plug screw 3, Packing 13, Oit outlet 4. Drain plug 14, Over flow valve 5, Seating plate 15. Oil inlet 6, Filter body 16. Seating plate 7. Filter element 17. Oil drain gallery 8. Center bolt 18. Valve seat 9. Packing 19. By-pass valve 10. O-ring Disassembly © Drain the oil filter body by removing the drain plug. © Remove the oil filter assembly from the engine. © Loosen the center bolt and take out the filter element. © Remove the by-pass valve from the oil filter —85-5 LUBRICATING SYSTEM © Screw out both valve cones of the by-pass 1, Water outlet pipe 8, Center bolt 2. Water inlet pi 9. Packing 3. By-pass valve 10. Oil filter housing 4. Oil cooler housing 11. Oil filter element 5. Oil fiter head 12, Packing 6. Spring 13, By-pass valve 7. Drain plug 14, Relief valve Disassembly © Drain the oil filter body by removing the drain plus. © ‘Screw out the over-flow valve screw plug. Inspection © Visually check the oil filter body for eracks for damage and replace as necessary. © Visually check the oil filter cover for cracks, distortion or damage and replace as necessary. © Visually check valve spring and cone for damage and replace as necessary. © Visually check valve spring and plunger for damage and replace as necessary. © Loosen the oil cooler cover fixing bolts and remove the cooler cover. Reassembly To reassemble, follow the disassembly procedure in the reverse order. ~86~LUBRICATING SYSTEM ‘* Remove the oil cooler element from the oil Inspection cooler housing. ‘© Visually check the oil cooler cover and Remove the by-pass valve from the oil cooler housing, and the oil filter housing for eracks housing or damage and replace necessary. Loosen the center bolt and take out the © Visually check the valves for damage and filter element. replace as necessary. © Remove the relief valve and by-pass valve from the oil filter head. cea © To. reassemble, follow the disassembly procedure in the reverse order. 5, TROUBLE SHOOTING Complaint Cause Correction it consumption | Wrong it in use | rain and refi with specified oi excessive Oil seal or gasket defective Correct Piston rings or ring grooves worn Replace piston rings or piston Cylinder tiners worn Replace cylinder liners Piston rings sticking Replace pistons and piston rings Valve guide oil seas, valve guides or it seals or valve stem worn Replace valve guides, oi valve Oil pressure totow — | Use of wrong oil Drain and refill with specified oi! [feseeeercue reas Restrictions in il pump strainer Clean strainer | Oil pump gears worn Replace. | oi pump feed pipe cracked, broken or Correct o replace | joints leaking it pump defective Correct or replace | oi pressure gauge detective | Corrector replace | Ceankshatt or connecting od bearings | tnsall undesie earings | worn Oit deteriorates Restrictions in oil fiter Replace fitereloment uiekly | Gases eaking Banisee aston ing of yin | Air breather defective Corrector replace Use of wrong oil | Drain and ret with specified oi Oil not reaching valve Oil ports in cylinder body and | can system cylinder head clogged Oil ports in rocker arm shaft clogged Clean Oil ports in rocker arm shaft brackets. | Clean. | clogged Olt port in rocker arms clogged Clean ~87-6 FUEL SYSTEM Section6 FUEL SYSTEM CONTENTS PAGE 1. General Description. . cesses 94 2, Main Data and Specification........ 92 3. Exterior View of Main Component...... 93 4, Injection Pump... 94 4-1, Construction and Operation ......... 04 4-2, Characteristic of PE-P Type Injection Pump ...... 94 4-3. Disassembly. .. 96 4-4, Inspection of Disassembled Parts. . 100 4.5, Reassembly 102 46. Adjustment * 104 5. Governor. . 108 5-1. Construction and Operation . 106 5-2. Disassembly. = 108 5.3. Inspection of Disassembled Parts, . 14 5.4, Reassembly. 15 5.5. Adjustment. . W7 6. Automatic Timer. 126 6-1. Construction and Operation. ... 6.2, Disassembly. 127 129 seen 499 6-3. Inspection of Disassembled Parts. .. 6-4, Reassembly .. 6.5. Testing... 00-0. eeeec eee ee es 1306 FUEL SYSTEM 7. Fuel Feed Pump . 7-1, Construction and Operation ............00005 130 130 7-2. Disassembly. ....... “431 7-3. Inspection of Disassemblec Parts. $133 7-4, Reassembly .. cece eee 433, 7-5. Testing «22... “134 8. Fuel Injection Nozzle ......... 135 8-1, Construction and Operation... ...66e ccc cee see eeee cette eee ee eee 135 8-2, Disassembly. 0.2... eee veeeeeeeeeeeeeeee fone 196 83. Inspection of Disassembled Parts. . “136 84. Reassembly....... --136 85. Testing --136 9, Trouble Shooting ...... vette eeeeee Peeeeee eee 136)1. GENERAL DESCRIPTION ‘The fuel system consists of the fuel tank, in- jection pump, injection nozzle, fuel filter and the necessary connecting fuel lines. The engine torque is transmitted, via the coupling, to the injection pump camshaft which, in tur, drives the feed pump sucks in fuel from (01146 /D1146T ENG) ~91- 6 FUEL SYSTEM the fuel tank and delivers it to the fuel filter. ‘The fuel through the fuel filter is fed to the fuel injection pump. The injection pump force the fuel, under high pressure, through the in- jection lines to the nozzles where it is injected into the precombustion chambers Fuel System 1, Primary fuel filter (felt type) 12. Secondary fuel filter (paper type) 2, Air bleeding screw 3 Injection nozzle 4, Over flow hose 5. Fuel pipe (filter injection pump) 6. Over flow valve 7. Injection pipe 8. Fuel pipe (feed pump — filter) 9, Fuel tank 10, Fuel return pipe 11, Suction pipe 12, Feed pump 13. Injection pump6 FUEL SYSTEM 2, MAIN DATA AND SPECIFICATION ITEM Injection Timing Injection Order Type Type Modet & Type Mode Timer Type Pump Model Type Modes Injection nozzle Type Fitter Plunger lift injection port {diameter-No.) Plunger diameter Lubricating type |_Irieetion pressure NP-EP/RFD200/ | NP-EP/RFD200) | NP-EP/RFO200/ 1600 AF @CHL B50 PF OCZR | 1650PF 9CHR: | centrifugal — _ | NP-EP/SP 700 | NP-EP/SP.950 | NP-EP/SP 600 | -125084R =| -115024R | -1100 25.6R Plunger type ad NP.FP/KE ADS | NP-FP/K-P ‘Multi hole type = DLLA1S0 $312 DLLA150 1064) DLLA50 $308 | 9029-5 goai-5 | $0.32-8 214 + 8 kglem — — Double filtering — — (felt and paper) oiaet | 2366 5236607 {| etocis? =| aToc11° | 153624 — = kc, PE-P = _ NPPEGA.D95 | NP-PEGP120/ | _ cicero 9.5mm | 12mm | _ _ 4.8mm | 4.2mm 48mm 4.7mm | Pressure lubri = ~— _ cation | —_ — — — Mechanical = = (RFD) } | NP-EP/RFD200/ 1650 PF 9CWR NP-EP/SD 600 =11002 30R DLLAI50 $310 9033-53. EXTERIOR VIEW OF MAIN COMPONENT 1. Injection pump 2. Fuel strainer 3. Hollow serew 4. Seal ring 5. Hollow screw 6. Adapter 7. Double banjo union 8. Seal ring 9. Air hose 10. Hose clamp 11. Automatic timer 12, Fuel feed pump 13. Governor 14, Shim(For D2366 ENG) 15. 16. 17, 18, 19 20. a. 2. 23. 28. 27. 28. 6 FUEL SYSTEM See Foroaseng = Bracket (For D2366 ENG) Stud bolt (For 02366 ENG) Spring washer (For 02366 ENG) Hex. bolt M12x1.5x60 (For D2366 ENG) Hex. nut (For D2366 ENG) Dowel pin (For 01146 ENG) Shim (For 01146 ENG) Bracket (For 01146 ENG) Spring washer (For 01146 ENG) Hex. bolt M10x10 (For D1146 ENG) Stud bolt (For 01146 ENG) Hex. Nut (For D1146 ENG) Washer (For 01146 ENG) Hex. bolt (For 01146 ENG) —93-6 FUEL SYSTEM 4. INJECTION PUMP 4-1, Construction and Operation Adjusting sien Delivery valve The pump housing of PE-P type injection pump is totally enclosed type and major parts such as plungers, delivery valve, etc, organize @ plunger block assembly, this type is particularly suited for heavy duty diesel engines or direct-injection engines as it has a large capacity for the size of the pump housing and working parts are carefully designed to withstand heavy load. The injection pump is the nucleus of the diesel engine designed to pressurize and deliver metered volume of fuel into the engine at @ correct timing according to change in the engine load and speed. The injection pump is driven by the engine via the injection pump camshaft. The injection pump plungers are pushed up in contact with the cam lobes and pushed down by ‘the plunger spring to maintain reciprocal motion. The fuel chamber housing has a fuel chamber which is filled with fuel fed past the feed pump and fuel filter. The inlet and outlet ports in the plunger barrel are communicated with the fuel chamber, so that when the plunger descends and its upper end meets the port in the plunger barrel, fuel flows into the plunger barrel until the plunger reaches the lowermost position of the stroke ‘As the camshaft rotates and plunger is pushed Lp against the plunger spring tension, and intake and delivery ports in the plunger barrel are ‘covered up with the end of the plunger, the fuel Delivery valve holder Detivery valve gesker ~94- ‘trapped within the barrel is pressurized. When ‘the pressure of fuel overcomes the residual pressure of fuel within the injection pipe, the delivery valve is pushed open, allowing pressurized fuel to flow into the injection nozzle past the nozzle holder. ‘As the plunger ascends further and pressure of fuel becomes higher than injection starting (nozzle valve opening pressure) pressure, the fuel pushed open the needle valve in the injection nozzle finding @ way out into the combustion chamber. ‘As the plunger strokes to continue injection and plunger lead meets with the intake and delivery ports in the plunger barrel, further delivery and injection are interrupted. 42. ic of PE-P Type Injection ‘The delivery valves are semi-metal tight gasket type and O-ring is installed on the outer part of the delivery valve holder to maintain sealing against high and low pressures. In this type injection pump, “L” type contro! rod is used to attain controlling of injection volume, The control rod has grooves corresponding to plungers in the pump and they are fitted with the ball welded to the control sleeve. As the control rod is moved, its movement is relayed to the control sleeve and causes the plunger to move, thereby to control injection volume.6 FUEL SYSTEM u {In the PE-P type injection pump, the plunger barrels are improved in design and pressurized fuel is applied to the upper portion of the plunger bareets (Bund). In order to control fuel leak-off, pressure control ring groove (communicated with the fuel reservoir) is provided in the plunger barrel, so that the fuel leaking off past the clearance between the plunger and plunger barrel is returned into the fuel chamber within the pump housing, Serew plug . Bearing cover O+ing Shim Oil seal Shim Ring 9. Key 10. Genter bearing 11. Gamshatt 12. Tappet 13. Lower spring seat 14, Plunger | 16, Plunger spring ; Jp, 16. Control sleeve | iB) 17, Upper spring seat { LG 18. Cover it 419, Plunger block assembly 20. Screw bushing 21. Rod busihing 22, Pin | 23. Control rod | |. Bottom cover ‘The plunger, delivery valve, delivery valve spring, etc. are secured to the plunger sleeve by means of the delivery valve holder and fixed to the pump housing with nut and washer. The plunger barrel is fitted in position with locating pin ‘press-fitted into the flange sleeve. ‘The plunger barrel has, on its outer circum: ference a deflector which serves to protect the ump housing against corrosive action provided through counterflow of fuel at end of injection cycles ~95-6 FUEL SYSTEM 4-3. Disassembly 4-3-1. Inspection of injection pump prior to diassembly Prior to disassembly, check the following points to determine whether or not overhauling is necesary. ‘© Check the pump housing visually for cracking ‘and resulting fuel leaks. © Check the upper face of the pump housing for a sign of fuel leaks from around the delivery valve holders, (Leakage of fuel is mostly due to defective delivery valve gaskets.) ‘© Check that the injection pump camshaft turns smoothly. If rotation of the camshaft is un- smooth, bearing damage or plunger spring breakage is suspectable. © Check the internal part of the pump for Presence of water with the tappet chamber cover removed. ‘© Check state of oll to see if the fuel is leaking into the cam chamber. (Check viscosity, color and odor of fuel to determine whether ‘or not fuel is leaking into cam chamber.) ‘A small amount of fuel leaking past the clearance between the injection pump plungers and plunger barrels is normal as it serves to fubricate the parts. Check for fuel leaks from the feed pump and from around the clearance between the pump housing and plunger barrels, 4-3-2, Preparation for disassembly © Prior to disassembly, wash clean the exterior of the injection pump, exercising care not to permit detergent oil into te delivery valves, © Unscrew the hollow bolts of the fuel inlet and outlet port, and then assemble the fitting plate SAS ASL oh re ‘© Mount the fixing stand on the universal vise. ‘© ‘Mount the injection pump on the fixing stand by aligning the guide pin of the fitting plate with the guide hole of fixing stand, and then tighten two bolts. © Take out the screw plug, then bring each tappet to the top dead center by turning the camshaft and keep the tappets in elevated position by inserting the tappet holder into the hole in the screw plug hole.© Remove the governor assembly from the injection pump body. (Refer to the disassembly procedure of governor assembly in this section) © Remove the automatic timer according to ‘the following procedure 1) Remove the round nut and spring washer using socket wrench. When turning the round nut, set special wrench to the holes in the timer side to prevent turning of the shaft 2) Lock the camshaft with special wrench and remove the automatic timer by screwing projected portion of extractor into the threaded hole at the center of the fiyweight. 3) Remove the woodruff key to the camshaft. 4.3.3. Diassembly of Injection Pump © Pivot the universal vise to bring the injection ump into the horizontal position. © Take out the setting screw on the bottom face of the injection pump and remove the bottom cover. 6 FUEL SYSTEM © Unscrew the center bearing fixing serew on ‘the bottom face of the injection pump. © Remove the 4 screws fixing the bearing cover, then remove the bearing cover, Note When removing the bearing cover, use the oil seal guide to prevent the oil seal lip from damge. ‘© Remove the center bearing together with the camshaft by tapping on the end of the camshaft from the governnor side using a mallet6 FUEL SYSTEM Then take out 7 bolts and remove governor housing the ‘© Assemble the tappet mounting device to the both side of injection pump body. © Raise the tappet with the aid of the mounting device: tappet and remove the tappet holder. © Take out the tappet. procedure on each tappet. Repeat the same ‘© Remove the lower spring seats from the flange portion of the plungers © Clamp the flanged portion and pull out the plungers with the plunger extracter. —98- Note ‘Keep the parts in clean kerosene in each cylinder group to avoid interchanging of the parts Remove the plunger carefully not to bring into contact with the adjacent parts, ‘© Remove the control sleeves and upper spring seats using a pincers ‘ & Pivot the universal vice to bring the injection pump into the ver the upper cover. (© Remove the 2 nuts fixing flange sleeve. ical position, then remove6 FUEL SYSTEM © Loosen the delivery valve holders by using @ box wrench before removing the plunger block assembly, © Take out the lock nut and remove each plunger block assembly by using the extractor. © Take out the control rod bushing screw. © Pull out the control rod toward the drive side and remove the guide pin. © Remove the control rod from the injection ump body. © Disassemble the cylinder block according to the following procedure. assembly v0 1) Take out the snap ring by using snap ring plier. 2) Remove the deflector, then remove the washer, o-ring, distance ring and shim. =~ / ovary 3) Screw out the delivery valve holder with hand and remove the dilivery valve and plunger barrel6 FUEL SYSTEM 7. Delivery valve holder 14. Flange sleeve 1. Snap ing 8 Ovi | (2 batecor ©. Dalvery ae sring [3 Waster 10, Caste | [a Ove M1 Davey ate | 5. Dinanoe ing 12, Pane bara 6. Shim 13. Oring | =100- © To remove the bearing outer race, hold the tapered portion of the extractor into the clearance between the bearing cover and ‘outer race and turn the nut fully, then force out the bearing outer race by tapping with a hammer or applying pressure from the knurled side of the bolt to the race using a bench press. -4. Inspection of Disassembled Parts 44-41. Plungers ‘© Check the lapped face for wear and scores. Replace the parts if the upper end or the groove is found to be worn or scored, a lapped face is dull of corroded. © Wash clean the plunger and hold it at an angle of about 60 degrees from the horizontal level6 FUEL SYSTEM © Slowly stroke the plunger and see if it moves smoothly. The plunger is normal if it slides freely without binding. Repeat the test several times with the plunger turned slightly ‘each time. 4.4.2, Delivery valves é ov362 ‘© Check the piston and valve seat for scores caused by abrasive action of foreign matter in diese! fuel. Replace the parts if the lapped face of the piston is found to be dull in appearance. ‘© Plug the lower end of the valve seat finger and depress the valve lightly with another finger. Release the finger and see if the valve snaps back into the original position. If returning action of the valve is sluggish, replace the valve. 4.43, Control rod ‘© Check the control rod for wear or damage and control rod for bending by rolling it over a surface place. Replace the control rod if found to be bent. 44-4, Camshaft. © Check fit of the key into the key groove for looseness and replace either the key or the camshaft. © Check the tapered portion for roughness and correct with an oil stone as necessary, © Check the threads for damage and replace the parts as necessary, © Check the cam face carefully for damage, ‘wear or deformation and replace the camshaft as necessary. © Check the camshaft bearings for wear or damage and replace as necessary. U eb T © With @ dial indicator, check the total amount of clearance between the roller and bushing and between the bushing and roller pin. [uimetmm | {_Limi (rn) © Measure the amount of wear in the tappets. © Check the amount of depression in the tappet head using a diat indicator. © Replace the adjusting bolt depression is beyond 0.2 mm. ‘© The standard clearance between the pump housing and tappet body is 0.03 - 0.07 mm Replace the tappet body if the clearance Is in excess of 0.18 mm. the amount of 4.4.6, Plunger spring © Check the springs visually for wear or damage and replace with new ones as necessary. -101-6 FUEL SYSTEM 45. Reassembly Piror to reassembly, wash clean the parts paying close attention to the fuel ports. Discard dotivery valve gaskets, oll seals and O-rings and install new ones at reassembly. 45-1, Reassombly of plunger block assembly S) Dowel pin ‘© Install the plunger barrel in position by aligning the dowel pin on the flange sleeve. Assemble the delivery valve, gasket and delivery valve spring to the flange sleeve in sequence. ovata © Assemble the delivery valve spring to the flange sleeve and install the delivery valve holder. Be sure to install O-ring in the delivery valve hholder after lubricating it with timer grease to Prevent it from scratching. =102- © Assemble the shim, distance ring or gasket, O-ring, washer and deflector to the plunger block from the lower side in that order and secure them in position with the snap ring, Note ‘Make certain the holes in the deflector are on the lower side. ovai7 © Install the two O-ring in position. 45-2. Reassembly of injection pump6 FUEL SYSTEM ‘© Remove the plungers and install the plunger block assembly in position on the injection ump from the upper side so that the dowel pins are turned toward the front of the injection pump (pointed away from the control rod). _ ov420 © Pivot the universal vise to bring the injection ump into the horizontal position. © Insert the control rod into position from the drive side and secure the governor side tend of the control rod in position with the bushing insert the control sleeves into position from the lower side carefully to be sure the ball fon the sleeves are fitted properly into the corresponding slot in the control rod. -103- © When the control sleeves are installed, insert the upper spring seat and plunger springs into position in the order mentioned, so that the mark on each plunger is turned toward the front of the injection pump (the mark is in Jine with the dowel pins). © Install the tower spring seat. ova2a © Assemble the tappets, making sure they are installed in their original position. Notched tine ova23 © Install the bearing using bearing inner race installer. © Insert the camshaft into the pump housing from the automatic timer side, so that its end with notched line is turned to the timer side. © Install the bearing outer race in the bearing ‘cover using bearing outer race installer © install the bearing cover with O-ring on the pump body.6 FUEL SYSTEM © Measure the camshaft end play. If necessary, adjust with the adjusting shims. ‘© When the reassembly operation is completed, pull the controled with a pull scale and check to make sure it moves smoothly through the entire stroke (0- 21 mm) and the pull required is within the limit. — = 104- 46. Adjustment 4.6-1, Adjustment procedure (for P type in- jection pump) (© The injection pump should be tested by using an electric pump tester which is known to be accurate. Use clean fuel as specifically in the workshop manual. © Check to be sure the meters and indicators Con the tester give accurate reading. © Keep injection nozzle valve opening pressure adjusted properly. Prior to testing, bleed the injection pump completely. © Control rod zero {0) position setting Take out the cap from the end of the injection pump and install the control rod stroke measuring device in plece. Adjust the tension of the governor spring by means of the speed adjusting bolts so that the governor begins to work when the pump speed is increased to 500-600 rom, Further increase the pump speed until the control ‘0d is pulled in toward zero (0) position and push the end of the control rod all way in toward the fuel cut position to determine the zero (0) pasition of the control rod When zero position is determined, calibrate the scale to zero point. Note Avoid determining the zero position of the control rod by operating the contrat lever as it ‘may cause damage to the linkage and other delicate parts of the governor.4.6.2, Adjustment of injection timing Using the socket wrench and take out the delivery valve spring, delivery valve and delivery valve gasket © Install the plunger stroke measuring device in position of the delivery valve holder. © Fix the control rod in “FULL-LOAD” position and bring the plunger to bottom dead center by turning the pump manually and calibrate the dial indicator. Turn the pump slowly in clockwise direction and note the flow of fuel out from the over 6 FUEL SYSTEM flow pipe on the plunger stroke measuring device. Make necessary adjustment by means of the adjusting shim in position between the flange sleeve and pump housing, so that the flow of fuel stops when the plunger is lifted to 3.040.05 mm point. ‘The plunger barrels are numbered ir sequence of No, 1, No. 2 and so on from the drive side of the injection pump, © When injection timing adjustment an the No. 1 cylinder is completed, repeat the same adjustment procedure on each cylinder in sequence of the firing order. The timing interval between each cylinder must be 60 degrees + 30 seconds for 6 cylinders engine. 4.6.3, Adjustment of injection volume © Injection volume should be tested and adjusted under the conditions as specified as follows; 1) It is essential to use specified injection nozzles, nozzle holders and injection pipes for testing. (Refer to ergine work- shop manual) 2) Use test fuel at temperature of 40:45°C. 3) Keep delivery pressure adjusted to 1.6 kglem? ‘© To adjust the injection volume, loosen 2 nuts fixing the flange sleeve and turn the flange sleeve as necessary by using the long hole in the steeve. (Flange sleeve turns with the plunger barrel) Turn the flange sleave Clockwise to increase the injection volume and counter-clockwise to reduce tre injection volume,6 FUEL SYSTEM 5. GOVERNOR 5-1. Construction and Operation Governor spring Control rack Start spring ‘Speed setting ever Floating lever Sling levee ‘The injection pump camshaft is fitted with the fiyweights which swing about the pin press: fitted to the flyweight holder. As the flyweights fiy outward, the sleeve is forced to move in the axial direction in contact with the roller installed fon the end of the flyweight arm. The sleeve slidingly mounted on the flyweight roller, is ‘connected by means of the snap ring to the shifter_which is fitted to the guide lever suspended by the pin on the governor cover. Provided on the intermediate part of the guide lever is @ shaft to which the floating lever is installed. The pin press-ftted to lower end of the floating lever is connected to lower part of sliding lever. The control lever is connected, via the eccentric shaft, to the sliding lever, s0 that floating lever can be moved by operating the control lever. The injection pump contro! rod is connected, via the link on the floating lever, to the upper part of the floating lever, and start spring Is connected at one end to the upper part of the floating lever and at the other end to the spring eye on the governor housing. The tension lever is installed on the tension lever shaft to which the guide lever is fitted, and ‘governor spring is connected between the tension lever and speed setting lever. Tension of the -106- Tension lever ‘Speed control lever governor spring is controlled by means of the speed control lever connected to the speed setting lever shaft. While the injection pump is running at speed within normal operating range, the lower end of the tension lever is held in contact with stroke adjusting bolt. Lower side face of the tension lever has a pin which is fitted Into groove in the upper part of the sliding lever. Owing to the arrangement of the levers and linkages, the leverage at high- speed governing can be varied greatly by the action of the pin press-fitted to the tension lever, sliding lever and floating lever linkage. The governor can be set to suit any speed as the governor spring tension is changed with the tilting angle of the speed control lever. Owing to tuniqu. design and construction, the RFD type governs can be used selectively as minimum: ‘maximum speed governor by operating the load control fever with the accelerator pedal with speed control lever set in position for maximum ‘governed speed by mean of the link rod on the engine side, or as a variable speed governor by ‘operating the speed control lever with load control lever fixed in full-oad pos The tension lever is fitted at its lower end with the idling spring which serves to control low speed.5-4-1. Governor action at engine starting and iting Moet os oe ete ‘costa we or Leeda C fang position When the engine is stationary, the flyweights ‘are held in fully retracted position by the action of the governor spring, idling spring and start spring, As the load control lever and speed control lever are tilted in direction of fuel in- ‘ease, the control rod is moved, by the action Of the start spring and idling spring, to a point beyond the full-load setting to provide maximum volume of fuel injection for engine starting (the control rod advances until it makes contact with stopper when control rod limiter is provided.) Once the engine is started and load contro! lever is returned to idling position, the centrifugal force created through rotation of ‘the flyweights balances with the product of the Idling spring and start spring tension and maintains the control rod at a position, allowing the engine to smooth idle (as the centrifugal force created through rotation of the flyweight varies with the pump speeed).. =107- 6 FUEL SYSTEM 5-1-2. Governor action at normal speed When the load control lever is moved in direction of fuel increase (in position in contact, with the maximum speed stopper bolt), the sliding lever is made , by the action of the eccentric shaft linked to the load control lever, to pivot about the pin on the lower part of the ‘tension lever. The floating lever is also made to swing about the common fulerum point “B” ‘and forces the control rack to move in direction of fuel increase, thereby causing the engine speed 10 increase. When the engine speed increases beyond the governor idle speed range, the idling spring is fully compressed within the tension lever and brings the shifter into direct contact with the tension lever. However, the tension lever is blocked in cBntact with the stroke adjusting bolt by the action of the governar spring which is stretched by the speed control lever. Further movernent of the tension lever is limited as the centrifugal force created through rotation of the flyweights while ‘the engine is running at idle is relatively weak. Since the position of the common fulerum point "B" remain unchanged, movement of the control lover is relayed, via the eccentric shaft, to the control rod directly, to control the volume of fuel injection.6 FUEL SYSTEM 5-1-3. Governing of maximum speed ‘As the engine speed reaches the specified maximum speed range due to change in the engine load, the centrifugal force acting on the fiyweights overcomes the tension of the governor spring and the flyweights begin to fly outward. Movement of the flyweights forces the shifter and tension lever to move to the right and ‘causes the common fulerum point "D", the tension lever and lower fulcrum “C” of the floating lever to move to position of “D1”, and "C1" respectively. As a result, the control rod is pulled in direction of fuel decrease, preventing the engine speed from increasing beyond the specified maximum speed, When the governor is used as all-speed governor: The engine speed can be varied by operating the speed control lever with the load control lever fixed in full-load position. More specifically, the engine speed is determined according to inclination of the speed control fever, but when the engine load varies, resulting change in the engine speed is automatically compensated for by the governor to maintain the engine speed constant, For instance, when the speed control lever is tilted to position for maximum output (position in contact with maximum speed stopper bolt) and engine speed is increased, the centrifugal force acting on the flyweight overcomes the tension of the governor spring which exerts pull on the tension lever, and allowing flyweights to begin flying outward. Outward movement of the flyweights forces the shifter and tension lever to move the right and causes the common fulcrum point "B”, fulerum point “D” on the tension lever and lower fulcrum point “C” of the floating lever to move to position of "BI", "DI" and “C1” respectively. As a result, the control rod is pulled in direction of fuel decrease, stabilizing the engine speed. When the engine speed lowers as a result of increase in the engine load, the centrifugal force acting on the flyweights becomes weaker than the governor spring tension and allows the ‘common fulcrum point "81," fulcrum point "D1" of the tension lever and lower fulerum point “C1” of the floating lever to move to position of “8”, “D" and "C”, respectively, causing the control rod to move in direction of fuel increase. load can be automatically compensated for by the action of the governor, to maintain the engine speed constant. 5.2. Disassembly ‘© Keep the workshop and work bench clean, © Before disassembly, clean completely, the outside surface of the governor. ‘© Extract lubricating oil from the cam chamber and the governor chamber © Arrange disassembled component parts in ‘order on the work bench. © The figures parenthesized after the description of each component part refer to it its key ‘number give in the figure.6 FUEL SYSTEM © Clamp injection pump assembly to universal ‘© Remove four bolts (82) clamping cover (80) to remove the cover. © Loosen guide screw (141), then remove idling spring assembly (140). © Using socket wrench remove lock nut (332) from second torque contro! spring assembly (340), and remove the assembly. Note This applies only to RFD-K type governor. © Remove cap nut (223) and remove lock nut assembly (220) ‘© Remove guide screw (341) from first torque control spring assembly (331), and remove the assembly. Note This applies only to RFD-K type governor. ~109-> FUEL SYSTEM ob, i: ie om a | 4a) ale ey ‘Major Parts Name 2. Governor housing g, Lever shaft b. Flyweight hh. Guide lever ass’y ©. Nut i. Bushing d. Sleeve i. Link . Adjusting shim k, Governor spring f. Sliding lever |. Tension lever lis co = S eee im. Speed setting levers. Speed control lever 1. Governor cover t._Load control lever ©. Plug u. Cover p. Tension lever shaft 4. Lock nut Idle spring ass'y -110- Loosen nut (14) and screw (53), to release the governor spring.6 FUEL SYSTEM © Remove bolts (51 and 62, C type: 6 bolts, D type: 7 bolts) to separate governor cover (35) from governor housing (130). ‘this, push down from above leaf spring with 2 screw driver as shown in the figure. Then, slide governor cover horizontal so that link in may be removed from the hole on the control rod. ASS) a ity longnoe irs tov ore oa (132) tom sing oe (2), © Insert tappet holder in the injection pump tappet, and separate tappet assembly from cam shaft, -ml-6 FUEL SYSTEM © Remove seven screws (6xSWI0 mm and 1x ‘SW12 mm). together with spring eye (9). 2) Loosen bolt (SW10 mm), to remove speed control lever (191), woodruff key (159), washers (161 and 156), collar (160) and shim (155). © Give governor housing a light tap with mallet to remove governor housing from pump housing. ‘© Removal of parts in governor cover 1) Draw out tension lever shaft (182). -112- screw driver. 4) Give speed setting lever (150) a light tap with a mallet to remove two bushes (151).6 FUEL SYSTEM 5) After removing both the block of floating lever and the pin of tension lever (181) from sliding lever (207), remove tension lever, guide lever assembly (170) and two ‘bushes (183) altogether, in the direction of the arrow. (This applies only to RFD-K type governor For RFD type governor, remove guide lever assembly in the direction opposite 10 the arrow. lever. (190). 9) Remove sliding lever with eccentric shaft (205) attached, (from within governor cover). 7) Removes speed setting lever from governor -1B-6 FUEL SYSTEM 10) Remove snap ring installed within sleeve, ‘10 separate sleeve from shifter. To remove both the plate bearing pressed into the sleeve and the bush pressed into the shifter. In this operation, use care so as to prevent damage to the chrome-plated surface at the top of shifter. Note ‘Never remove plate bearing and bush unless they are worn excessively, or the thickness of shim has to be altered. 5-3. Inspection of Disassembled Parts 53-2, Tension lever Check for wear © When clearance between tension lever shaft and tension lever is excessive due to wear, replace tension lever. I © When clearance between flyweight pin and bush or flyweight) is excessive due to wear, replace flyweight. ZS © When the contact surface between snd sleeve is worn excessively or clearance between slider and on is excessive, likewise, replace flyweight. -1d- ‘© Also when the contact sections between stroke adjusting screw, shifter and sliding lever are worn excessively, replace tension lever. 533, Guide | When the surface of shifter (ie. its contact surface with tension lever) is worn, (i. the chrome plating is peeling off), replace guide lever assembly.Pate bearing ‘A worn plate bearing is primarily responsible for excessive axial play between shifter and sleeve. If worn, replace sleeve assembly when there is a too much play in the ‘connection between shifter and guide lever, replace quide lever assembly. 53.4, the block Of floating lever is worn excessively, replace sliding lever. =15- 6 FUEL_SYSTEM 5-35, Spoed setting lever and load control lever. © Oi leakage from the shaft portion of speed setting lever indicates excessive wear of shaft or block. Replace the worn component with 2 now one. If only minor woar, replace the oil seal or O-ring concerned. If abnormal wear is noticed in the section in contact with the respective stopper bolts, replace lever with a new one. 536. Springs Replace any springs showing damage (i.e. bent, extended, etc.) flaws or rust 5-4, Reassembly For reassembling RFD or RFD-K type Governor, reverse the disassembly procedure. Point requiring special precautions when reassembling are explained below. 544, Reassembly of governor cover inner ‘components. RED-K type governor © After installing sliding lever and load control lever on governor cover, incorporate (together with guide lever assembly) the speed setting lever and tension lever (both of which remain connected with governor spring) into governor cover. Ensure governor spring has its hooked Portion, which is shaved flat, facing the link (174) when connecting speed setting lever.6 FUEL SYSTEM 5-4-3, Mounting weight rr Tension lever shaft pa ‘© Next, incorporate tension lever shaft. Ensure ‘that bushes (183) are inserted. Note During this operation, pin and block sometimes come off sliding lever. Recheck as per point 2 above. 5-4-2. RFD type governor © Unlike the RFD-K type governor, this type allows tension lever and guide lever assembly ‘to be incorporated in state in whish speed setting lever is locked in position by bushes (151). © Assembly position for governor spring is identical to that of the RFD-K type governor. ~116- ‘Make sure holds tension lever pin and the block of © Tighten round nut (103) of flyweight floating lever. securely, to the specified torque. Bush Specified tightening cove | 5 to 6 kgm 5-4-4, Assembling + Plate bearing A ‘© As shown in figure press plate bearing and bush correctly into sleeve and shifter respectively.Note Shifter Shim is provided to adjust the load contro! lever angle to the standard value. Be sure to use shim of the same thickness as the one used before disassembly. © Connect sleeve to the guide lever assembly, fitted with shifter, using snap ring. 5-45, Assembly Instructions Assemble and temporarily set full load stopper bolt, stroke adjusting bolt, idling spring, torque control springs, maximum speed stopper bolt, etc. adjust them on a pump test stand to the respective standard values, 5.5. Adjustment 55-1. Preparations © Remove damper spring (220), cover (80), torque control springs (340 and 331) and idling spring (140), and loosen adjusting serews (181/3). ‘© Mount injection pump assembly securely on 2 pump test stand. Then, attach the test nozzle and nozzle holder assembly, test lines ‘and measuring device to measure control rod travel, to injection pump. 6 FUEL SYSTEM ‘© Fill governor chamber and camshaft chamber with injection pump oil © Mount measuring device to measure the angle of load control lever. ith injection pump off, assure by moving load control lever in the directions of both “increase fuel” and “decrease fuel,” that control rod. travels smoothly. -u7-6 FUEL SYSTEM 55:2. Setting the control rod zero point © After fixing toad control lever in the idling position, temporarily set speed control lever so that governor begins to move the control rod to the fuel decrease direction at pump speed of 500 to 600 rpm. 55:3. Torque control stroke (RFD-K type only) © Fix load control lever In the full toad position, t j Purp speed {rpm} o {Control rod position (mm © Temporarily hold speed control lever in position so that governor begins to move the control rod to the fuel decrease direction at pump speed of approx. 800 rpm. | & g Pump speed trom)" 2 Increase pump speed so that control rod travels to the non Injection position, Then, press with a screw driver the up of control rod or control pinion until it stops. Make this position the “zero” point of control rod, and set the indicating pointer of measuring device to correspond with "zero" of scale. Note The operation of stopping lever will not cause control rod to travel to “zero” point. -1s- ° — Control rod position (mm) —= © Using a wrench make adjustments by means of adjustment screws (181/3), while raising ‘and lowering pump speed within the range ‘of 600 to 600 rpm, so that control rod position corresponds with the specified value "0",6 FUEL SYSTEM 55-4. Flyweight lift and full load position {Common to RFD and RFD-K) ‘The total lift off flyweight is divided into two categories: one for high speed control and the ‘other for idling control, firstly, adjust the fiyweight lift for high speed control © Fix load control lever at full pnsition {control rod position “Rb"), and temporarily set speed control lever so that governor bagins to move the control rod to the fuel decrease direction at pump speed to 700 to 800 rpm. oR Re ‘Control tod position (mm) —— © Next, decrease pump speed to “Nb” and by means of stroke adjusting screw (38) adjust flyweight lift for high speed control "“L” (control rod position Rb") Note Uf the control rod is set to the “Ra plus 2 mm” position in Step 2, set the stroke adjusting screw to the “Rb plus 2 mm" position oa a Control rod positon vr) —e © While raising pump speed to “Na,” made adjustments by means of full load stopper bolt (48) so that control rod rosition ‘corresponds with "Ra.”. Note:1) The control rod position “Ra” is the result of control rod position “Rb” ‘minus the travel “L”. oR io 2) If “Ra” is below “zero”, sot the control rod to “Ra plus 2 mm” position Pump speed (rpm) —— Control rod position {mm} —e -19-6 FUEL SYSTEM 5555. Idling (Common To RFD and RFD-K) i Ew ? Ft 2 O'R ontol vod position fmm) a Run injection pump at “Ne” (Nd + 100 rom) rpm. © Make adjustments by means of idling adjusting screw (50) so that control rod position corresponds with “Re”. ~120- © Decrease pump speed so as to maintain "Ne" = ul i” 5 Eu — ore ae Control rod position (mmm) —* rpm ‘© Install idling spring assemblies (140 and 141) into tension lever. Screw in the assemblies until control rod position corresponds with “Rd”, and then lock them at this point using a wreneh, Note At this time, pump speed may sometimes drop. Ascertain that the “Ne” rom is maintained, '® Make sure control rod position remains above “Re” even when pump speed is brought down to Oxpm. ‘© Next, raise pump speed slowly and ensure that when control rod reaches the position “Re” ‘the corresponding speed is “Nd” rpm. © Measure the load control lever angle, When load contro! lever is depressed toward the “full” position, replace shifter shim with a thicker one. When load contro! lever is depressed toward the “idling” position side, replace shifter shim with a thinner one.55.6, Damper spring (common to RFD and 6 FUEL SYSTEM 55-7. Stopper bolt (common to RFD and RFD-K) RFD-k) Pump speed rom) —e zs NS ih ‘© Fix load control lever at “idling” control position © Riase pump speed slowly from “idling” speed (Ne rpm) to the speed where control rod position corresponds with “RF” minus 0.2 ‘mm, and maintain this speed. Damer spring sting Nc Pump speed rem) —= UI © Screw in damper spring until control rod position corresponds with “RF” minus 0.1 ‘mm and lock the spring at this poin:. Pump speed ram) —= Control rod position Ap Ad Ae If idling performance is included in service data, as represented by dotted line in the figure adjust the setting of stopper bolt (60) © After setting damper spring, when pump speed is brought to 0 rpm, control rod posi- tion moves to “Re” © After loosening the stopper bolt move the load contro! lever until control rod position is “Ag” and set stopper bolt at this point. 558. Torque control device (RFD-k only) 1 Pump speed pm e wen Conttol rod postion jy) —— ~121-6 FUEL SYSTEM © Fix load control lever at full load position, © Ensure that when pump speed is at “No”. rpm, the corresponding control rod position is at "Rb". Furthermore, ensure that when pump speed is at "Nb" the corresponding control rod position is at “Rb”, © When pump speed is at “Ne”, fit first torque control spring (331) into guide screw (141), and lock it with guide screw (341) immediately before control rod position “Rb"-& changes. Control rod ostion ‘© Then, raise pump speed to "NI", ensure that control rod commences to travel in the “increase fuel delivery" direction, in RD Control roc position a) = ‘© When pump speed is at “Ng” rpm, fit second torque contro! spring (47) into guide screw (341), Serew it in until control rod position reaches “Rh”, and then lock it by means of nut (332), © Confirm that “Nh rpm represents the pump speed when the first torque control spring stops moving, and that “'Ni"" rpm and "Nj" rpm represent the pump speed when the second torque contro! spring begins to and stops moving respectively, Note 1) The setting force of first torque control spring and that of second torque control spring may be changed by varying the thickness of shim used and by the adjusting screw, respectively. 2) If high-speed contro! commences during the operation of second torque control spring, regulate high-speed control.55:9. Highspeed contro! starting point and ‘speed droop check) {Common to RFD and RFD-K) © Fix load control lever at “full” position, Pump speed vom) a ° W Control tod position ge os Raise pump speed slowly to “Nk” rpm, Make adjustments to stopper bolt (53) so that control rod commences to travel from ‘the position "Rb". ‘© Ensure by raising pump speed that it remains below “NI” rpm when control rod position reaches “Ri” Note If “NI” rpm exceed the standard value the no- Toad maximum speed of the engine is also Increased, creating dangerous conditions. Recheck both “Rb”, [fullload rod position) and “AE“0.1 mm, [the set position of damper spring]. ‘© Further increase the pump speed to Nm rpm ‘and ensure the control rod reaches in the non injection zone (injection quantities are less ‘than 3ce per 1,000 strokes). -123- 6 FUEL SYSTEM 55-10,Stopper bolt (common to RFD and RFD) © When used as minimum-maximum speed governor, screw in stopper bolt (12) until it strikes the speed control lever, and then lock it with nut (14), Pump speed vem) = Control rod position tx) —— ‘When used as variable speed governor. 1) After making adjustments as described in Figure fix load control lever at full load position. 2) Then, run the injection pump at speed "Ny" rpm which is slightly higher than the idling speed. 3) Return stopper bolt (53) to the tow- speed position side and lock it with nut (14), at control rod position Rd mm.6 FUEL SYSTEM 55.11, Fulload fuel delivery (common to RFD and RFD-k) © Readjust the fulload stopper bolt to the fulload fuel injection quantity position according to the service data. 55-12, Microswitch (Common to RFD and RFD) Run injection pump at speed indicated in calibration data © Move load controf lever and lock it at the point where the specified control rod position may be obtained, © Screw in ajusting screw until microswiteh turns an, and then lock it. = 124- 55-13, Smoke limiter (common to RFD and RFD) © Fix load contro! lever at full position. ‘© Main pump speed at "Nn" rpm. ‘Serew in spring capsule or screw and lock it at point E, where the specified fuel delivery ‘may be obtained. Pump seed (om) Contato poston (mm) —=6 FUEL SYSTEM Pump see om) 1 Housing 10 Diaphragm n Push Rod: 15 Stopper 16 Spring 7 Gasket | oe Cover | 6 Cap Nut 62 Adjusting Screw 63 Nut ca Gasket 31 ‘Spring Capsule 92 Nut 93 Cop Nut 97 Gasket Conta 4 position (mm) 55-14. Boost compensator (common to RFD and RFD-K) ‘The method of adjustment for the improved- type boost compensator (adjustable spring setting force type) is expalined below. Fig. A shows @ cross section of the boost com- pensator. Fig. B shows boost compensator performance and Fig. C shows governor full- load performance. For adjustment of the boost compensator ‘an air compressor equipped with regulator and pressure gauge is required. Control rod position sma) —= © After making the necessary adjustments while the spring capsule (91) is fully loosened, adjust boost compensator. -125-6 FUEL SYSTEM Np pump speed ‘vpn —e o 7 Control rod_ position in © Set load control lever to the position where, when pump speed is Np rpm, control rod position comes to Ra mm, Note At that time, control rod position Ry may change. If so, readjust spring capsule (91). Convo! rod position —= Boost pressure im) —— © Increase pressure further, and make certain that when control rod returns to position Ry mm, the available pressure corresponds top; mmHg. 6. AUTOMATIC TIMER 6-1. Construction and Operation Control rod position ewe Boost pressure neta) —— ‘© Screw in spring capsule (91) until control rod position comes to Ry mm, and then lock it with nut (92). © Apply possitive pressure to diaphragm (10) and Inerease the pressure slowly. fo / a oF Boost pressure ‘eth —— ‘Control rod position ng ——- © Adjust by means of adjusting serew (62) s0 that when pressure is at P,_mmHa, control rod begins to move from R, mm in the direction of “fuel delivery inerease,”” Then lock it with ut (63). = 16- In a diesel engine, a certain period of time is taken before combustion takes place after the fuel is injected into the combustion chamber, and this period is called “Ignition time delay” Since the ignition time delay does not vary greatly with the engine speed, the angle to which the crankshaft rotates within the period of ignition time delay tends to increase with the engine speed, that is, delay in ignition timing relative to the crank angle tends to increase with engine speed, causing engine performance to deteriorate. And, to permit controlling of injection timing along with change in engineSpeed, thereby to maintain optimum ignition timing through all ranges of engine speed, an automatic timer is employed. The automatic timer is installed in position between the injection pump drive and driven shaft and has 2 pair of flyweights which fly outward by the centrifugal force created through high speed operation, As the flyweights fly outward against the timer spring tension, the phase of flyweight holder relative to the flange becomes sifted and causes the fuel injection timing to increase autom: atically. As the engine speed lowers, the flyweights are pulled inward by the action of the springs and causes the injection timing to retard. When engineissationary ova When the engine is stationary or running at ow speed, the centrifugal force does not act on the flyweights, so that flyweights are held in retracted position by the action of the timer ng (at this stage, the timer spring fitted between A and B is fully stretched). “A (flyweight holder pin) is connected to the pump camshaft while “B" (foot of flange) is connected, via the coupling, to the pump drive shaft in the engine. ‘At maximum advonce angle ove 6 FUEL SYSTEM When the engine is running at maximum speed, the flyweight pivotally mounted on the flyweight holder pin flies outward against the timer spring tension on the pivot point of A. ‘Outward movement of the flyweight forces ” to move in direction of “A” but "B” remains in position as it is connected, via the flange pin, to drive shaft in the engine. ‘As a result, the flyweight holder pin “A’ pulled in direction of rotation and causes the ump camshaft to rotate causing the injection timing to advance. 6-2. Disassembly © Take out the automatic timer assembly from the injection pump. © Unscrew the bolt on the holder. © Clamp the base of special tool in a vise to facilitate disassembly operation. -127-6 FUEL SYSTEM © Remove the timer flange carefully using @ pair of screw drivers, so as not to lose timer springs and adjusting shims. © Remove the timer case by using the band wrench, ed ‘The automatic timer having the timer case with right-hand and leftthand threads are available for selective application depending ‘on rotative direction of the injection pump. © Remove the timer spring from the flyweight holder. Note Use care not to lose the timer spring, adjusting shim and other small parts. 6. Bott 6. Oil seal Timer case 7. Shim Oil seat 8. Timer spring O-ring 9. Flyweight Timer flange 10. Holder \ ~128~6 FUEL SYSTEM 6-3. Inspection of Disassembled Parts. © Check the pins on the flyweight holder and flyweight holes for wear, then check fit of pins to the flyweight holder. © Check the timer springs for weakening or breakage. If the timer spring is found to be defective, replace both of the springs at a time together with the adjusting washers as the tension of the springs are factory-adjusted with the washers, © Check the parts for binding and correct or ovie? replace as necessary. ‘© Install the flange and hook the fingers of the special wrench to the flange. Install the 6-4. Reassembly thrust bushing washer and bolt on the flange. Insert @ screw driver into the hole in the flange and set the timer spring in position between the pin on the flyweight holder and pin on the flan. z EB E © Clamp the base in a vise. Install the bolt on the base. Install the flyweight holder on the bbase by aligning the pin holes in the holder with the pins on the base. © After installation of the timer flange, check ss that the spring is correctly installed in the fiyweight by inserting a screwdriver through the hole in the timer flange. © Assemble the flyweights to the pins on the flyweight holder. Install the adjusting shim Dy ict ‘and timer spring on the pin. Secure the ‘© Install the seal guide and timer case. Tighten spring by positioning supporter under the the timer case with band wrench. Note the spring. Serew the guide into the guide bolt direction of threads when tightening the timer case. = 129-6 FUEL SYSTEM © When reassembly operation is completed, remove 2 plugs from the flyweight holder and apply timer grease (150gr) into the fiyweight holder. © Caulk the grooved portion of the timer case to prevent loosening, 655. Testing ‘Measurement of advance angle 651. © Prepare a stroboscope for measurement of timing advance angle. Set the synchronizer ‘0 the pump tappet. Operate the pump and aim the scale on the ump tester with strobo light and take reading at various pump speed with the control lever ‘on the governor fixed If the advance angle at rated pump speed deviates from the specification, make ‘an adjustment with the adjusting shim fitted behind the timer spring. 65-2. Automatic timer characteristic diagram > > > ‘Advance angle (dag) 2 > =130- 7. FUEL FEED PUMP ‘The feed pump tappet is driven by the eccentric ‘cam on the injection pump camshaft and move ment of the tappet is relayed, via the push-rod, to the piston. As the piston operates, the fuel within the fuel tank is drawn in through the fuel filter and delivered to the injection pump under pressure. To permit manual feeding of fuel even when the engine is stationary, a priming pump ' installed which is independent of the mechanical pump driven by the eccentric cam, aS, Ate ste Sa, ‘ow When the camshaft is in position as iustrated, the piston is pushed up and check valve on the inlet side is closed, so that pressurized fuel within the inner chamber pushes open the check valve on the outlet side, filling the outer chamber (a part of fuel finds a way into the fuet fitter).6 FUEL SYSTEM When the camshaft is rotated as illustrated, the piston is pushed down by the action of the piston spring and fuel within the outer chamber is forced out, past the outlet side, into the fuel filter. Since removal of fuel within the outer chamber causes the pressure of fuel within the inner chamber to lower, the check valve on the outlet side closes and check valve on the inlet side ‘opens, leading additional fuel into te inner chamber. This cycle tinuously. is repeated to deliver fuel con: A strainer is fitted into joint bolt on the inlet side of the fuel feed pump to prevent dust particles from entering the fuel injection pump. ‘As the pressure of delivery exceeds the piston spring tension, the piston is held in lifted Position to interrupt further delivery of fuel and to prevent, preventing unnecessary increase in the feeding pressure. -131- Manual priming pump is installed on the fuel feed pump, so that fuel can be pumped out into the injection pump after installation of a new Injection pump or when engine is stationary, ‘for bleeding fuet system. It is necessary to make a test on the priming pump and fuel feed pump independently as the priming pump is built independently of the mechanical feed pump which is driven by the Injection pump camshaft. 7-2. Disassembly ovi316 FUEL SYSTEM '* inspection of fuel feed pump before disasse- mbly, Push in on the tappet with the thumb. {f the tappet can not be pushed all the way in, it indicates that either the piston or the push 0d is seized up or sticking © Inspection of priming pump before disassem bly, If the pump handle does not snap out when screwed off the position, it indicates that the internal parts are seized up or sticking, ‘© Remove the inlet side and outlet side joint bolt respectively, © Remove the priming pump and plug, then remove the check valves, and valve springs. note the position of check valves and valve springs to prevent interchanging. © Remove the piston chamber plug and gasket, then remove the piston spring and piston, Y, iy f ‘© Pull out the snap ring and remove the tappet assembly carefully to prevent the tappet guide from falling off.6 FUEL SYSTEM 1. Inlet side joint bolt 12, Spring 2. Strainer 13, Check vale 3. Gasket 14, Piston chamber plug 4. Outlet side joint bolt 15. Gasket 5 16. Piston spring 6. 17. Piston 7. Gasket 18, Push rod 8. Soring 39, Snap ring 9. Check valve 20. Tappet 0. 21. Housing 1 7-3. Inspection © Check the gauze filter for restrictions and wash clean as necessary. Replace the filter with @ new one if found to be damaged. © Check valve 1) Check the seating face for step wear or cracking and replace the check valve with a new one if wear or damage is beyond ‘correction. Check valve with slight step wear can be corrected by lapping on a ‘lass sheet using fine lapping compound. 2) Check the valve seat in the housing for distortion or damage and replace the body if found to be defective. 3) Check the valve spring for cracking, distor- tion or damage and replace as necessary. ‘© Check operation of the priming pump handle and replace if its movement is unsmooth. © Check the piston for cracking or scuffs and replace if any abnormal condition is, noticeable. ‘© Check the push-rod for wear or damage. when replacement of push rod becomes necessary due to excess wear, it must be replaced together with the pump housing. © Check the tappet roller and pin for abnormal wear or cracking and replace as necessary. Assemble the pin to the roller and check for looseness of fit and replace if an excess play is noticeable. ‘© Check the threaded portions of the housing for damage and replace as necessary. 7-4, Reassembly © Install the push rod in posi housing, so that its end with heavy chamfering is turned to the piston. vena! ovis © Insert the piston into position in the pump housing, so that its concaved face is turned to the push rod. © Install the piston spring6 FUEL SYSTEM © Apply liquid gasket to the threaded portion and seating face of the piston chamber plug Torque (kg-m) © Insert the tappet roller into the tappet body and align the pin holes, then install the roller pin, A kN © Align the end of the roller pin with the face tof the tappet body and install the tappet guide. ~1t- fovia2 © Push the tappet all the way in and fit the hooked end of the snap ring into the corresponding hole in the pump body, then insert the ring into the ring groove around the body. ‘© Install the check valves on the pump housing (Install the check valve on the delivery side and on the priming pump side at a time.) © Install the check valve springs © Install the priming pump assembly and plug fon the pump housing ‘© Install the joint bolts. 7-5. Testing 7-5-1. Suction capacity test © Connect a pipe to the inlet side of the feed pump and submerge the other end of the pipe into the fuel tank. ‘© Hold the pump in a position about 1 meter above the level of fuel in the fuel tank. Operate the tappet at the rate of 100 rpm and see if fuel is drawn in and delivered within 40 seconds or so.7-5-2, Delivery test conom ff © Make @ test with the pump mounted on pump tester. Operate the pump at the rate of 1,000 rpm and see if pump delivery is more than 405 oc per 15 seconds. 753, Sealing test 6 FUEL SYSTEM 8. FUEL INJECTION NOZZLE 8-1. Construction and Operation Nozzle holder body} Cap Nut Adjusting shim . Compression spring Spindle ‘Spacer . Nozzle nut 8, Nozzle Feed pomp ‘© Submerge the feed pump assembly completely in diesel fuel with the delivery port plugged ‘and compressed air of approximately 2 kg/cm? applied into pump from intake (suction) side. =135- The injection nozzle consist of the nozzle body and needle valve assembly. The injection nozzle assembly is so designed that pressurized fuel from the injection pump is spraged into the engine combustion chamber past the orifice provided in the nozzle body. The fuel Injected should necessarily be ignited immediately and combusted in a short period of time, as too long @ combustion period will prevent high speed operation of the engine and ‘can cause serious engine knocking6 FUEL SYSTEM The hole type injection nozzle are generally used for direct.injection type diesel engines ‘and injection starting pressure is_normally adjusted to 180 ~ 300 kg/em?, The end of needle valve of the hole type in jection nozzle is conical faced. ‘The hole type injection nozzles can be classified into single hole type and multihole type according to number of injection orifices provided. The hole type injection nozzles have relatively high injection pressure to ensure efficient atomization and distribution. 8-2. Disassembly Exercise extreme care when handling the injec: nnozdle assembly, particularly the nozzle body and needle valves as these parts are ultra: precision finished, Wash clean the injection nozzle assembly remove from the engine prior to disassembling © Clamp the nozzle holder in a vise and remove the cap nut, © Remove the adjust screw lock nut and emove the adjust screw, then remove the spring and ush-rod. ‘© Clamp the nozzle holder body with the nozzle side up in a vise © With a wrench remove the nozzle nut using ‘care not to drop the nozzle. Remove the nozzle carefully not to drop the needle valve |. Nozzle holder . Guide bush Coil spring Shim 3 Union aut Intermediate washer . Nozzle 1. Seal ring PN eHeune 8-3. Inspection of disassembled parts Wash clean the disassembled parts in clean kero- seme and insert the needle valve into the nozzle body in new kerosene, If the negcle valves are fouled with carbon deposit, clean them in kero- sene by using a piece of wood and avoid the use Of abrasive particles and other metal cleaners. Keep fingers away from the lapped portion of the needle valves, or rust formation will esult Clean the internal part of the nozzle body in kerosene by using a piece of wood. 8-3-1. Visual inspection ‘After washing, check the injection nozzles against the following: © ‘Needle valves Check the valve seats, guide shafts and injection shaft for damage. © ‘Nozzle body Check the valve seats for carbon deposit and damage. Also check the injection orifices for uneven wear, Replace both of the parts by using asse: bly even if either of the needle valve or the nozzle body is found to be defective 83.2, Sliding test A sliding test should be made on the entire Injection nozzles often visual inspection. Hold the nozzle body vertically and pull the needle valve upward about 1/3 of ‘its entire length and release it and see if it lowers onto its seat by its own weight. If lowering of the needle valve is unsmooth check for presence of foreign matter and repeat the test. If the trouble persists, replace the entire nozzle assembly with a new one. 8-4, Reassembly Reassemble the nozzle and nozzle holder assembly in the reverse order of disassembly 8.5. Testing Make the following tests by using a nozzle tester © Injection starting pressure © Spray pattern and operating noise.6 FUEL SYSTEM 85-1. Injection starting pressure test pressure: 120 kg/em2) Clean the fuel tank on the tester, fuel pipe, nozzle nut and testing nozzle and use only clean kerosene (specific gravity: 0.82 ~ 0.84) in the tester after filtering to be sure it is absolutely free from foreign matters. When inserting the nozzle into the nozzle nut check the contact faces for damage and presence of foreign matters. Make sure to install the nozzle on the tester after turning loose the spring adjusting serew sufficiently. (standard Nozzle nut torque {kg-m] ens LS °" 1 When the nozzle assembly is installed on the tester. operate the hand lever 2 or 3 times to see if the nozzle is properly set in position. If the joints are free from leaks and the needle valve is working normally, the operation of the nozzle will be accompanied by whistling sound. Adjust the standard pressure by means of the spring adjusting screw. 85-2, Spray test Install the injection nozzle assembly on the tester ‘and operate the tester several times and visually check the spray patterns agdinst the following Replace the nozzle assembly if found to be out fof normal operating condition. The pressure gauge should be held out of function when making sprey test. Spray should be free from coarse particles, © Spray pattern should he uniform and free from spattering. © Nozzle should be free from dropping, =137- abnormal 85:3. Testing precautions © Exercise extreme care to avoid bringing the fuel sprayed from the nozzle on the tester into direct contact with your hands as the sprayed fuel particles will penetrate deeply into the skin and cause damage to the tissues and leading to blood poisoning, if allowed into blood vessels. © Use only new and clean kerosene in the tester and keep the surrounding free from ditt, dusts and other foreign matters. © Test the pressure gauge once a month an the indication is not accurate, replace the gauge or place a correction table on the gauge.6 FUEL SYSTEM 69, TROUBLE SHOOTING Complaint Cause Correction 1, Engine does not start 1) Fuel not being pumped | 1. Fuel pipes clogged or air in pipe line Correct ‘out from feed pump 2, Feed pump valves defective Replace 3, Feed pump piston or pushrod sticking | Correct or replace 4, Gauze filter in feed pump clogged Clean 2) Fuel not being injected | 1. Fuel filter element clogged Clean from injection pump 2. Fuel filter overflow valve remaining open | Replace valve | 3 Air in fuel fitter or injection pump Bleed 4, Plungers or delivery valves sticking Correct or replace 3) Fuel injection timing 1. Injection pump not properly installed | Correct incorrect ‘on pump bracket 2, Injection timing incorrect Correct 3. Cams on camshaft worn excessively Replace 1, Needle valves sticking Correct or replace 2. Fuel leaking past clearance between Correct or replace nozzle and needle valve 3, Injection pressure incorrect Adjust 2, Engine starts but stalls 1, Pipe fram feed pump to injection pump | Clean immediately clogged or filter clogged 2. Air in fuel Bleed 3, Feed pump delivery insufficient Correct or replace 4, Fuel delivery insufficient due to clogging | Clean or replace of fuel tank air breather. 3, Engine lacks power 1. Plungers worn excessively lace 2 Adjust 3. Replace 4, Nozzle leaks excessive Correct or replace 5. Nozzle not working normally Correct or replace 1, Injection timing too fast Adjust | 2. Nozzle injection pressure too high Adjust | 3. Nozzles not working normally Correct or replace 5. Engine knocks seriously | 1. Injection timing incorrect Adjust producing excessive 2. Nozzle injection pressure too low Adjust exhaust smoke 3. Nozzle spring broken Replace 4, Nozzles not working normally Correct or replace 5. Plungers worn excessively Replace =138-6 FUEL SYSTEM Complaint Cause Correction 6. Engine output unstable 7. Engine dose not reach maximum speed . Automatic timer defective Delivery valves seat defective Supply of fuel excessively Supply of fuel insufficient Air in fuel Water in fuel Operation of plungers unsmooth 3. Movement of control rack sluggish . Nozzles defective . Injection starting pressure of each barrel incorrect Nozzles not working normally . Governor defective Replace Check feed pump | cheek feed pump Bleed | Replace fuet Correct or replace Correct or replace Correct or replace Adjust Correct or replace Correct or replace Correct o replace 8. Engine idling unstable Movement of control rod sluggish Operation of plungers unsmooth Control pinions not engaged with control rod correctly Correct or replace Correct or replace Correct or replace =139-7_ENGINE ELECTRICAL Section7 ENGINE ELECTRICAL CONTENTS PAGE 1, Altemator . 1-1. Construction and Operation . .. 142 1-2. Main Data and Specification... +143 1-3, Disassembly .. 1-4, Inspection... 15. Reassembly .. 1-6. Trouble Shooting ... eee Boopanco §/¥) 20 Regulator nema eeereeee seer = 149 2:1: Construction and Operation : seveeees 149) 2-2. Main Data and Specification ... +151 2:3, Inspection . sees 151 3. Starter ... 3-1. Construction and Operation . . 3-2, Main Data and Specification ....... 3-3. Disassembly .. ++ 155 3-4, Inspection ... 157 3.5. Reassembly .. 160 3-6. Trobule Shooting ... 161 4. Preheating System ... 4-1. Construction and Operation ............ 4.2 Disassembled View of preheating system ..7_ENGINE ELECTRICAL 1, ALTERNATOR 1-1. Construction and Operation Storage battery (or batteries) is (are) used as @ Power source of the automotive electrical system. However, the capacity of the battery is limited and battery becomes undercharged as it is subjected to electrical loads and finally becomes unable to deliver electric power. Therefore, the battery should necessarily be recharged using @ charging system which consists principally of a generator and voltage regulator. ‘The generator is driven by the engine and develops, through magnetic induction alternating current which is rectified into direct current before it is fed to the battery, ignition system, lights and other electrical circuits. The regulator is designed to regulate the output of the generator thereby to hold it constant regardless of fluctuations in the engine. ‘An A.C. generator consists of the following parts as shown in the figure, 1) Rotor and rotor-coil 2) Stator and stator coil 3) Brush and slip ring 4) Diode 5) Pulley and fan Some A.C. generators self-contain regulators in their becks, and some others drive vacuum urnpe to take out vacuum for foot brake Mastervac. -12- 14-1, Stator Saige com ‘The stator consists of the stator core and stator windings and combines with the stator core fixed to the end frame to form a magnetic circuit. Three sets of independent stator windings (coils) are fitted into slots provided in the inner circumference of the core, and are connected in the form of the letter "Y”. While the generator is in operation, three-phase alternating current is induced in the stator windings. ‘The rotor assembly consists asially af the rotar core, rotor windings, slip rings, rotor shaft, etc. and is driven by the fan belt fitted to the crank shaft pulley. The rotor windings (coils) receive the electric current from the battery and induce ‘magnetic lines of force. The rotor windings areconnected at both ends to the slip rings ‘The rotor core becomes magnetized by the ‘action of the magnetic fluxes produced by the rotor windings. A pair of slip rings are used to carry the current from the battery to the rotor windings. ‘The faces of the slip rings in contact with brushes are smoothinished and slip rings are insulated from the rotor shaft, 14:3. Diode 1) Se ce There are two diode-holders in a A.C. generator. To each holder three sets of diodes are fitted, ‘and the positive diode holder is insulated from the rear cover. 14-4, Fan A fan is installed on the shaft pulley to cool the hheat generated portions. Cooling air flows as shown in the figure. 7_ENGINE ELECTRICAL 1-2, Main Data and Specification (Tem ‘Specification — Type 2 ete aerator Fated otage oy | Fated out sv | arated 11,000 em Speed ar Fates | Negative polarity Rotation | direction (Cloctowvien "The rated out put may vary upon the vehicle model. 1-3. Disassembly © Remove the through bolts and separate the body into front and rear sections. When separating, exercise care so as not to allow stator coils to come off the rear cover. © Clamp the rotor assembly in a vise and remove the pulley nut, then remove the pulley, front cover and rotor.7_ENGINE ELECTRICAL ‘© Remove the nuts fixing thesB te-minal and © Separate the diodes from the stator by diode holder, then remove the serew inside melting away solder on stator coil, diode and the stator. Separate the stator and rear cover. “N" terminal leads. Note the position of insulation washers to When melting solder, hold the lead wire with insure reassembly into original position. long nose pliers to prevent heat from being transferred to the diodes, |. Though bolt . Pulley nut Pulley Fan Spacer ring Rotor Screw Retainer plate 3. Ball bearing 10. Drive end frame 11, Nut 12, Insulator 13, Rear end frame 14, Insulator 18. Stator 16. Brush 17. Brush holder 18. Rectifier ~1d-7_ENGINE ELECTRICAL 1-4. Inspection Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection. 1.41. Ball bearing ‘© Replace those which do not turn lightly, drag or generate noise. 142. Slip ring When the sliding surface is not clean, wipe it with @ piece of cloth impregnated with alcohol, or polish it with a fine sand paper of $500 to 600 when roughened. When the slip ring is worn excessively and the outer diameter is tess than the use limit, replace the rotor assembly with « new one. 1.4.3. Rotor coil -15- (© Measure resistance across the slip rings, and replace the coil with a new one when resistance is improper. ‘© Measure insulation across the slip ring and rotor core and insulation across the slip ring and shaft. When continuity exists across them, replace the rotor 1-4-4, Stator coil © Check each stator coil for continuity, and replace the stator coll with new one when no ‘continuity exists Note When no continuity exists, check connected portion of the lead wire first. Measure insulation across the stator coil and stator cor Replace the stator coil with a new one when continuity existsZ_ENGINE ELECTRICAL 1.45. Brush Nim toe © For a brush which has a size reduction limit line, replace it with a new one when it is worn beyond the limit line Replace damaged brush with a new one. Replace the brush which does not move smoothly in the holder. Make @ test with the polarities reversed. If ‘no continuity exists the diode is in satis factory condition, If @ continuity exists at ‘any point, the diode is defective and should be replaced. Auxiliary diodes are not provided with the terminal and a continuity test should be made ‘across the terminals of the conventional diodes oiled terminals ‘non Posaive side (FF eoces Acro terminals “Tester in uvw, Positive sie No continuity [eon i ‘Across terminals © Length of the portion exposed from the brush holder. Replace when it is worn beyond the use Hieit. 1.46, Diode © Check for continuity across the terminals (example: across BAT and U). If a continuity exists the diode is in satisfactory condition. Hf no continuity exist the diode is defective. Tester pin Negative side Posie side Continuity | Negative side | Important -M6- 1) Do not use high voltage insulation resistance tester to check continuity of diode. The diode will be damaged. 2) The diode may be judged to be normal when difference between the forward and reverse resistances is large. 3) The diade consists of each three positive (+ and negative (—) diodes. Check continuity across the electrade and lead wire of each one of the diodes, The individual diodes cannot be measured unless the lead wire is disconnected. Each set of positive (t) or negative (-) side can ‘be measured,7_ENGINE ELECTRICAL 4) When anyone of the diodes is defective, . replace the whole assembly with 2 new one. 15. Reassembly To reassemble, follow the disassembly procedure in reverse order and note the following: © When connecting stator coil leads to rectifier using a soldering iron, solder quickly and use long-nose pliers or equivalant to allow When installing terminal bolts and rectifier fixing nuts, be sure insulation washers are in place. When fitting the rotor slip ring under the brushes hold the brushes in raised position by fitting @ piece of hard wire into guide hole in the drive and frame or rear end frame; Install a guide bar through holes in drive end frame and rear end frame for alignment of setting marks, then install through bolts Tighten fixing bolts, screws and nuts to the for heat dissipation. 16. Trouble Shooting 1. Check the circuit for connection specified torque. of each 2, Select those related to the battery and charge connector. light from the following table, and take ecessary action for them. Complaints | Faulty parts Possible cause Correction AC. 1. Grounded or broken stator coll. Repair or replace generator | 2. Broken rotor coi Replace | 3. Poor contact between brush and slip | Replace the brush | ring (improper brush alignment) with a new one if it | is worn, (Clean the holder) Polish the slip ing . Damaged diode. Replace the diode. . Damaged capacitor. Replace Wiring Broken wire or poor contact across | Repair. | starter switch and regulator terminal 1G. | 2, Blown out fuse of the above circuit or Replace the fuse or oor contact with the fuse holder. repair contact point | of the fuse holder. | 3. Broken wire or poor contact across Repair. regulator terminal F and A.C. generator terminal F. | Discharged Installation of | 1. Loosen fan belt. Adjust belt tension, battery. AC. generator | 2. improperly grounded AG generator. | Repair. Battery 1. Insufficient or improper battery fluid. | Replenish or adjust specific gravity. 2. Defective pole {interna short-circuit). | Replace. 3. Poor contact due to corroded terminal. | Clean and retighten. Regulator | 1. Poor contact of point at low speed Polish the point. side -uT-7_ENGINE ELECTRICAL Complaints | Faulty parts Possible cause | correction 2. Adjusted voltage is too low, | Readjust. 3. Fused point at high | Replace. | the alternator [nea | Anna ettitio | Bane oumt ot rod | pe Santest against normal driving speed. | Wiring 1, Erroneous connection or shorted | Correct. regulator terminal 1G and F. | 2. Improperly grounded regulator | Correct. terminal. 3, Broken wire or poor contact across. | Repair or replace. AG. generator terminal N and regulator terminal N Over-charged | Regulator 1. Broken wire of pressure coil. Replace battery. | 2. Fused point at low speed side. Replace. | 3. Poor contact of point at high Polish the point. | speed side. | 4, Adjusted voltage is too high. Readjust. | 8. Poor contact of field relay point. Polish the point. t + Fan belt 1. Loosened fan bet. Adjust belt tension, Charge light ~~ ee — flashes or am- | Staterswiteh | 1. Poor contact of starter swith, Replace meter indica- > — tion fluctuates, | Wiring 1. Loose connection or going to broken. Retighten or repair, Regulator 1. Unstable each point operation. Readjust. Wiring 1. Loosened wire at starter switch Retighten. Charge light terminal. dims during 2. Excessive resistance of the wire Replace the wire driving and | ‘between A.C. generator terminal 8 with a one of larger doesnot go | to the fuse holder to which the charge size and retighten ‘out completely | fight is connected, | each part, {in case of t — |} normally OFF | Starter switeh | 1. Poor contact. Replace typel. : - || Regulator 1. Poor contact of voltage relay point. Polish the point. AS. 1. Defective bearing. Replace the bearing Noise is genera-| generator | + and regrease ees 2. Damaged diode. Replace the diode pian 3. Grounded or inter-phase short Replace. Circuit of stator coil. I ~48~ENGINE ELECTRICAL Canna | Fron eoe | Ponies Corton Wireg [Ws Ground min Bra Teak Blown out fuse | ac, \* Damaged diodes in (+) and (—-) sides. Replace the end ctenaeer | AS frame comple Sheu |2, Damaged capacitor meolce Regulator |. Adjusted vote. Readius. Grory |. ovr conoced bey covet. 2, REGULATOR 2-1, Construction and Operation ster cit If the generator output is applied directly to the battery, lights or other electrical loads, battery ‘over-charging, burning out of light bulb, or other ‘electrical troubles will be caused when generator speed is increased. For this reason, generator circuit calls for an electrical device that regulates the output voltage to a constant level even when ‘generator speed is increased. This constant voltage device is called “Regul- ator.” Tirrill type (moving contact type) regulators have been widely used for their performance and dependability, however, stationary type regul- ators such as transistor regulators and ILC. regulators have been made available owing to recent advancement in semi-conductor tech- nology. In general, regulators with the function of a voltage regulator will suffice to keep the A.C. gonerator circuit working properly, In most cases, other electrical devices such as generator indicator light relay, field relay, ete. are combined with the voltage regulator. eguator t La ‘The regulator controls current to the rotor coil. When output voltage exceeds the rated value, the regulator reduces current to lower the output voltage. When output voltage drops below the rated value, the regulator increases -149~Z_ENGINE ELECTRICAL current to raise the output voltage. Repeating the above operations, the regulator maintains ‘output voltage within the rated range. Regulators can be classified into the following types according to construction. A contact point type regulator has 4 resistance connected in series with the field winding and contact breaker points are provided at end of the resistance for controlling field current. (1) Operation of single contact point type regulator {in the case of a single contact point type regulator, resistance R is connected in series to the field winding and resistance is shorted out by means of the contact breaker point. =150- When the generator is running at low speed, moving contact point P is closed and large field ‘current flows through the point side without Insorted resistance. ‘As the generator speed increases, electromotive force increases in proportion to the speed, Electromagnetic force also increases with the electromotive force and causes the contact point "P" to open. With the point “P opened, large field current which was flowing past the point “P” through circuit without resistance is made to flow the resistance “R’” and as a result of reduction in the current, electromotive force is decreased. ‘As the electromagnetic force of the winding “IM decreases with the electromotive force, ‘the contact point “P” closed by the action of the spring. As a result, the current “If” and ‘electromotive force increase until contact point ‘The above action takes place repeatedly to hold the output voltage at a constant level. This contact makes and breaks more frequently as generator speed increases, causing the mean current to reduce. In addition, when the point breaks, it sparks due to an inductance of the stator coll, causing service life of the contact to be shortene (2) Operation of double contact point type regulator ‘The resistance connected in series with the stator coil is reduced to reduce current at @ high speed. Further, this type is equipped with a high speed side contact to shorteircuit the stator coil when speed exceeds a certain level.7_ENGINE ELECTRICAL 2-3. Servicing of Tirrill Type Regulator (for havy-duty truck only) Fe to Geeator indicator To one ree Baueny Regulator Generator ‘Transistor type oo ‘A transistor takes place of relay contact, and the base current is interrupted and output voltage is detected by @ zener diode. This type eliminates moving part. 2.2, Main Data and Specification item Heavy doty ruck) Lar Bos Type Teil type Out putcurent | a8 | Ftd rate sew | 12 Vor | tim wor | i | Fuge alae | 27.8~208V Polarity grounded | Negative polarity | 23-41. Inspection ‘© Remove the regulator cover and check the parts for distortion, cracking, rusting or damage and replace the regulator assembly ith a new one as necessary. When checking the regulator, pay close attention to the seals and gaskets and gasket fitting face of the cover and body as poor sealing permits entry ‘of water and cause permanent trouble of the regulator. © Check the points for burning or roughness and dress with a fine sand paper ( #500-600) as necessary. © Check the resistance of the voltage regulator coil and field relay coil with a testor. If the testor indicates open and shorted coil, replace ‘the regulator assembly with a new one, Votogereputor cot raniarce | 20080) | et vely col revtance 715% [See ey cone © Check resistance of the resistor with tester, replace the resistor with new one if found to be defective. 23-2, Mechanical adjustment Check and adjust the voltage regulator and field relay gaps to the values specified in the following table in sequence of the yoke gap, core gap and point gap. -151-7 ENGINE ELECTRICAL [em | oteage euat | rity | Yore op tam] O2ermore | OS orle I Tosa. loun et [core op tr | Cormore [ronan imi) os-o7 [oana | core gop coemp iC SST stopper scream Yoke gap en 7 point stb ate point gap Voltage regulator Field ray 233. Adjustment of voltage regulator no-load voltage. © Disconnect the cable at the negative side terminal and remove the regulator cover. © Disconnect the cable from the generator B terminal. © Pull out the 1 terminal from the connector fon the regulator side and make a connection between the generator 8 taminal and | terminal. © Connect a DC voltmeter (30V) between the regulator | terminal and ground. © Connect the negative terminal of the battery. 5==0G4 | i Voltage { Generator © Start and keep the engine running for a while land increase the enging speed to 2000-2500 ‘pm and adjust the voltage with the adjusting screw, so that the voltmeter reads 27.5-29.5, volts Note If voltage is mot generated even when engine speed is increased, apply current ta the regulator Werminal for excitation, ~152~ 23.4, Adjustment of field relay © It is impracticable to check and adjust field relay on the vehicle. Engine running. . . .paints on lower side are closed jpoints on upper side are closed Engine stopped .. © Bench test 1) Connect a DC voltmeter between the ‘generator N terminal and ground. 2) Increase the generator speed gradually and adjust the field relay setting, so that the field relay points are closed when the voltmeter reads 5:6 volts, If the relay points remain open when voltmeter is reading 6 volts, turn out the adjusting serew. Conversely, if the relay points close before 5 volts, turn in the adjusting ae aE Vale | I regulator 3. STARTER 3-1, Construction and Operation Since enignes are not selfstartable, 2 means should necessarily be provided for turning the crankshaft thereby to bring the pistons into reciprocal motion for starting. This auxiliary system is refered to as starter system and con: sists of a starter motor, battery (or batteries), starter relay, starter switch, ete. This section deals mainly with the starter motor. The starter is a battery operated die. motor with mechanism which serves to carry the motor torque to the engine. The starter motor is @ series type high output motor and differs from the conventional electric ‘motors in that itis built compact for its output fon account of extremely short period rating {80 seconds).7_ENGINE ELECTRICAL Magnetic shift type starter motor is orincipally corsturcted with motor, pinion cutch and ‘magnetic switch. 34-1 Motor ‘The motor assembly consists of the stator and lings are connected in series to the and this type of starte’ moto “"D., series coll type.” The series type motor features a high starting torque. 34-2. Yoke The stators with 4 poles and 4 windings, and. with 4 potes and 2 windings are avalatie, The yoke assembly consists principally of the field windings, pole cores, ete The yoke is made of soft iron which is low in magnetic resistance to form the outer casing of the motor. It includes the field windings and ~153- pole cores. As the field windings are subjected to the same electrie current that flows through the armature windings, heavy copper wires having a rectang lular cross section are used. ‘These copper wires are wound around the cores through insulation material 343, Armature The armature assembly consists basically of the armature shaft, core, commutator, windings, ete, The armature core is of thin steel sheet laminated construction and has radial slots into which windings ae fitted Since large electric current flows through the armature windings, heavy copper wires having 4 rectangular cross section are used, and ends of the windings are connected to the commutator. The armature shaft is provided with splines (generally helical splines) by which the shaft is connected with the overrunning elutehZ_ENGINE ELECTRICAL © Disconnect the lead wire from magnetic switch. =156- ing long-nose pliers, remove the brushes and pull out the brush holder from the armature. Note 1) When removing brush (+) on field coil side, raise brush spring, then remove the brush from holder. 2) Raise brush spring on brush holder side and pull the brush (—). © Using a plastic hammer, tap on the yok: to separate the armature from yoke. \ | ‘© Remove two sorews from drive housing and separate the drive housing from magnetic switch. ‘© Remove remove the two pinions and overrunning clutch and retainer.© Remove the return spring from magnetic, switch. 7_ENGINE ELECTRICAL 1. Nut 2. Connecting lead 3, Through bolt 4, Screw 8. End frame 6. Cover 7. Brush 8 Brush holder 9. Yoke 10. Armature 11, Felt washer 12. Lock plate 13. Screw 14. Housing 15. Idler gear 16. Retainer 17. Roller 18. Clutch 19. Steel ball 20. Return spring 21. Magnetic switch © Remove the steel ball from overrunning clutch. 3-4, Inspection ‘The following outlines the inspection and service procedures for disessembled parts of the starter motor. Correction or parts replacement should be made if wear, damage or any other abnormal condition is found through inspection, 34-1. Amature -157~7 ENGINE ELECTRICAL © Check the commutator face for roughness and dress with a fine sand paper { #500-600) as necessary. © Check the insulation resistance across the commutator and armature core using @ circuit tester. Replace if defective. ‘© Measure the largest and smallest diameters of the commutator, then compare measurements to determine the amount of out of round. If the amount of out of round deviates from the standard value, turn the commutator in a lathe. Replacement is necessary if the amount of out of round is beyond the limit of correction. Bad correction ms orroet by Segment 1: Depth of undercutting © ‘Measure the depth of undercut mica between commutator segment and correct as necessary. Depth of mice segment (om) | stand =158- © Connect the probes of a circuit tester across the 2 segments. There should be continuity at any test points. Replace if it is open: circuited. 3.4.2, Yoke© Check the insulation resistance across the field windings and yoke core. Using circuit tester, touch one probe to the field winding end or brush and the other to the bare surtace of yoke body, There should be no continuity. If the tester indicates a continuity, the field coil is ‘grounded and yoke assembly should be replaced. © Check for continuity across the connecting leads and brushes. Using a circuit tester, touch one probe to the “C" terminal lead wire and the other to the brush, There should be a continuity. Replace the yoke if itis open. rush and brush holder ‘© Check the contact face of the brushes for roughness and correct as necessary. © Check the amount of wear in brushes. Replace the brushes if the amount of wear is beyond the limit. Sanat) ni }-~—— [zs Brush length | —__ (mm) aoe 7 ENGINE ELECTRICAL ‘© Check the brush holders for © Check movement of brush in each brush holder. Clean or correct as necessary. 3-4-4, Overrunning Clutch © Inspect the teeth of pinion for wear and damage. Replace it if damaged. Rotate the pinion in direction of rotation (clockwise). It should rotate smoothly. But in opposite direction, it should be locked 3.45, Bearing © Check the bearings for wear and damage. If the bearings are noisy during operation, ‘they should be replaced. 3.4.6. Magnetic siwtch The following magnetic switch tests should be performed with the starter assembled. -159-7 ENGINE ELECTRICAL Disconnect the yoke lead wire from “°C” Each test should be completed in a short time {3-5 sec.) to prevent the coil from burning. © Pullout test ‘The pinion should be pulled-out strongly if the magnetic switch is satisfactory, when the following connections are completed. 1) Connect the battery negative test leads to the starter body and ""C” terminal. 2) Connect the battery positive test leads to 60" terminal. © Holdin test ‘This test is conducted in the same way as the pull-out test with the “C” terminal test lead disconnected. If the pinion is in the pulled- ‘out position the magnetic switch is satisfactory. ~160- © Return test ‘The pinion should be pulled-in to its home position if the magnetic switch is satisfactory, when the following connections are completed. 1) Connect the battery negative test leads to the starter body and “50” terminal 2) Connect the battery positive test leads to the “C" terminal. 3.5. Reassembly To reassemble, follow the disassembly procedure in reverse order and note the followit © When installing rotating or sliding parts, check to make sure they operate smoothly before proceeding to following step. (© Make sure to install the steel ball and return spring. © When installing the brushes, take care not to ‘cause damage and get oil on it Always replace O-rings with new ones. © Properly align the setting marks applied to the yoke or end frame at disassembly before tightening © Tighten fixing bolts, screws and nuts to the specified torques.Z_ENGINE ELECTRICAL 36. Trouble shooting © Check the circuit for connection of each © Select those related to starter motor oper- ‘connector. ations from the following table, and take necessary actions for them, Complaints | Probable cause | Item to be checked. | Remarks 1. Fuel system. |. Incase of anew car, troubleshooting is 2. laition system. |" comparatively cary becave inthe most The engine | Defetin 3. Preheating | eases fatal rouble has ocurred in one create | emgne ie system portion. In cae of ecar used fort long erect. 4. Engine period of time, however, troubleshooting Compreson | and ections tobe taken are herder because multiple number of parts have ben partly deteriorated, 1, Specific gravity i" ‘The starter may be defective, however, cf bttery id. | in many eae, onteof roe Detect in power | 2. Contact of poe. | exes in the battery wiring supply side, | 8. Contact of gone | 1 fanpage wpa berweon drops to 18°C or below and Soe ote Visconty of | car alot nan outdoor place, the ‘The engine plata i ‘engine will not start easily. stopercon | | a after sare 1. Giuteh for | When one a these defects grows, the ing; or The slipping. engine will not start naturally. engine does. 2. Voltage drop at rot operate | Defective starter. | magnetic switch. | cr | 3. Contact be- | | te rh ad | commutator. | | 4. Shorted or | | grounded arma ‘ture, field coil. | 5. Worn bearing. | It looks the Pinion and ring, 1. Gear teeth. I Crunching noise can be heard as the sareris | gurerenot | 2 Pink | starter suns in high epeed without a lao [fessrreamene but the 1 cnineson | Treducrn [cue | not start. slipping. | -161-7_ENGINE ELECTRICAL 1 Probable cause | ~ ttem to be checked. Seu Temas traudte | resins | ataarter | svt wenkened untae ranted when |not ued to | swchand | voltage opt the sare vith tRepinon ure [pop out by fratercclay. | wiring connect terminals Band Gof the Aesinst therind|grratin force | Defective mag | magnetic switch directly, The engine Sercanar ye (serzcting free | eamich | wl hen start normaly Reamer lotthemametic | operation, | Unlenn sie portion of the sat | 3.Stanpot | trends may cause the uth not 0 | | clutch. ‘operate smoothly. 1. Broken shunt. When te shunt ol a rok, the colt ogre sich des rt provide ‘The pinion repeats popping out and. Defective | magnetic switch. . Voltage drop at starter switch attracting force because the series coil is shorted as the main contact makes, and and starter the return spring causes the pinion to relay. return. Defect in power | 1. Discharged — |. When the main contact makes and a large supply side. battery, | current causes a large voltage drop, this trouble occurs. Return of con- |. When the pinion does not leave correctly, ‘the pinion-bush and shaft will be seized, switch returns [switeh. tact. tothe original | | or even the armature col eome out postion after : Stating the | Defective 1. Return of engine, the | magnetic contac. starter does | switch | 2, Return of not top. pinion. {car with Poor contact. battery relay) [Detective —-|--2 Deective No reaction is [battery relay. | magnet co ‘made when the battery switch ~162-4, PREHEATING SYSTEM 4-1, Construction and Operation When air is highly compressed, it is heated. Diesel engines inject fuel oil into the heated air for combustion. When temperature of intake air low or engine is cold, temperature of com: pressed air is not sufficiently high, making it difficult for the engine to start, To ease engine starting, the diesel engine is equipped with a preheater as an auxiliary device. The preheater is briefly classfied into [Intake Heater System] which heats intake air and [Glow Plug System] which heats air in the ‘combustion chamber and injected fuel. Daewoo 1146 /T and D 2366/T Engine are equipped with the intake heater system, |. Preheater plug Intake manifold |. Magnet valve Fuel filter Fuel return pipe Injection pump 7. Fuel tank 8. Over flow valve This system leads fuel passed through a fuel filter Into an intake heater unit provided in the intake manifold, where the fuel is burnt, heating the intake air For fuel supply system, there are 9 system which uses. ahead of float chamber and a system which controls compressed fuel with a magnetic valve. In ease of D1146/T and 02366/T engine, the ‘magnetic valve opens and closes for leading fuel into the intake heater. =163- 7 ENGINE ELECTRICAL (Outer cover Nozzle body Suela => Fuel inlet ontice tahiter Heater coi! Terminal ‘This intake heater mainly consists of @ nozzle body, orifice, heater coll which heats body and igniter which ignites fuel The difference from the intake heater for float chamber type is that no ball valve is used but led fuel is controlled by the magnetic valve. In addition, an orifice is used to measure volume of fuel and to spray fuel because fuel pressure is high. Starting key box . Resistance Magnetic valve Preheater plug Control lampZ_ENGINE ELECTRICAL To operate the intake heater, the intake heater switch must have been set to "PRE HEAT” position. When the starter switch is heated, electric current flows to the igniter and heater coil which is connected in series with the control resistor, causing the nozzle body to be heated by the heater coil and igniter to be red-heated. 42. Disassembled View of Preheating System When the starter switch is set to ST (start, electric current flows directly to the intake hhester and to the magnetic valve, Then, the valve opens, compressed fuel goes through the Intake valve, and heated fuel is sprayed into the nozzle body. Gasified fuel is ignited by the igniter, and heated taken into the cylinders 1D1146, D1146T Engine « 1, Preheater plug 11, Seal ring 2, Magnet valve 24V 12. Hollow screw 3, Holder 13. Fuel hose 4, Spring washer 14. Seal ring 5. Hex. bolt MIOx18 15. Hollow screw 6. Spring washer 16. Seal ring 7. Hex. bolt M6x12 17. Hollow screw 8 Fuel pipe ass'y 18. Holder ©. Fuel pipe ass’y 19. Hex. bolt 12x20 10, Fuel pipe ass'y 20. Spring washer 102366, D2366T Engine 8. Fuol pipe ass’y 1. Preheater plug 9. Fuel pipe ass'y 2, Magnet valve 24V 10, Hollow screw M10x1.0 3. Spring washer 11. Hollow serew 4, Hex. bolt MGx12_12, Seal ring 5. Holder 13. Fuel hose 6. Spring washer 14. Hollow screw 7. Hex bolt 15. Seal ring = 164~8 TURBOCHARGER Section8 TURBOCHARGER CONTENTS PAGE 1. General Description ....... Main data and Specification . .. 2. eee eee eee eeeeeeer en 3. Disassembled View of Turbocharger : area 4, Maintenance . “168 5. Measurement of Bearing Clearances fee 5-1. Bearing Axial Clearance . 169 5-2. Bearing Radial Clearance = 469 6. Disassembly and Reassembly 169 6-1. Disassembly 169 6-2. _ Inspection “int 63. Reassembly . “172 Lubrication... ee cece 174 8, Precaution for Installation .. “174 9. Trouble Shooting ......... 6... eee “1758 TURBOCHARGER 1. GENERAL DESCRIPTION ‘The turbocharger is a unit designed to make use of the engine exhaust gas energy to charge additional air into the cylinders, thereby to increase the engine output. The exhaust gas driven turbine and air com: pressor for compressing air fed past the air ‘leaner are mounted on the same shaft, As the high density air delivered by the tur- ocharger contains a large amount of oxygen greater amount of fuel than with the non: aspirated engine can be injected into the cylinders to make the engine dativer higher output without adversely affecting fuel com- bustion efficiency. ‘The turbocharger helps to improve fuel economy. The turbine and impeller should be checked and serviced with meticulous care as ‘they are subjected to high temperature and high speed. The exhaust gas inlet of the turbine housing Is ‘connected with the engine exhaust manifold and ‘exhaust gases are applied to the turbine wheel ‘past the guide within the turbine housing, This drives the turbine wheel and also the impeller (compressor) installed in the opposite position of the same shaft. ‘As a result, air from the air cleaner is com- pressed by the action of the impeller and further accelerated while passing through the clearance between the compressor ‘nousing and back plate, before it is fod into the intake manifold. ~166- Engine ora one d= discharge| [mb compres arti iet As the turbine wheel speed increases with an increase in the exhaust gases, the impeller speed also increases to deliver larger amount of air into intake manifold, ‘As the amount of exhaust gases decreases, impeller speed lowers causing a reduction in the volume of air supply into the intake manifold. 1. Impeller housing inlet 2. Impelier B. Air outlet 3. Seal ring C. Gas inlet 4. Oil thrower D. Gas outlet 5. Turbine housing €, Oil supply 6. Turbine rotor —F. Oil return 7. Bearing 8, Bearing housing The turbocharger consists principally of 3 major components which include turbine housing, compressor housing, shaft, wheel, impeller, center housing, bearings, etc. of which rotating assembly is the most important part of the ‘turbocharger. The compressor housing is Installed on the end of the center housing and8 TURBOCHARGER encases the impeller while the turbine housing the flow of heat from the exhaust gases thereby including turbine wheel, is installed on the to prevent deterioration of il ted past the ‘opposite end of the eenter housing. The center center housing housing supporting the shaft and wheel I pro- ‘The individual pats organizing rotating unit are vided with oil port, through which engine olf carefully balanced to ensure smooth operation fed past the oll inlet is directed to the journal even at high speed bearing and thrust bearing on back plate for ‘The journal bearing is @ fullfloating type \ubrication and cooling lubricated with the engine oll and is ful Oi is then returned 10 the oil pan past the ol floatingly supported on the oil film when the outlet. Provided between the turbine and turbocharger is running at high speed Center housing is @ heat shroud which interrupts Tho bearing is rotated by the action of oil forced into slats in the inner and outer circum ferences of the bearing for reduction of relative speed between bearing and shaft ensuring longer service life of the parts. ‘The turbine wheel and rotary shaft are integrated to form a shaft wheel assembly and turbine wheel is made of heat resisting alloy to withstand high temperature of exhaust gases. The impeller is made of light alloy and is attached to the end of shaft with lock not. ‘The theust bearing is installed on the compressor side, to minimize affect of heat from the turbine side and is designed to take up thrust force created by the turbine and compressor. MAIN DATA AND SPECIFICATION ee | 01146 T o2366T | +} Model RHC? RHpea | ait pre > compressor outlet 12a kalem? gage | 1.257 kaon? gauge | ‘At maximum Air suction volume 13.6 m/min 119.0 m3/min | output | | pe Speed of turbine T peaiiont 110.000 RPM | 96.000 RPM | Maximum allowable speed 120,000 RPM 110.000 RPM | Max. allowable temperature pg Perot exhaust gas at turbine inlet_| 750°C 750° | Lubricating system Exrerat oil supply | = 1 Weight Take | ~167-8 TURBOCHARGER 3, DISASSEMBLED VIEW OF TURBOCHARGER 4. MAINTENANCE © All air duct connections and gaskets should be checked regularly for leaks and loose or leaky connection repaired immediately. Intake of dirt into the compressor can cause wear of the parts and damage to both the turbocharger and the engine. Leaky pressure Joints can cause toss of power and engine overheating. (© Excessive dirt build up in the compressor can also cause a considerable loss of power and ‘overheating. ‘© Such accumulations should be removed using rnon-caustic cleaning solution. © The engine workshop manual recommend- ations for proper types of engine cil, oil filters, and scheduled change periods should be followed to ensure nomal service life of the ‘turbocharger bearings. © Turbocharged engines should be operated at idle speed for several minutes after starting to prevent failure of the turbocharger bearings due to lack of lubrication, This is particularly important during cold weather or if the turbocharger has not been ‘operated for extended periods, =168- Turbine shaft ass'y Thrust bush . Oil thrower - Lock nut Seal ring Seal ring Seal ring Compressor wheel 1. Turbine housing 10. Bolt 11. Clamp. 12, Bearing housing 13, Retaining ring 14, Seal plate 18. Thrust bearing 16. Journal bearing 17. Screw 18. Screw 19. Heat protector 20. Compressor housing 21. Clamp 22. Bolt eervemsena © When stopping the engine, allow it to cool off (5 minutes or so depending on the ‘operating conditions) before turning off the switch, to protect the bearings and journals against adverse affect of heat. 5. MEASUREMENT OF BEARING CLEARANCES ‘The purpose of bearing clearance inspection is to determine whether the condition of the rotating assembly and thrust absorbing components of the turbocharger Is satisfactory for continued usage. In most cases, necessary checks can be made with the turbocharger mounted on the engine . When necessary checks should be made after the removal of turbocharger from the engine but before any diseasembly procedures are followed.© Set a dial indicator to the turbine housing ‘mounting flange, using a magnetic base. so that the indicator probe rests on the end Of the turbine wheel. © Move the rotating assembly foreandaft in line with the axis of the shaft and take reading of the dial indicator. Serviee Standard | Limit for oo75~o11 | oz 8 TURBOCHARGER Set a dial indicator to the turbine housing mounting flange, using a magnetic base. So that the indicator probe rests on the shaft of the turbine wheel, Apply pressure equally to both the com: pressor wheel and turbine wheel hubs as required to move the rotating assembly alternately in toward and away from the dial indicator probe and take reading of the dial indicator. | Senvice Limit for | Standard uve | Racial Cearane (nm + L oar ~o20 | a4 ev dh “Sgr eS 5-2, Bearing Radial Clearance ~ 169 ‘© Apply the setting mark on the compressor housing, center housing, and turbine housing, Using a felt-tip marking pen or scriber, to facilitate alignment of these components during reassembly if the same components are to be reinstalled, Unscrew the clamp bolt and remove the clamp.8 TURBOCHARGER © Loosen the compressor housing by tapping the air outlet part with @ wooden hammer, then remove the compressor housing, Note Exercise care when removing turbine housing and compressor housing to avoid damaging the wheel blades. The housing must be pulled straight off and not pried or cocked daring removal © Attach a spanner to turbine shaft to act as counterstay, then unscrew the shaft lock nut. Note The turbine shaft lock nut has left-hand thread. © Remove the compressor wheel, from the ‘compressor housing. -170- ‘© Unscrew the clamp bolt and remove the clamp from the turbine housing, © Remove the turbine housing using care not to damage the turbine whee! ‘© Remove the turbine shaft assembly with the heat protector. © Remove the heat protector from the turbine shaft assembly. © Unscrew the seal plate fixing bolts, then remove the seal plate from the bearing housing '® Remove the oil thrower. © Remove the thrust bearing and thrust bush from the bearing housing using @ copper ber.@ Remove the snap ring from the bearing housing using a snapring plier, then remove the journal bearing. ring from the turbine shaft, and the compressor side seal rings from the oil thrower. Remove the 6-2. Inspection © Inspect the compressor housing for damage ‘caused by rubbing of the compressor whee. ‘© Inspect the compressor whe and for nicked, worn, stripped, cr crossed threads, -171- 8 TURBOCHARGER * Inspect the compressor wheel for blade damage due to rubbing on the compressor housing, for erosion of blade tips due to ingestion of dirt and sand into the com: pressor, and for foreign object impact __ Inspect the blade damage of the turbine Whee! due to rubbing on the turbine housing Ingpeet the blade damage of the turbine wheel due to impact with foreign objects expelled from the engine and ingested by the turbine | | © Inspect the blade tip erosion and blade tip thickness. Blade tips must not be feather edged or torn,8 TURBOCHARGER 63. Reassembly ‘© Install the snap ring into the groove of bearing housing using a snap ring plier. Note When installing the snap ring, the opening of snap ring should point towards the oi! outlet port with spherical end turned to the bearing. ‘© Apply engine oil to the journal bearing, then install the journal bearing in position. ‘© Install the snap ring into the groove of bearing housing using a snap ring plier. © Install the seal ring onto the turbine shaft. © Install the heat protector on the turbine side of bearing housing, ‘© Apply engine oil to the turbine shaft, then install it to the bearing housing Note:1) When installing the turbine shaft exercise care not to damage the housing. 2) When installing the seal ring the opening of seal ring should point towards the oll inlet port. -1- © Install the thrust bush on to the turbine shaft © Apply engine oil to the thrust bearing, then install it to the bearing housing, ‘© Apply Loctite to the threaded portion of the thrust bearing fixing screw, then install and tighten the screw to the specified torque. j © Insert two seal rings into the oil thrower Using a seal ring installer. ‘© Insert the oil thrower into the seal plate, Note When installing the seal rings, the opening of ‘seal rings should be in position as shown in the Figure. ‘© Apply liquid gasket (Super Three Bond No. 1207C) to the seal plate with 0.1 ~0.2 mm of thickness, © Install the seal plate to the bearing housing, © Apply Loctite to the threaded portion of the seal plate fixing screw, then install and tighten the screw to the specified torque.© Assemble the compressor wheel to the turbine shaft, then tighten the nut by the setting marks applied at disassembly. Compressor wheel turbin shaft Serting mark © Install the turbine housing to the bearing housing Note 1) When installing compressor housing and turbine housing on the center housing and rotor assembly, exercise care so as ‘not to cause damage to the compressor wheel blades and turbine wheel blades. The rotor will be thrown out of balance when the blades are distorted, 8 TURBOCHARGER 2) Assemble the center housing and rotor assembly with compressor housing and turbine housing by aligning the setting ‘marks applied at disassembly. If the setting marks have been rubbed off or any one of the housings has been replaced, install the parts to the specified angles. © Before instalation of the clamp apply anti seizing agent to the threaded portion of the clamp fixing bolts, then install the clamp and tighten the fixing bolts to the specified torque © Apply liquid gasket (Super three Bond No. 1218) to the contacting face of compressor housing with 0.1-0.2 mm of thickness. © Assemble the bearing housing with com: pressor housing by aligning the setting marks applied at disassembly. © Install the clamp and tighten the fixing bolts to the specified torque. ‘© After completion of reassembly operation, turn the rotor assembly with hand to be sure it rotates smoothly without producing abnormal noise.8 TURBOCHARGER 7. LUBRICATION ANY © Units to be installed as replacements or those that have not been operated for a long period should be preoiled before instalation. ‘This is accomplished by pouring 110 ~140 g of clean engine off through the oil inlet opening of the center housing, and turning the rotating assembly by hand to coat al internal parts with oil. © After installing the turbocharger, the install- ation should be checked for uniterrupted supply of oil to the turbocharger. ‘This is accomplished by disconnecting the oi rain line, setting @ socket wrench to the compressor wheel lock nut to prevent the rotating assembly from turning, starting the engine, and observing for a continuous flow of oil from the turbocharger ‘© When the oil flow is steady, stop the engine, release the rotating assembly, and reconnect the oll drain fine, Restart the engine and allow it to idle for three to five minutes, then, check for leaks at all oil line connections. -1m4- Preoiling in the above manner is also advised after oil changing or filter servicing to assure complete removal of air from the oil lines and oil filters. 3. PRECAUTIONS FOR INSTALLATION ‘Alaways use new turbocharger mounting nuts (or and washers) and torque them only to specification as they are subject to heat distortion. Install the oil outlet pipe and apply a small amount of clean engine oil into the oil intake port, before installation of the oil intake pipe, and turn the rotor assembly with hand to thoroughly lubricate the bearings and working faces of the journals The direction of installation of the housings must be adjusted during installation of the turbocharger_on the engine so that the compressor housing and the turbine housing ‘opening can be connected to the engine duct without imposing a side load on the housing. Inspect all components of the air induction system for loose connections, cuts, cracks, punctures, and corrosion or other evidence of deterioration. If evidence is found of any defect that could permit air leakage between the air cleaner and the compressor, perform the following additional procedures: 1) Disconnect the air duct from the ‘compressor air intake and inspect the edge of the compressor wheel blades for damage. Examine the wheel for dirt build-up and the presence of oil. Check for evidence of the wheel rubbing on the housing 2) Replace damaged air ducting components. Check the air duct connections between the compressor and the engine intake manifold, Tighten loose connections as required. Check the oil line connections at the center housing oll feed and return ports for oil leakage. Tighten loose connections as required. Recheck the connections for feakage following the next engine startup,8 TURBOCHARGER 9, TROUBLE SHOOTING Complaint Possible Cause Correction smoke or Engine lacks power xcesive isk | | Blue or white smoke Excessive engine cil consumption 1. Dirty air cleaner element 2. Restrictions in air duct 3, Leakage at intake and exhaust manifold 4. Leakage at turbo charger mounting flange 8. Restrictions in intake manifold or exhaust manifold, 6. Binding or dragging the rotating assembly Clean or replace Clean or repair ‘Check and repair ‘Check and tighten Correct or replace Overhaul or replace Dirty air cleaner element Loose duct connections, Leakage at intake manifold it filter plugged Restricted duct between air cleaner and ‘turbocharger | 6. Seal leakage at compressor end 2, Seal leakage at compressor end or turbine end 3, Malfunction of engine components (rings, pistons, valves, etc) Turbocharger | 1. Dirty air cleaner element 2. Foreign object or material in intake duct or compressor housing 3, Restrictions in exhaust system 4, Carbon build-up in turbine housing 5. Binding or dragging the rotating assembly Clean or replace Tighten or correct, Check and repir Clean or replace Correct or replace Correct or replace Replace with recommended lubricant: Correct or replace Correct or replace Clean or replacement Remove foreign object and repair. Correct or repair Clean Overhaul or replace 115 -SUPPLEMENT SUPPLEMENT‘SUPPLEMENT. 1. ENGINE TIGHTENING TORQUE 1-1, Major Part Tightening Torque Deseption Dia xPiten mm) | Torah ema Cylinder ned bot maxis | ats Connecting rd bearing ep bot mig 8 praorr ene wisx 15 2 02366/T ENG Crank shaft mein eaingeap bolt | M8 1.8 a | Balance weight fixing bolt MI2x 1.5 10 | D1ae/T ENG macs Q 02366/T ENG Flywhee intuson bot | wars ns | Crankshaft gear fixing bot Max 1 ws | 1-2. Injection Pumy stem ia Sy Unit: m-kg Diieer assert 1. Inscion pump delivery alveholers | 25 ~80 20~0 2. Nozzle holder cap nut 70 | 70 3. Nozzle cap nut: 6.0~80 | 6.0~8.0 4. High pressure Inston pipe cap mt 2a~32 30~s0 ‘The torque values given in the following table in the next page should be applied where @ particular torque isnot specified -178-SUPPLEMENT 1-3, Standard Bolt Torque Table Degree of Strength 36 | 46; 48/56 | 58] 66) 68| 69| 88] 109] 129 4a) _|_(4D)/_ (4s) | 60) | ts) | 160) | _(6s)| (6G) | _(8G)] (10K)] (12K) Designation ae Limit Value for Elasticity kale [i [Tm] sf | ao[ se | ao] os | oe 108 | Tightening Torque (kgm) ms | 018 | o16| 025 | 022/031] 028| 043 | o48| 0.50 [we | 5 | 047| 077 | o85| ooo | 125| 150 M7 o7| 1.20 | 1.30| 140] 1.95] 235 we 310 | 3.80 Mext 3a5| 4.10 io 620/720 | Mioxi | 7.00 | 840 m2) 430 | 1050) 1250 Mi2x15 5.00 ma | 7.50 1200 Mig x15) 660 | 5.70 | 830 13.00 mie 9.00 | 8.00 [11.50 18.50 Miex15 [970 | 860 /12.50 20.00 ma 7.80 | 8:30 /12.50 | 11.00 [16.00 28.50. misx1s) 9.10 | 950/144 | 1250 [18.50 28.50 m20__| 11.80 | 12.00|18.00 | 1600 [22.00 36.00 M20 x1. 12.80 | 1350/2060 | 18.00 [25.00 41,00 zz | 18.60 | 16.00 |24.60 | 21.00 [30.00 | | 49.00 M22 x1.5| 17.00 | 18.50 |28.00 | 24.00 [34.00 | 29.00 |47.00 | 52.00 56.00 iM24__| 20.50 | 21.50|99.00 | 27.00 40,00 34.00 |86,00 | 68.00] 63.00 24x15] 23.00 | 36.00 |37.00 | 31.00 |48.00 | 38.00 61.00 | 67.00] 74.00 =179-‘SUPPLEMENT 00'0 (wuy va 9 en ewe yuen weidaal up| oes oc-teoe| wae (os 0 ‘yews woe wide] cap) ses eSBs ce (une wes Say saps e Ag 122100] 100 7 —| 8 juny 8 9 usm ieunor ByperAatunnenai | sv] 7900-900 Bu HO vorsid 99 Buys aoejdany| ‘s¥0! zo1'oL00 Guy pug sa 696 (PEAY ANIEA ® WEIS anJEA uaaMiag ino-Und [eIpes “Wag Bur Ey Sun 10. eel uy sono o fon pve 90 aa ae Sonor “ore mrve Bore-so'e Buy vorsid yo uIpIM, ea worn Zo[ eee ere a Waid aang URI aasaiaosont Taiowe oon OL aa Coe) ay ‘Haine 1293) 30 ePID wo aT Beau ie weidau| voor] —_FOLFeeOE Tabing pea VO Fo~o Tes pam —- at vosssudep seas an | sopunkd — aes sapuyfo jo manoND t008 usu anon abe Sh soo 300 22} 1201 028 po spiky ore ro — voscenog | aay] Aya oy sum uop2edu venom ‘aut6U3 1/9PLLG 404 suoneoytoadg soueumureW “Z, ~ 180-SUPPLEMENT es eee — = See cawan nye ne a sempre ope tan min sae este = __ oa snes pons an ae nouns oe on — mae ot eI Wwe] uy eyeajo moma = werner # = Tirb wen serial sro | OWT I a a a Tina] “wereneienns | own ‘ ao | seer | 97] aa a Ta SESS — saat | eras ero Tel re] So ee = — ‘mba a0 | ar0av0 I mm - T ‘2ei109 dsnayp soejdoul £0 “sv oeroo cu {aaa Se ees wmamaeamat — ve {eee eee Seema — we reer el L ~~ t ‘eS oR 7S (Way peg WES Jo DeWeIP OPI IAD & Tian mie nay a Tt 909 GS Booey pervade sabia Bunce, ' + ss ES pS RTT — =I | Feo Tuan Boe por Ue iwooao raya BOTH aR 6 Ra UnTNG EN] POM ——_T (por uos sede sO ‘Bee OLLO ‘(Wu BOF" USD 10 Aelia DUS = TT —— eee oars a | eaeremaatrias ie Tamera eee a Coy 2 eunseOR 08 ((w9/6) HeUs yueD jo SuReG a a a win | ee ee ae = ae a a Sao sue wena | | nen | — —‘SUPPLEMENT. cos veee.z | wena soveu | gee v2r we ret cnou | osc0u" | eovarosea | aw too. wie mea veovore yeu oS Buna eb “ie Ta HR wei wooesoo | meq dund ow Ta a e1r93500 ver unk et to so] + co 10 se eam paar = veddes aoeidey 8966 1-y96' 6s one aot wesc once | ro] wowseo eaau| eo ines por nou | acer we Te aT Rw OU - aga we sco] ceocao0 yn ios von Snes Tae ena ToD <0 9 nm NOTED | mp ceo wea aa cou away cis] ceaeza| 99 sno oven | mes = cen sus wee ce oorrez | 98 {95a} 298) uorsuar Buri at ipa soe] sees) a vw won 898 | gaaae 9 {yi6u9) 995) Suds ane pouey | ret — voranieg su vosatnn vos ~ 182-SUPPLEMENT ‘Avo sorta | 212200 9 peoy"40 soerdou ‘peoy ag) uo ayzzou par2efond yo wah anjen majneno jo sznsaid Beda | warshs veg ayo oa wieuep 10) 1ap|04 BTOU'® Add VORDATU aSTTAMG] Burda trou po wd 6 mompave | eau pn ee 73 fixvan eyrd pH phan wD $80) 20 6 ves im um so sot ai ie 6 see8 yoo ‘ine 31 noae Tp die Bi nyu paoeins jst seo ey oa gous ‘sient 064 anoay ‘gga aint (up union Aoning esooce pees und a a {Gi assed Butuco 10) anata wan wes 50 ma a zee0t at] sven tonya 10 wai a 144 10 was09 3 teeies 9 wr] seep 7 ones enceu (Gani aer00 Fe aI ane sone (uni dnd a am eaaea emme ceo =A mien eecee ronwoo wae soozo une 10 ews venoeu sonics | argue soy | anon ona a eo wiry | enyen puepueig | jeunuony NOS)SUPPLEMENT. out ooet | —ooes | (8) usmq yo ansaid Buns | Buuds Pe | vag why | 8 sz v6 (uy wana 403607 oweinunwo> Jo 24305 ToiRinanweD jo aoe se1s0v0 soso ous sorinsutimsiapum 40 yi6o0, wor | #010500 {Wu DeveIMUIWOD Jo pURO>}OINO oe ae (wa) oieIRaiuad jo sa saves zo vie ‘Buueea worwg _yeys 20 yang soerceu your weg | SSB UE | aseuay ve wong wane9| #170 FO vie yeas jo unouny ane 300119) BuyaaiyBA Noe nn20j0p_ senezre TA) abe on upand Aes pour | sone st aujod reunuuan ya vase TAT seen paNeRBSE | -moyag | _ab10A 0008 vst ‘nse, ous a oped 290601 ne. ‘onu39j0 swessz | __ 008 unde 1 apeidas 10 1291809) ri vn wmaeinne | 48 | soreway! 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Se | 96907 |Bs.t | a8 80 Ba ge | ete | per | Sta tae| 20 53 | Hah Se| fin ote | 3.23 | 30y gus | Sn Seu 32t 3 | 33a | acta | sooaet| 3 & | 570 | 3.38 | os ope | Su tr | att ate Bs ge | to | aces | tee] $8 | aay he | 2p da | er re | a | az me {fo.38 | fon 98 | Sn es | foes | 30 5 | Sa tee | $38 90 | Soca | 8-03 | 207 gut $5355 | tao | sorta | cian | $9 | 06th | 5 oe | $93. uy | 39 99 | obs ae SSR | sats | 8-26 | Bae | 180 [8s tan | Sacer | ncaa | S31 | rus [ crt as. ar | Gost | one 779 | 9m ae | 19 CUBIC INCHES TO CUBIC CENTIMETERS TT Jel? le le lel? De) pe = a cent ent ent eat = = = = ve-207| aa. 9-101 | s.s8| a1.908] gn.az2] ie rp] t-on7 [ar aoe} — Wo | ea.ars | anda] 4-2 | 21:08] 6°48 | ot gos| att 22 | 2:28 | a9 or [37 S84 | 0 48 | 255224] Sats | 408 513 | Se 9s | 3B fo | tp sr | Fagen | ab ae | ooo | sg] 3 | fer ata| Soran | sarang | Sn 9s | $5710 | Sa sr | Se.9 | case | Sa. | op gon] 38 £0 | eben | 31 to | dante | Sou Se | Saran | say a | $53.00 | eps | Ses 299 or see | oo 53 | SiS | tau ao | S50 | gen Se | Se gr | guy sup |S 00 | Soe ons | $040 | te ee | 8 | us aze | on-air ordre foe ans hata 772 jes 15 hou. See hoy 9s pis sao [90.9% | 30 4 ter ne [das ltrs aun [a a8 fcc iyo ats a1 eye arts [age 30 | 90 © ato‘ dr 33 [ica [tote [a3 19es0 |208 Sa les es ecco [0-2 | 69 gar tu ants [aoa [sor cae (ae 71 [S01 ayes [008.908 eae ne | 90 18 ideas faa frat os:eoo ea 8s [3s 09088 38 a (EE ae & SATEa CONVERSION TABLES METERS TO FEET + — 7. I ) l l aoe ep ae pe s 2a0e| 6017] 0135] v.130¢| 19.002] v2 cam0| a2 eesp| wear | same | — io | szanee|sbcuna | aart | 0:85 | a5:pre | ao aoe | 22 tae | 23 fees | Goose | 323409] 0 | 5:Ses | 35 ere | 7a ras |75asra | reno | ofan | 20s | an ser | av -cts | na tee | 30 5. | eta jr uo fot age [oe er” [tues tau fit toe at at bu aie [ay 9a | 30 2 Ze [lu See [Sp oun [et aver [tx sara eae liso oes (su ts [tap taos [eo ere | 20 SS ak aco ley aun [oar [ane inte cct rain ore oar on ne | 38 & lige-esoe on 22 ona fg ovay fo. nrae aac fits [ayes [sort fae ap | So $9. ly inn ae ans fsa 210 is Sor fc Ye ie oo fur eae ar ecey (38 goes sp taee | $0, fk i i uo loons re om fr Ss rant fit see fas) anise it seh | 0 8 ss 92 lw See [o ears foe tra e-apo Breve ia ene fa-acs fat ua ie sue | $8 1S ie dao [it ce [su ar fay ves et are ux ans fu novo pt cee se 306 Br sie | 160 KILOMETERS TO MILES ele) LLL eo ose} 120) am| 246] aor] a.7m| «am je wo} sau] Se] 70%) are) Som) San] Soe] sole 2 8 | hs] She | Se Ge] te] S| tS] ee ° 3 | beh | fonts | toeee | fo:30s| ater] WF | a0] da oo 8 % | tesss| i2lrr | asm | erwe| dract| Grsea| daiaee| do doe 2 | Bde] Sido) fee | 3588) S00] S008 | Shoe) te 7 60 | 37.282] 37.904] 36.525] 39. 39.768 | 40.389) 41.01) | 41.631 $ fo | Baer| Whe) ieyse| ase | oes | tess | os | Gee | 2 % | torn | soase| Soo | STS) 08 | Sate] Be] Sos 8 % | Ssu| Ssa/ Siee| S7e| Sloe] ao) das] bos 2 i | Gia] Go| Bite | Home| atom | Bau] Base | Bee SQUARE CENTIMETERS TO SQUARE INCHES 7 Te Le Le Baa es a. 3] 0.210] ows] oom] 073] 0.0m] 1.09] 120) 1208] — ie] va] T708) Peso] Sots] Sm] $55] $46) Ha) dhe] deg] io | aie | 328] ato] 3505] Sym] 3695] tomo) tas] 120] Zs] a Se | tam] tas] tne] 313] 320] sas) 300) f7ss| Sem! sos] 3 | sam] sts] Sse] 3265] s'em| S975| 7390) 7as| tuo] 9 5s| | $70| rs) s000| S3| S| §s| ttm] tas] ame] aia] & | 30 wei] 933] sme | so. | 10390) S's | 10°30 | Sie] | iam ite | at ats | atcare | ttsas | zee | as] tea | 1226] Fe fe | 12: | tas | ta7t0| t2'e03| toon | tais| tase| taes| 13 | izes] 0 fo | Vago] sates | (do | EGS] 12°90 | lays | tease | 13.05 | 3:00) tees | Bo vos | 1500] 15.055] ts.eto| t3es| tatao| tears | temo | te:3e8] tecr@| tees] 198 Se] CUBIC CENTIMETERS TO CUBIC INCHES T° ] 1? 12> 11 1) racy z a 5 o.oni0 | 9.170] own] 02m] 0.20 | ose | oan = ig | osioe| oiens | Sirias| o:yss| olasca| Gist | oigyee| Sore ® so | tsms| Vers | V3ezs| faass| fiasco Sese| tide | eure & 50 | tazor| tanir| tee | aiorae| Barca a.tase| ieee | Suro 3 {© | 2toy | 2 So | 4Ses0] 3iearo| Fens) Zzuat| dans | dace s | Sosrs| Site] Sine] Sto] 3:20) 32500] Sarma) dose 2 | 3:serg| 3izane | Sas | Seaes| foes | Qocer| Cove | tone & fo | tare] acer | Cheat] ace | Se | ta] Cee | font s 2 |< ein| tan | Sn | Ssso| Sitso| Sitew| S00] Som 8 fo | Sain | $Sr| Sea | Serae| Sizer] Sten | Stes | Sern s vee | dst] ise | See] S08 | 22085) lo | 2483 | 2 See 3CONVERSION TABLES eee CUBIC FEET TO CUBIC METERS °° 3 fe ¢ 7 [8 7" z ee [aa 0 0.0850 | 0.1103 2.1699 0.2265 | 0.260] 5 18 | 0.2032 O°36e1 | 8.3964 oss! 8.2097 | 0-s360| 10 3 | bssas 025513 | o:6708 0°F362 o:7099 | olan | ® 3 | cass O°9345 | 0:9628 tose ‘oreo | Ttoua} 3 4 | tae Vive | 13039 5028 1399 | 13ers] 8 Bl as 5008 | 13231 13838 Vane | 1 e707 | ess0 yoo | ais V3e89 19236 | 19599] 2 | isan 2.061 | 210955 21st ze | 2270] 2 | 2 tesa 3°350 | 33706 238 baste | 2:5202] 1 | 2s 2ams | 2 sot 27 27731 | 2200 | ray aster | 2:9630 So0t6 3:05a3 | 3.0066 }ALLO! .) TO LITERS wy ft 2 7 1 = f¢ 7 ° * 13s asi ei Z z 7 z z z = 3.7054 | 7.8709 11.3589 | 15.1417 | 10.9271 | 22.7126 | 26.4900 | 30.2004 | 34.0030 to | s7.e5a3 | ai-43o7 | 45-4251 | 49-2105 | 32-9940 | 56: 7ara | 40.5560 | 64-2509 | 68-1377 | 71 saat 75.7085 | 794940 | 43.2794 | a7 0648 | 60.2302 | 94.6357 | 984211 |102: 2065 |105°9920 |109.7774 13.5328 |r17. 3482 [121-1937 [124.9191 [128.7043 |132 4099 [136.2754 f140 0808 |t4a- casa [147 616 st-4i71 |i5s.2025 [156.9679 {162.7734 [ise 5566 |:70.3442 |i74. 1296 [177.9151 {Iai 7005 |1a5. 4839 hae: 2713 |193: 0368 |196.8422 |200. 6276 [204.4131 |z08: 1963 [2t1 9939 [215.7699 [zi9.ssae [223.3402 lar 1256 [230 9110 [234.4965 f23e 4919 [242.2673 [248 0527 [249 e382 [253.6736 [257-4000 [zat 1945 fasa'9799 fase 7450 [272507 [z7s. 3342 [200.1216 |203.9070 [eer spaa [291.4779 [295.2639 [299 0487 3028342 ft0s6196 [310.4030 fa14. 1904 [317.9739 fa 7613 [s25.sea7 fo29.3921 f339.1176 [S36 9090 40 ea04 fsa 473s [sas. 2593 [s52 0447 [ass. 0201 (250 6158 [s4s- 010 fs67-re6e 370.9718 fara. 7373 fs. sezr faz 3201 [306.1135 [s99. 0990 [sea sec [397 ase lot 2589 [40S 0407 fos ezet tz. 115 Sassseses GALLONS (IMP.) TO LITERS ale 2 3 4 5 ‘ 7 2 7 z z z z z z Z z Z = 4.5460 13.6379 | 18.1838 [ 22.7208 | 27-2750 | 31.0717 | 36.2677 | 40.9136 | — 10 | 45.4896 | 50-0058 5910975 | 63.6434 | 68-1894 | 72°295¢ | 77-2019 | at 875 | 86.3732 | 10 20 | 90°9192 | 95.4652 jos.s571 fio. 1030 |113.44s0 [178.1950 122.7409 |rar_ zee fis) aaze | 20 30 fae: 37a8 [1409248 130.0167 [154.626 |1 59. Tons [163 654s |i6e 000s [172.7465 [177.2904 | o0 40 ial oes [1 3044 95.4743 |200 0222 [204.5682 [209° 1142 23-6401 [2ra. 206! f2z2.7520 | 40 50 {227.2990 [231 a0 [20 9359 [aus. 4810 [250.0276 [rsa.s738 [259.197 favs. cesr fase. 2iis | $0 $0 far2'7sre [err sans fz 3955 [p90 pata [295.4874 [p00 0x34 fsou 5793 hop. 1253 fara.ari2 | 60 7 fata.aiza fsa 7632 31 assi [538.4010 {240.9470 fas. 4930 [3500389 fase. seep [257-1908 | 70 0 fs8.6768 fose: 2023, fa77:3147 [bet esos jes 406 70: 9526 f395\498s [uoo.o4es [aon spot | 00 90 [aoy 1964 13.824 22.7743 [427.3202 [31.0667 136.4122 [40.9561 |445. 9041 [450.0500 | 90 100 fst: eo fp: t4z0 fa 2339 fra:7700 773256 katara fae.ai77 liso 9637 [avs 00s | 100 POUNDS TO KILOGRAMS ——— ———— - : - > — te |e = ves 2.72 3.175] 3.6] 4.002) — 0 6.350 7237| 77} sites] este] 10 2 10.986 11-393 | 12-247 | 2'701 | 13-154 | 20 » isa 1a.329 | 16:73 | 17257] 17-490] 30 o 19°938 pole6s| 21319] 21772] 2228] 40 2 24.496 25.401 | 25\858| 26/308 | 26.762 | 90 « 39.000 dp.ear| 20.301 | doce | 1.290] 60 7 33.508 30473 | 34/927 | 35/300 | 33.804 | 70 » bate 3e009 | 39:489 | 39.916 | 40.370] 80 2 a8 23'si5 | 13.990 | 444ss | A4%908 | 90 160 | seta | dass | ds.raa | aa-vre| ariser | dacomr | aa: sse| da-oan | 49.402 | 10——_—————— CONVERSION TABLES CUBIC METERS TO CUBIC FEET —————— sr re ee ROT 76] wse| ual ie| as aval — io | ass. 5] ase] aset| dee] ste] Saso sno 10 x | 06a] ras] fen | Sinz | guy's] aan] 910.2 vom | 39 30 | 1059-4 9] 1130:1 | ates: | 1200:7] 1236.0) 1271-3 977.3) 30 a | tine) tears sie s| 1330.6 1389.2) te2us ioe} 0 So | iss.7 | toro] tessa | ta7t-7 | tsor.0| iser.3 | t9e7.6 206 | 39 $ | miece| zse2] 2199'S] 2220/8] 2260.1 | 2295.4 | 2300.8 za? | 30 % | dur2's| daar 3| Gsta'e | 28700) Gets: | dees’ | dees’ 9 dave | 70 ft | 2025°2| 2040's | 2e9ss | Zest t | Gous.4| Soot? | dosy.0 Sta. | 60 vo | 310.3 | s2ia.¢| 3240-9) 324.2] Jaros | tases] 33002 suse. | 90 voo | asar'« | 3566°7| 3602.0 | 3637.3 | Sar2'7| 08.0] 370.3 aauo.2 | 100 LITERS TO GALLONS (U.S. ) «|e 1 2 3 4 3 4 7 ® 3 |e gar get gal_[ gat | “gat | get at} gat = (0.2442 | 0.5263 | 0.7025] 1 cse7 1.5850] 1.0492 | 2.1134 | 2.a775 to | 2.647] 29039 | 3.1701 | 34302 | 3'speu ane? | 4asee | 2 7sst | 5.0192 | 10 20 | Si2ase| 5'su76| Siante | 6.0750 | 2 s400 hese | 7°136 | 753968 | 7'ss10] 20 xo | 7a | & e'ds35 | e7i7s | Bete 95162 | 9.7743 | 10.0388 | 19.3027 | 30 40 | v0: 5648 | 10-0310 | 11-0982 | 11.3594 | 11-6295, sDisig | 1274160 | 12°6802 | 12 9440 | 40 $0 | 13° 2086 | 13-4727 | 13°7368 | r4’o011 | 142552 14.7906 | 15.0879 | 15:9209 | 15.5861 | 50 0. | 18.8509 | 161144 | 16/3786 | 16.6428 | 16.9060 17'4385 | 17°4995 | 17-9636 | 18.2276 | 40 70 | 19.4920 | 18-7361 | 19.0203 | 19.2645 | 19-5407 20.0770 | 20'3412 | 20.6059 | 20°6895 | 70 0 | 21:1337 | 21° 397s | 214620 | 219262 | 22-1904 2a vier | Fa'oea9 | 28.2070 | 33.5112 | 60 90 | 25:75 | 24/0306 | 24/3097 | 24°so79 | 2a a3at | 25 0002 | 25.2404 | 25.6040 | 25.a0ae | 26.1529 | 90 von | 26-4171 | as-eeis | 26.9454 | 27-2096 | 27-090 | 27 7380] 2. oat | 2.263 | 98.505] 20-7908 | 100 LITERS TO GALLONS (IMP. ) ot. Te]? ll? le 1?) 1° é é alae paar gat ot Taal et 7 0.2200 | 0.4599 | 0.0799 | 1.0999| 1.2199| 1.5990] 1.7596 | 1.9798 0 | 2.1998] 2.4187 | 28507 | 30797 | a"2086| a\sive | 3.7396 | 2.9see | act795| 10 20 | 43995] 415195 | Siosea | $.27e4| Stone | Sirive| sigan | e.isea | Sarva | 20 50 | i390 | laiea 7.2392| 7.4792 | 7.4902 | 79191 | e181 | 83591 | 8.701 | 0 40 | 8.7990 | 90190 9.4300 | 9.4769 | 9°996¢ | 10-9189 | 10.3300 | 10.3808 | 10'7768 | 40, 50 | 10.9988 | 11 2108, 11857 | 11 e7e7 | 12"opa7 | 12°3087 | 12 330s | 12°7588 | 12-9705 | 30 $0 | 13.1966 | 13-4195 | 13°43e5 | 13'ases | 14 Ores | 14.90 | racsiea | 14.730 | 14°95ae | 151780 | 60 70 | 153983 | 15.6183 | 13.8393 | 16.0382 | 16.2762 | 1e.ae2 | 16-7182 | 16.9342 | 17-1881 | 17-3781 | 70, A ‘181 | 18.0360 | 18.2500 | 18.4760 | 16.5900 | 18.9179 | 19.1379 | 19-3570 | 19-5779] 60 %0 20.0178 | 20.2376 | 20.4578 | 20.6777 | 20.9977 | 21-1177 | 21.3397 | 21.5878 | 207776 | 90, 100 a airs | aaasye | 22.0575 | 22.6775 | 23.0075 23.3175] za bara | Za ror | Zara] 100 KILOGRAMS TO POUNDS a | 0 1 2 2 a 5 6 7 @ ° | ee ee be e rn ry = = 2.205 { «4o7] osia] sere) 11.029] 13.276] 15.432] 17.637 = wo | 22.046 | 24.251 | 26.455 | 26.640! 20.805 | 23.069] 35.2% | 32-479] 36.689 0 20 | 44-092 | Z8:267 | 4e's02 | $0.08 | s2'er | Sstie| 7-320] 39.s25| ar92e 2 30 | 66.139 | 43'343 | 70'sue | 72-752 | 74.957 | 77 142) 79 368] a1-s71 | 93.778 30 40 | acted | 90 sey | g2.seu | 94-709 | $7 003 | 99.208 | 101 at | 103:62' | 105.62 2 So | vto.23 | sa'4a’ | rtacse | rtecee | ig.0s. | 129s | 129.48 | 125.66 | 127 87 0 eo | 3226 | taaaa | 36°69 | t38'99 [iat to | t43.90 | tasist | tare | 149.9) © 70 | 154.32 | 156-53 | 158.73 | 140.94 | 143 14 | 145.35 | 147.55 | 189.76 | 171.96 70 0 | 176/37 | 70:37 | ra0'7a | 12.90 | 195.19 | 197.39 | ter.eo | 191-80 | toe.or 20 90 | 196.42 | 200.62 | 202.e3 | 205.03 | 207.23 | 200.as | 2iv ee 216-05 50 oo | 220-46 | 222:67 | 224-87 | 227-08 | 229.20 | 25n-ao | 233.69 | 235.89 | 738.10 100CONVERSION TABLES ee POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS wie] 0 7 2 3 « 3 é 7 @ owe [Charen [arent [valen® [talent [talent [Waren] talen® [arent [torent [arent ‘.1408| 0.2100] 0.2812] 0.355[ 0.4218| 0.4921] 0.5625] o.ea2e| — to | 0.7031 leas? | ovotao| 0.9843 | ass | T1249 | 11952 | 1.2638 0 2 | 14082 Vsaee | Siz | Visara | 1.7577 | Ve2e0 | goes | 1 e686 2 So | 2°tove 2inave| 2.3202 | 2990s) 2l4soa | 2'sa00 | 2eore | e717 30 ao | 2a 2.9sze | 40202 | Sosas| d.texe | 3.2542 | 3308 | 33748 * So | 35154 | 3:ses7 | 4-6s60 | 317263 | 3.7060 | 3.aseo | 3.9372 | 4\0072 | «0779 ” fo | dares | 4:2ee | 495m | 4.439 | 44697 | 4'5700| 4.6403 | 4°06 | 49000 © 50 | Coate | Wore | Sosa | 5.1525) 5:z026 | Si2zar | S's4se | Siaia7 | 5 4e4o 50 8 | sis2us | Sieoap | 57652 | 5.2356 | 5089 | 59762 | 6:o4es | oitie8| 6.1871 a 90 | &:277 | 6c39m0 | 6.4483 | 6's3e6 | sieceo | 6.4709 | 8.7496 | Siai9p | 6.8902 by woo | 70x00 | 710m | 7.1714 | F.2arr | 713120 | 93am | 74526 | 9 S299 | 75909 100 KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES 3 4 3 ‘ 7 @ 9 | term Tere [ ea [aya eT weer] s6.09{ 71.12] 95.34 tee's0| 199.12 | 219135 | 97.57 saris) s4t.36| 355/38 | 69°80 469.36 | deas9 | ayia | 312.03, i140 | G2sie2 | 60.04 | 654.37 753.43 | 748.03 | 742.28 | 796.50 96:08 | 910.26 | 924.31 | $38.73, ose-s) | 1052'5" | 1046.7" | 1081-0 Mao's | 1194: | 1209.0 | 1299.2 iazai7 | a7. | ast.2 | 1465-4 1465.0 | 1479.2 | 1493-4 | 1507.7 Sassssssys! FOOT POUNDS TO KILOGRAMETERS we] o 7 2 3 4 3 6 7 8 ° ise eget T= = 0.138 0.276{ oats] 0.553| 0.691 | 0.829 v2 | — wo | vse] Vis] 14s] 78] Vom] gor] ar 225| 10 zo | 2:74] 2'902| s'ou0] atv] site| Sass] 3.50 ‘007 | 20 30 | Ate] tian] 4422] L560! ase | ear | dors Siae0 | 30 40 | Sisze| 5656] Sieoe| Sioaz| g.080| s.zio| g.3s7 eam | 40 So | 910] yo] 7196] 73) 7482] peor! F739 a1 | 50 go | a2| a'a0| o'se| 6'700| seca! f'sen| 9.121 9335 | 60 7 | 9.6) 9/812] 91950 | so.dse | 10.227 | 0.365 | 10.502 10.918 | 70 0 | 11056 | nt | 11'332 | 0490 | 105609 | 19947 | 13805, 12:30 | 20 go | 124se| i2.s76| 27a | r2.ass| 2g | 13120 13.267 13:882 | 90. yoo | 13:620| 13.956] 14.096 | 14.235] iaca7a| 14lsit | alee, 064 | 100 a eee siz] aa4o] 0.63] 97.67] 45.10 21.70 to | 72.33] 79.87] o6.80| 94-03 os:s0 | 15:74] 12°97 | 130/20] 157.63] 10 wo | salar | 15190 | 159-13 | 66°37 190.84 | 88°08 | 195/30 | 20254 | 209°77 | 20 30 | 217-00] 224.23 | 2314s | 298.70 250.17 | 240.41 | 267.83 | 2acar | e210] 30 40 | 209'3¢| 296.57 | 302.79 | Sir oe 3as.s0| Sa275| Savco8 | 321 | asa | ao 5 | Secs | 4s6.a9 | 376.12 | aan.36 397'82 | 405.07 | 412.20 | 41953) 426.76] 50 20 | auoo| dar a3 | due a5 | 435 70, aor | ara | aaa se a9.10] 40 70 | S054} 513-57) 520.00] S28 a4 Si2.sa| 509.75] S56.98 gra] 70 a | syecs8| Sa5'01 | S9a.14| éc0.38 4ia'as | 622.09 | 479.41 san| a 90 | $51.00 | 636.23) sasias| 472.70] 79°93 | Ga7-17| o4-at | 70163 Reto] 90 100 rast | 100 ras:s4 | 730.57 | 737:80 | 745.04 | 752.27 | 759.31 | 706.75 | 774.07ey Ni Velen a AMI Peal tog MACHINERY LTD. AROUND THE WORLD vrayenes . 4 Pesci, me oe {China anu SpuLiKorea) Us) a \ et fen BPE re pina Frome, arLanta | gPNEw vensey eager oe Gee i ae as BS Would ‘ a scoortfltin, Aa Q G ‘ (Colombia) ® - > “sao PAULO, ? , Bat ~oryuneseu evoner ae Bed 7 y¥ Head otice Daewoo Heavy Industries America Cleveland Ortice Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea. Tol :82-32-760-1114 Fax: 82-92-762-1546 Seoul Office 8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34, ‘Youido-Dong, Youngdungpo-Gu, Seoul, Korea Tol: 82-2:2167-91 18 Fax 82-2-785-2677 ASIA & OCEANIA Daewoo Heavy Industries Australia Pty. Lid Suite 5, Level 4,20 Charles St, Parramatia NSW 2150, Australia Tol "61-2-9639-4544 Fax: 612-969-5266 Daewoo Machinery Co., Ltd 1No.83 Wen#iwa 1st. Road, Kueishan Hsiang, Taoyuan Hsien, Taiwan FOC Tol : 886-3-327-5576 Fax: 886-9-827-9013 Xinjiang Daewoo Machinery Co., Ltd No, 178, Hetanbei Road, Wurumuql, Xinjiang, China Tol: 86-991-469-2217 Fax :66-991-461-8641 Dajian(Tianjin) Mechanical Construction Co., Ltd. No.87 Gongeing Fload, Tanggu, Tianin, china Tel: 86:202- 521-0840 Fax: 86-220-921-0714 Daewoo Heavy Industries Yantai Co., Lid £428, Wushishan Road, Eo0.& Tech, Development Zone, Yantai, Shandong, China| Tol 6-535-698-2000 Fax : 86-535-638-2008 Daewoo Construction Machinery Co., Ltd 31d Flor, kt BI, 19-4, Nishi-shinbashi2-Chome, Minato-Ku, Tokyo, Japan Phone :81-3-8439-8400 Fax: 81-3-3439-8648, NORTH AMERICA Daewoo Heavy Industries America Corp. 2005 Shawnee Industrial Way, Suwanee, Georgia 30024, U. S.A Tol 1-770-831-2200 Fax: 1-770-831-0480 Daewoo Heavy Industries America N.J. Office 8 York Avenue, West Caldwell, N.J.07006, U.S.A “Tol 1-873-518-2500 Fax: 1-973-618-2501 14530 Renaissance Parkway, Warrensville Heights, OH 44128, USA Tel 1-216-505-1212 Fax: 1-216-595-1214 Daewoo Rep. C/O Boeing Co. P.0.Box 3707 MVS 30-AH, Seatto, WA 98124-2207, U.S.A Tel 1-425-266-0478 Fax: 1-425-266-0518 EUROPE Euro Daewoo U,K Ltd Daewoo House, Unit 6.3 Nantgarw Park, Cardiff CPA7QU, UK} Tel: 44-1449-04-2273 Fax :44-1449-04-1099, Daewoo Maschinen Vertriebs GmbH Hans-Bocker strasse 29, D-40764, Langenteld-Funkamp, Germany / Tel: 49-2173:8509.20 Fax = 49-2173-8509-60 Euro Daewoo S. A ‘1A Pup Achile Dograce 7080 Framers Belgium ‘Tel: 32-65-61-2201 Fax: 92-65-61-2298 Euro Daewoo S. A France ‘2Eme Etago, 1/3 Avenue Pavley, ZA, Des Bruyeres 78190 ‘Trappes France Tol! 33-1-9016-2140 Fax: 301-016-2144 SOUTH AMERICA Daewoo Maquinas | Equipamentos Lida AV Tres Andradas 519- Jd. Prtininga - CEP (06290-050: Osasco - SP- Brazil Phone : 85-11-3686-0177 Fax: 55-11-9686-0970 DHIAC Colomt on Office Diagonalt27 A No, 17:34 Oficina 302 Bogota, Colombia AFRICA Daewoo Heavy Industries South Africa Pty. Lid {60C Electron Road Isando 1600, Johannesburg, South Arica Phone :27-11-974-2005 Fax : 271-974-2778