8 GENERAL INFORMATION 2. MODEL 3LD1 a Engine modells) aint Type In-line water cooled 4-cycle type, OHV: diesel engine Timing drive system Geardrive 7 Number of piston rings Compression rings 2, and oil ring 1 No. of eylinders~ bore x stroke (ram) 3-83.1x92 Displacement w Preeeelapo erect Compression ratio 2:1 Type of combustion chamber Swirl chamber Hl Overall length xwidthxheight. = (mm) | * 871.5 x 478 x 609 Dry weight tig) | * 132 Fuot injection timing (BTOC) (when at stop) | * _ 19° : Firing order 1-3-2 Fuel Highspeed diesel fuol (SAE No.2) | Idling speed (min | * 850 Compression pressure MPa (kgiem) 8.04 (31) oF more/260 min Valve clearence (cold) ¢mm |? ae Exhaust 0.20 Open (BTDC) 18 vo | Inikovave eee pe a operating timing | exhaust valve | Ope (EPPO 7 aeaseeee Close (ATDC) 16° Injoction pump Bosch type Governor Mechanical type “| Nozzle 7 Throttle type Injection pressure MPa (kglem®) | * 18.2 (136) Oil pump ce Trochoid typo Oil filter Cartridge type Lubricant capacity: In total wy About 88 Genorator output HEH EOC An=| deci eeereeree 12-20 eee [sterter output w-Kw | = 12-12 (Note) These specifications may be subject to change without notice. Figures in the column with an asterisk (*) are different for each machine. Refer to the specifica- tions provided by machine manufacturors,GENERAL INFORMATION 9 | TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. STANDARD BOLT Nem (kgm), Q Boke entifcation Bott Diameter pitch (mm) | was re 170 0a~ 18 nee 2268 12 28 we7~ soe 7 30 axtas (04 7500 80~ 75) coe~ 9126 62~ 99 ro5-1140 (77-118 | Max 765~116.0( 7.8~117) 932~1990( 95~142) as0o~ 1710 (11.6174) | « saiex20 rie-t070¢79~108 ce2~19101 90-104), 1070-1600 408-183) 6x18 toko~t670 1100-1601 rmo~mnorioe-200 | 1600-2400 4189-248) | [+ amex20 moose 02-182) teao~t940132~108) onan 86289) | » M18 «1.5 151.0~226.0 (15.4~23.0) 195.0~293.0 {19.9~29.9} 230.0~345.0 {23.4~35.2} r + x25 wio-zsocss-z.0 | we0~2040(200~200 10-9480 236~955) i weox18 zos0-s100 (210-310 270-4060 218-413) si70~m7e023~485) + M2025 190.0~286.0 (19.4~29.2) 249.0~376.0 (25.4~38.2) 298.0~440,0 (29.9~44.9} | enue : 359.0~-640.0 (36,.6~55.0) 431.0~711.0 (43.9~72.5) 864.0~-831.0 (56.5~84.7) + wax30 ssscwsorowas~sin | anomeoanrsta-c20 210-7820 631-702 An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting.10 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unloss otherwise specified. FLANGED HEAD BOLT Nem (kgf-m) Bolt Edentifieation Bott Diametor x pitch {mmm} Me x10 46~ 85 05~ 09) 68~ 122( 06~ 12) Me x1.25 WO5~ 198 ( 4.1~ 2.0, 1Ba~ 284 ( 1.6~ 2.9) 18A~ 9964 2.1~ 3.4) m0 1.28 23.1~ 98.5( 2A~ 39) 96.4~ 58.9{ 36~ 6.1) 428~ 108{ 43~ 7.2) * mox15 22.3 87.24 23~ 3.8) 945~ 57.51 35~ 5.8) 40.1~ 66.9¢ 41~ 68) 12% 1.25 54 9~ 8231 58~ 8.4) THI~N794 19-119) 85.0~1280({ 87~13.0) max 1.78 BLO~ 76.5 $.2~ 7.8) T4~107.0{ 73~109) 79.5~119.0( 8.1~12.2) mats: 88.0~126.0( 85~12,7} 118.0~172.0(11.7~17.5) 128.0~185.0(12.6~18.9) miax20 71.2~118.0( 79~118) 108.0~162.011.1~16.6) e0~173.0(118~17.7) Mi6x18 1100~173.0(11.8~17.7 171.0~287.0(17.4~26.2) 17.0~265.0 (18.0~27.1) + 18x20 109.0~1640 (11.2~16.7) 162.0~244,0 (16.8~24.9) 169.0~263.0(17.2~25.8) Abolt with an asterisk (*) is used for female screws of soft materlal such as cast iron. ©20_GENERAL INFORMATION MAINTENANCE wwe CLEARANCE AND ADJUSTMENT al & No.t evindor exhaust Cylinder No. Valve arrangement ‘No. t cylinder Toc torcom. | O]O pression ‘No. 1 yinder TOC for exhaust ee Tylntake Ey Exhaust Fig. 23 Note: The cylinder head bolts were previously tightoned with the “Angular Tightening Method”. Therefore, it is not Recessary to retighten the cylinder head bolts before adjusting the valve clearance. 1. Bring the piston in either the No. 1 cylinder or the No. 3 eylinder to Top Dead Center on the compres- sion stroke by turning the crankshaft until the TDC mark on the front cover aligns with the groove mark on the crankshaft pulley, 2. Check to seo if there is play in the No. 1 Intake and exhaust valve rocker arms. If the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. 1 piston is at TOC on the compression stroke, If the No. 1 cylinder intake and exhaust valve rockor arms are depressed, the No. 3 piston is at TDC on the compression stroke, Adjust the No. 1 or the No. 3 cylinder valve clear- ances while their respective cylinders are at TDC on the compression stroke, mm (in) ino aii Exhaust 0.20 + 0.05 (0.008 + 0.002) Vaive Clearance (cold) 3. Loosen each valve clearance adjusting screw as shown in the illustration. 4. Insert a 0.20 mm (0.008 in) feoler gauge between the rocker arm and the valve stem end. 5. Turn the valve clearance adjusting screw until a slight drag can be belt on the feeler gauge, 6. Tighten the lock nut securely, 7. Rotate the crankshaft 360°, Realign the crankshaft pulley. 8. Adjust the clearances for the remaining valves as shown in tho illustration,NERAL INFORMATION INJECTION TIMING {Timing gear), case cover Srenk a Injection pump Cylinder block mark Note: Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made. {1) Remove the injection pipe of the No. 1 cylinder, (2) Remove the delivery valve holder of the pump of the No. 1 cylinder, and then pull out the delivery spring. (3) With the spring ieft removed, install the delivery valve holder. {4) Slowly turn the crankshaft pulley clockwise, at the ‘same time, continue to feed the fuel. When the fuel stop flowing out from the No. 1 deliv: ery valve holder, stop turning the crankshaft, This crank angle position is the starting point of injection. (5) In the condition at Step (4) above, confirm what degree the “groove mark” of the crank pulley is at, when seen by the “timing mark", provided in the timing gear case. When the value is out of the range of the normal injection timing, adjust it accordingly. * Injection timing] 3LA1, 3L81, 3L01 | _BTDC 19° Not The injection timing varies according to the specifica- tions of the machine. (6) Adjust the injection timing with a shim between the injection pump and the cylinder block. Shim is avellable in the following 9 types, and “iden- tification mark” is stamped (or imprinted) on the top face. Identification mark of shim and its thickness. (mm) ‘Mark [ Thickness] Mark | Thickness] Mark | Thickness 2 | 02 s | os | 8 | os 3 03 e | os | w | 10 «| os [7 for |e Lo Note: For each of the injection pumps of three cylinders, the shim adjustment is made at the same time. When a shim is missing while overhauling the engine and the shim thickness is unknown, assemble the engine with provisional shim inserted. After assembling the engine, check the injection timing and adjust the shim until the normal injection timing is obtained. Reference: To add the 0.1 mm shim thickness corresponds to the 1 degree of crankshaft angle advance, 0Compression gatige Wc nan nthe GENERAL INFORMATION 23 V Air bleeding from fuel (automatic air-bleeding system) 1. For the automatic alr-bleeding system When the starter switch is set to “OPERATION”, the electromagnetic pump is activated to force-feed fuel to the fuel pipe and the Ieak-off pipe, and air in the fuol system is automatically bled. 2. For non-automatic sir-bleeding system While sending fuel by means of the force of the elec- tromagnetic pump, the fall from the fuel tank or the, feed pump lover, bleed air oist of the fuel pipe eye bolt of the No. 1 cylinder injection pump, the leak-off pipe eye bolt of the injection nozzle and the air- bleeder plug of the ful filter, starting with the one installed the lower most and upward. OMPRESSION PRESSURE MEASUREMENT 4, Operate the engine to warm-up until the coolant temperature reachs to 75°C (167°F). 2, Remove all of the glow plugs and the injection pipes. 3, Attach a compression gauge to the No. 1 cylinder glow plug installation threads. Note: Compression pressure may be measured starting at any cylinder and in no particular cylinder order. However, it is very important that the compression pressure be measured in each cylinder. Therefore, start at the No. 1 cylinder and work back. In this way, you will be sure to measure the compression pressure in each cylinder. Compression Gauge 608840-2675-0 Compression Gauge Adapter 5-8840-9026-0 4, Crank the engine with the starter motor and take the compression gauge reading. kglom? (psi) at 250 rpm [Standard Limit 31,0 (441) 26.0 (370) 5, Repeat the procedure (Steps 3 and 4) for the Femaining cylinders. Compression pressure should be epproximately the same for each cylinder. A variation exceeding 2.0 kglem? (28.44 psi) is unaccoptable. If the measured value exceeds the spe the related parts must be checked. d limit,QENERAL INFORMATION EL SYSTEM Fuel Filter Replacement -On) Type Cartridge (Spi Removal 1, Loosen the fuel filter by turning it counterclockwise with the filter wrench or your hand, Discard the used filter. Filter Wrench 2, Wipe the fuel filter fitting face clean with a rag. This will allow the new fuel filter to seat properly. Installation 1. Apply a light coat of engine oil to the O-ring, 2. Supply fuel to the new filter. This will facilitate air bleeding. 3, Turn in the new fuol filter unt ted against the sealing face. 4. Use the filter wrench to tur tional 2/3 of a turn. the filter O-ring is fit- ) the fuel filter an addi- Injection nozzle eck to sae if the spray condition and the injection \ssure are normal. Adjust them to the specified value oly when they don't meet the standard valve. MPa (kg/om?/PSI) 13.2 (135/1920) Using a nozzle tester, adjust the injection pressure with a shim. Special tool: Nozzle toster 0scsi paitaiennaentnistsiuscananaciiigs alata bien inecicnLsestnscEncemuilitibauascaia ENGINE 43 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. 1. CYLINDER BLOCK ig. 87 Bore grade mark {Stamp position) Cylinder block Check the cylinder block for wear, damage or any other defects, . Use the hydraulic gauge to check the water jacket water pressure. Apply water pressure to the water jacket at 8 kg/cm? (71.1 psi) for three minutes. _—" CG Meastirement position: 13mm below the top, (Measure in X-X and Y-Y directions.) (Near the No. 1 compression ring) der by mm (in.) Engine Limit Repair method SAI Perform boring and 3LB1 0.2 (0.007). | honing of the inner 3LD1 diameter. Cylinder bore diameter and grade mark The grade mark is stamped on the top surface of the cylinder block (on tho mating face with the cylinder head),44 ENGINE mm (in) Engine Bore Diameter Grade 70,000 - 70.010 a (2.7859 ~ 2.7663) 70.011 - 70.020 ” (2.7563 - 2.7567) ia 70.021 ~70.030 ie (2.7567 = 2.7571) 77.800 ~77.410 A (3.0472 - 3.0876) 77.411 ~77.420 S181 | (3.0476 3.0480) B 77.421 - 77.430 Z (3.0480 ~ 3.0484) 83.100 63.110 i: (3.2716 - 3.2720) 83.111 ~83.120 at (3.2720 -3.2724) e ae 83.421-—89,130 iz (3.2724 32728) Cylinder Body Upper Face Warpage) Use a straight edge.@ and-afééler gauge ® to measure the four sides and the two diagonals of the cylinder body upper face. Regrind the cylinder body upper face if the measured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values oxceed the maximum grinding allowance, the cylinder body must be replaced. Cylinder Body Upper Face Warpage mm {in.) i ‘Maximum Grinding Standard Limit “Aliceaes! 0.075 (0.0029) _J 0.75 (0.0069) 0.3 (0.0118) If the measured value is jess than the limit, the cylinder body may be reground. Cylinder Body Height @) (Reference) mm fin.) Engine Standard Timit ‘SLA 3LB1 281,(11.0830) | 280.7 (11.0512) 3LD1 308 (12.1260) | 307.7 (12.1142)Sts snanteionenaneuainLUsstieninemenetanitaune ccna nasticneseaslon 2. CYLINDER HEAD Fe ENGINE 45 Cylinder head inspection Remove carbon deposit on the bottom surface of the head with care not to damage the valvo seat. Leakage: Water pressure test Skg/om? (for 3 minutes) Cylinder Head Lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. Regrind the cylinder head lower fece if the mea- sured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced. Cylinder Head Lower Face Warpage mm {in.) ‘Maximum Grinding Standard Limit Pikes 0.075 (0.0029) | 0.15 10,0058) |__0.3 (0.0118) Gylinder Head Height () (Reference) mm (in) it 64 (2.5197) 63.7 (2.5079) Note: If the cylinder head lower face is reground, valve depression must be checked.48_ENGINE Heat Shield Install Install the heat shield to the cylinder head from the noz- zle holder installation hole side. Lightly tap the heat shield flange into place with a hammer and a brass bar. The heat shield flange side must be facing up. : O Note: i Always install a new heat shield. Never reuse the old heat shield. 3. WALVE, VALVE SEAT INSERT AND VALVE SEAL 3 a Inspection of valve seat | 1. A= Contact width 1 cylinder head a] o . B- Valve depress i Lp vere [eo] 2 /alve depression ne ! ie Standard Limit 4 | [re] Contact width 2.0 (0.0787) | 2.5 (0.0984) ) SS Valve depression | 0.7 (0.0276) | 1.2 (0.0427) 7 fa Valve thickness Nominal Limit Repair method ' 10 07 i [ro] (0.03937) (0.0276) Replace : Valve Stem Outside Diameter Measure the valve stem diameter at three points. > If the measured value is less than the specitied limit, tho valve must be replaced. Valve Stem Outside Diamoter mm ind) Standard Timit 70 6.85 ea (0.2756) (0.2697) — 70 6.80 or [EEADaet Yee (0.2756) (0.267)50 ENGINE 3. Apply abrasive compound to the valve seat insert surface, 4. Insert the valve into the vaive guide. 5. Apply light pressure to the valve while turning it to fit the valve seat insert, 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. : 8 Clean tho héad and valves to remove the abrasive Fig. a2 aaiae compound and metal patticies. 4, NALVE SPRING J Valve Spring Inclination Uso a surface plate and @ square to measure the valve spring inclinations. If the measured value exceeds the specified limit, the valve spring must be replaced. mm in.) ) —_— Standard imi Valve Spring 18 2. Inclination (0.0709) (0.0984) & Fig, 83 | Valve Spring Tension f Use a spring tester to measure the valve spring tension, If the measured value is less than the specified limit, the 7 valve spring must be replaced. N (kgf) | Standard ti { Valve Spring d | 167 147 S Tension at 29.8 mm wits Set Length (17.0937.5) | (18.0/33.1) Valve Spring Free Length Uso a vernier caliper to measure the valve spring free length, If the measured value is less than the specified limit, the valve spring must be replaced. mm tin.) Standard Limit i Exhaust and Intake 5 i 42.1 40.0 ; ae abd ted (1.657) (1.575) ‘a a 5. AAPPET (Cam Follower or Valve Lifter) AND PUSH ROD Fig. 8 TAPPET ENGINE 51 Inspoct the tappets for excessive wear, damage and any abnormalities. Uso a micrometer to measure the tappet diameter. pe mm (in) Standard | Tappet Diameter 20.967 - 20.980 (0.82547 - 0.82598) Use a dial indicator to measure the clearance between the tappot and cylinder body tappet travelling bore, mm fin.) Standard imit Tappet and Tappet | 9.979 -o.054 . i .020 .08 Travelling Bore Clearance {0.00078 - 0.00213)| (0.00315) PUSH ROD Use a filler gauge to measure the valve push rod runout. Roll the push rod along a smooth flat surface (illustra: tion). mm (in) rt Limit Push Rod Run-Out (0.3 (0.0118)164 aoe i 8. pron, PISTON PIN AND PISTON RING : Clearance between piston and cylinder hore (1) Measure the outside diameter of the piston at about 60 mm from the top in a right angle to the piston pin (in the unit of 1/1,000 mm). (2) Calculate the clearance based on the measurements of the cylinder bore and the outside diamotor of the piston. mm (in.) Clearance 0.015 ~ 0,035 (0.0006 - 0.0014) Fio.67 Piston outside diameter for service parts The piston installed at the factory has three grades, but the one for service does not have grade. mm find Model Outside diameter Grade f ) 69,975 ~ 69.990 ne (2.7549 - 2.7585) Non ‘ 77.375 ~ 77.390 : eevee eee ware eereereerer ee on (3.0463 - 3.0469) a : 83.075 - 63.080 i on (3.2707 - 3.2713) a i Wear of piston pin (outside diameter} i 2 mm in) [er Model_| Nominal [Limit Remarks : Slat 210 20.87 atpi_| (0.8268) | (0.8256) _| Replace if worn ae beyond limit ar 25.0 24.97 | bev it (o.9843) | (0.9831)ENGINE 55 Clearance between piston pin and piston pin hole mm (in) (e] Standard 0.002 - 0.012 SLA1, 3LB1, 3LD1 {0.00008 ~ 0.00047) Piston ring gap With the ring inserted into the cylindor bore, push it in with the piston head so that it becomes a right angle to the cylinder, and then measure the gap of the piston ring. If worn beyond the limit, replace the rings. EE) mm in.) —— “Standard Limit ist 0.2- 0.35 compression ring _ | (0.0079 - 0.0138) 3tai| 02-04 20 2nd ___| 3LB1|{0,0078 -0,0157)} (0.07874) compression ery ting [2'|norecoson| aaa 0.20.4 1.0 Pee (0.0079 -0.0157)} (0.03937) Fig. 107 Clearance between piston ring groove and ring a Measure clearance at several places on the circumfer- ence. If worn beyond the limit, replace the rings or piston. Lat mm (in) ———_] Standara Limit ist 0.065 - 0.1 compression ring |{0.0026- 0.003, 0.3 2nd 0.03-0.065 | (0.0072) compression ring (0.0012 - 0.0026) a 0.02 - 0.06 0.18 enune (0.0008 0.0024) (0.0059) 3LB1 mm (in, — Standard Lie 0.065 - 0.1 compression ring |(0.0026-0,0030) 9.3 2nd 0.03-0.07 | (0.0012) “compression ring _|{0.0012 - 0.0026] ay 0.02 0.08 0.16 ane (0.0008 - 0.0024)) (0.0059)56 ENGINE alot mm (in) Pee Standard Limit ist 0.088 — 0.108 compression ring | (0.0033- 0.0041} gg 2nd 0.08~0.088 | (0.0072) compression ring | (0.002 - 0.0033) i 0.03 - 0.07 05 Oring (0.0012~0.0028)] _ (0,008) Piston ring tension 3LAt Nkgffb.) Sipps Standard Limi = 102-147 compression ring |(, 1,04 15/. |) 74-113 anda ete 0.75~ 1.15 / 03) compression ring |( Poe seas) | (oss a 21-36 6 Oil ing 21-3.7/ 06/ 4.631 8.159 1.323 3LB1 N (kgffb.) ——= Standard Limit a 105-180 4 Hen 1.07 -1.53, 04) compression ring |(2\359~ San (ose ) 76-115 be 077-1477 oa) compression ring | (O75 1.17 a8 24-36 “| Oil ring 2-971)! ( 06) 5.298.159) | (1.323 3ip1 N (kgffb.) ————__ Standara imi 112-159) Ast compressionring (th ore) | mer o6/ 2nd aes 1.328 compression ring |( pm 1431 "25-39 Oil ing 25-40) 18) 5.513 - 8.82 3.969 oO.TROUBLESHOOTING SECTION 6 TROUBLESHOOTING Engine does not start [ Starter does not run Starter runs but does} Engine starts | not start does not rut Check battory ies Engine Fuol system Bul injoctod ‘ir mixed OK fuel pure aischarging chant 4 Cc ratio injooted 7H Check wl ; FRetighton] a replec Check if fuel Chesk | [OK pecking, [ ] Low OK ‘comes preheating bleed air Loosened | [OK] | compression to fuel pump! circuit connector or ratio broken wire -— FE (Retighton or i Check for air [ replace with Defecti cing Poor | [ Normal |{ Disordorec ‘new wiring) valve, spring, operation | | operation |] ialing ‘gasket, ete of glow | | “oF glow (eee (Overhaul) (Ecce plug plug ‘Airmixed | [OK] | controt_ | | controt Check starter ewitel (Retighton't, resistance | | resistance |— replace (Replace) | | OK ppacking, blood T 9 L peeseine ey [ Adjust Check idling aiase injection Check fuel timing fiter Check magnetic 1 ‘ewiteh L. [ Abnormai | [OK Gioaged | [OR] |_Aciuso (| (Clean 7 Doteative | [OK ee (Replace) Chock ongino stop wl solenoid return Defective K camo Genet Cheek solenoid f 1 Defective injection Poor contact] [0 ie (Repair or ‘Stuck solenoid or | [OK pump (Bring jr operation itto a specialty replace) oor op b (Repair or 1eplace) shop for repait) — Dafactive starter + Note: “Bring it to @ apacialty shop" means that dofective parts of the injection P |(Bring it to @ specialty] and electricals must be brought to a specialty shop for repair. (This note it shop for repair) ‘pplicable to all the following procedures.)106 TROUBLESHOOTING ‘Check nozzle Defective | [OK (Repair or replace) ‘Check oylinder for uneven compression pressure Uneven OK sompression| pressure (adjust) Defective injaction pump (Bring It toa ‘specialty shop for repair) l Unstable engine Idling speed Unstable rotation at | [ Unstabie rotation at | [Engine does not iding 09 high ‘medium speed igh spoed change from high to (Hunting) —-— |“ tow rotation Dofective taling Defective controt_ | [Governor spring || Check fuel for air | [Check accelerator adjustmont lover adjustment deteriorated mixing pedal [ Defective OK] | Defective OK Podal [0K valve return (Ropeir or sticking or Adjust) replace) hitching (Clean or replace) pressure | { Defective injection | [ Check fuel pipe for | [ Chock fuel fitter for pipe for cracking, || pump (Bring ito a crash slogging clogging or bending | | ‘specialty shop for — Defective repair) ump (Bring itto a a ‘specialty shop for Cresh OK] | Clogged ] [OK oral: Cracked, | [OK (Replace) (Clean or clogged or replace) bent (Replace) ‘Cheok unsven fuel Injection ae Uneven ‘OK tAdjust) [Chock valve clearanes adjustment Poor OK adjustment (adjust) Defective injection pump (Bring itto a specialty shop for repair)TROUBLESHOOTING 107 [Check fuel for air mixing Mechanical ‘system [ Cooina ayers Handling (Adjust) 7, Gemaien) [OR] Check cooling Check fan belt used ain ‘water level for stip is inferior quality Check engine —~——} Porengine oll i 1 | = aes i too much Slipping | [OK (Adjust) cc Clogged Cc [Reptenit] ‘Check intot ‘temperature pe [Cheok thermostat a (Clean or| Replace) pressure pip bending POE [eee Check high clogging or ieee 30 for Sele [Clogged] [OK or bent Roptco) [Check ronia Detective] [01 [*Repair or replace) fMattunetio) [OK (Replace) framsawal Leak to] [Leak to fax ftw eternal inten come timers system for stain, iston ‘and radiator for «| evsiray] L"" tooaing = Repair replace | ——[—— Insufficient inlet Bele air [Stained of --+ clogged | | (Clean) | [OK fart OK stained (lean or replace) C Check valve clearance and cam lift format] [OK] heck nodion | fads iming pleas) “I se [aeeeca eect FAbnorma) [OK] [Brscomproa (Adjust) ‘pressure Defecve pump tering tio specialized sh for repair) 0p Excossive| biow-by ges (Overhaul Gas leak from valve and gasket {Repair or replacal perature abnormally high ~~ Improve ventifation108 TROUBLESHOOTING ‘Abnormal exhaust gas L Black smoke too much od Perec eee ee HE Check if fuel used is of Check fuel for water Check nozsla dogged Inferior quality mixing co OL Batoatve [0K]. | Replacoair | [OK Change fuel [OK] | Wator mixed OK] {Repair or roplace) jcteaner element] =F | tchenge fuei) L LC EE ae c— Check if engine ole too c— Check injection timing ] [Check alrhose for crash mich ‘Check injection ct _frtvancottoomen] [OR] Delayed OK ‘adjue (Adjust) 7 — ‘Check injection pump Check compres _ ct Defe jection pump: [ox Tow OK] | (ring ito. spectaty shop for repait) ‘a es tek trom Excessive | | velveena | | Checkup and 1. Disordered valve timing low-by gas| ssket (Res i 2, Broken piston ring or 3. Worn camshaft 4.Worn valve or insert _ [Stack (Overhaut {Overhaul Over-discharge of battery || Battery, Wiring Regulator and generator [ [ i Check eleatolyte lavel Check terminals for warp, Check bet for slip or damage ee eer deformation or corrosion Low OK aaa doling OK a OK] | damaged Repair (Repair or replace) or replace) Battery Cr ast charging condition Leroea ‘Check for broken wire ee ar vane —— (Repair or replace) a 1 [Note: Improper maintenance ‘Abnormal OK a Chock specific gravity Low Recharging Recharge Impossible Bring it to a batiery spe ity shop Bring itto a battory shop| TROUBLESHOOTING 109 [_Oilpressuretoolow _]] [il consumption too much] {Oi consumption too much) | Check olliovel Check for olfeakage | Check or oilleskoge_—] | ql ok [ mat T i 1 L za eat eee Low (Replenish) | OK Leaking (Retighten, OK Leaking (Retighten, OK post a replace packing seal) replace packing seal) Check cooling water temperature [seestnecsenss | aces Chock oll quality High OK (Soe “Overheat”) ive aK Poor quality OK eT {Repair or roplace) [(change to specified ot i | Check ol in crankoase Cc oc | . . Checkinjection timing | [Check bleeder for clogging i (Pererteereeeeeeeee [Abnormal (Adjust) _] OK} [Clogged (Clean) OK Wetor or fuel mixed. Check fuet co co () — |_s¥stem and cooling system ‘Check compression ratio [Check up and down movement of oil " 7 = 1 Slit Check relief valve Low OK 4, Oil pump malfunction c 1 J 2. Loosened or eracked pipe — de - 3. Wear of sliding part Defective etectve injection pump] | & Oil pump clogged {Repair oF replace) {Bring ito a speciaity | | 5, Defective valve stom seal ‘shop for repair) (Overhaul) 4, Oil pump malfaneion _——— (°) Worn boreand worn or broken 2. Loosened or cracked pipe Excessive] { Gasleak from ring (Measure compression 3. Wear of sliding part blow-by gas | |vaive and gacket| Pressure, and check entrance of 4. Oil pump clogged (Repair or dust) (Overhauit replace) ___ Engine knocking Mechenicalsystem | [Fuel system i Check up mavement of ol Chosk injection timing co Oil stained (Overhaul) OK | [Abnormal (Adjust) |] OK Check compression pressure EEE “Check nozile [__Ghesk nore fear Geert Low OK Defective OK } {Ropair or roplace) | [Tefal ayoom | fuel system | : Noto: Fue! used is of poor quality Excessive | [ Gas leak from blow-by gas | valve and gasket {Ovorhau) (Ropair or SaSnaSE replace}