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Engine Service Manual FD6 FD6T PDF
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For use with Kobelco LK400 FD6T
ENGI QUICK REFERENCE INDEX
SERVICE
SERVICE
MAUAL
�:2ISAEMBLY JUDGNT , ". ?·ir; '-it1
JUDGNT ,·<
MODEL
FD6 & FD6T
Applicable Engine Numbers
FD6
FD6-005001
FD6T
FD6010001T
'I
,\ FOREWORD
OREWORD
',;\:i FD6 Thandservce manual covers rpr procedure of the
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© 1988 NISSAN
NISSAN DESEL MOTOR CO., LTD
sued: Apr 88
880426-2232-300K3Z()
1 GENRAL
EF1-002
s chaper d esib es ha ndl n g cutons of hs mnul a n engine
geneal. eefoe, when epi in
in g FD6 a nd FD6T en g ines by us in
in g h i s
mnual, ed hs chpe
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
METHOD OF USING THS MANUAL . 1-1
EGNE SPECFATONS 1-2
LBRATIONS ND FUEL 1- 4
GENRAL 1 - 1
METHOD OF USING HI
METHOD HI MANUAL
STANDARDZATON OF TES 1 mm .. 00394 in
1 kg . . 2205 lb
GI PII 1 kgm . 7 23 lb. ft
1 kg/cm 2 • • 42 3 psi
1 er
0 20 Ipalal
1 064 U.S. al
er al
°
( F) = 3 + ¾ T
C
RIGHT
Howv, h u of hospow uses
Howv,
Fa hopow
BBVII
I h aual h followg abba-
REAR
FRON o a ud
OD
OD Oud Da
ID
ID
d Da
Da
OS
OS O Sz
US
Ud Sz
BTDC
Bf Top Dad
CA-52
C
ABDC
ABDCAf Boo
Dad C
BBDC Bfo Boto
Dad Ct
ATDC Af Top Dad
Cr
PTO Pow Tak Off
N H NAL
NAL
MIC
MIC Wea lmt h aual co of ah hap
M h h oubl po ar ucla
Wa l dca ha h pa o hap 2 DalJg
Maintenance standard
Maintenance xdd h g wa l ad
ha xdd ad loca h roubl po
"Maac adad dca h ut b plad f rrg
Pp h a ool f rrg
claac wh pa ar
adad claac o Chap 4.
bld
bld o h adad po
po Eg d
Th o hap 3 Eg
o ably pa abl ad ou h oubl
UI
opo ad pa b g o
Rpa lm Th u o au ud houghou h hap 4 Eg pop o
"Rp l dca h p h aual a acodac wh chap ua qup fo
ca h claac bw h c Wh
Wh coo o ch opo Fo hc o h
pa o h pa a o h h opodg Eglh u (Foo g poac f o hap
lu g h pa l a o poud ) ca ul h 2 Eg podu Mo
b aad followg o a adad ad
ghg ou ar olld
hap "Sc daa
1-2 GENERAL
ENGINE SPECIFCATIONS
Model FD6 I FD6
Type Diesel
Cooling sstem Water cooled
Number of clinders an clinder configuraton 6, in-line
Number of circles 4
Tpe of combston chamber Diret fel injection
Valve mechanism Oerea ale gearren
Tpe of clinder liner Wet
Bore x stroke [mm! 100 20
Piston otal isplacemen cc] 564
ompression ratio 17.0: 1
liner copressin ( kgcm2 rpm) Mre an 30 200
ompressin ring 2
Numbe of piston rings
Oil ring 1
°
Open 1 DC
Intake ale ting
Clos 7 AD.
Open 3 ° .D.
Exhaust ale timing
lose 9 A.
ntake 04
Vale clearance m
xhas 04
niion sse opressin ignition
uel injection timing DC 1 0' I 10
gniion orer 14263
Q
pe sc A pe
E
I
:
E
u
Q lunger diameer m 90 8
C
O ·
>
" ·;
<
a li [m! 80
Q u
:s Goernor entrifgal
imer Centrifgal
C
.i
Nozzle hlder lange tpe
u
! , 4
C
·- "
0
Nmber of inectin nzzle
- C
I
I Injecton pressure kg/cm J · 200 220
GENERAL 1-3
Model FD6 FD6T
ype Cyclone or oil bath
Ai cleae
Nume 1
pe R tp
A hear
Volage [V] x Curet
A] x numer 2 2 X 0 X 1
E
.
� p - 04893
.
Etea mes -
X
C (Lgth x Wt x Hgt } 210 20 15
"
C
" Ma. pmble otuou
C
uag - 1 2 ,0
p pm)
C
- Culokwse a
t f tat - vee fm te haus
tue de
A m [kg/m] - 2
Cmp t - 3. 0
>
E O um Gea pump
" Fufw P mt
l
O f
·
"
u
.
B-p
Lut p [Q]
Pap lmet
15
',;.I
'fi"1
'I O W te tp
·Ii.,
::I.;/1,i1P.;' � .··:'1 ·<1
1 p F ut
>
E
I 1i ,
C
Rda Cor ug ated f in
, .
l
Col wa ter ca py (on for h ngin)[Q]
[
if,:1q 0
0 W p Ct
i:1 u
'i)/
m W plt
p AC -
>.
.
l
.5 E
E
C f O [V-A] - 0 - 2 - 0 2 - 5 2 - 2
u.
7
g eut yp
u
·
Sft y
u
C
5
u 0
�E O [VkW] 24 - 3. 24 - 4 2 · 0 2 - 5 2 .
V
GENERAL 1-5
BEARING GREASE COONG SYSTEM WATER
(Brand recommended: LG o. 2, i -Soap base) Be sue to use lean sof wate su as t wate n he ool-
ing sstem. Do not use hard wate su as well wae o ve
This grease may be used on geneato fan puley braket water ecause su water an easly form sale n the system
stating motor, and et. Be areful of ontamnaton whle Note that sale attahed to th water passag n he ooling
gease s n stoage sstem (partularl in te radator) an aus engne oe-
heating
Petroleum and
Mke FUE
CALTEX MARFAK MULTPURPOSE NO. 2
CALEX
The Nissan Diese engine is designed to podue pow
CALTEX MARFAK ALL PURPOSE NO 2 using lght oil as fue Do not use any fuel exept lgt o;
TEXACO MARFAK MULTPURPOSE NO 2
othewise engne toule will result.
TEXACO • Te lght o soud ae a etane numbe geater tan 45
TEXACO MARFAK LL PRPOSE NO 2
spef gaty of 0.81 to 085 bong pont anging from
°
ESSO MULTIPURPOSE GREASE 180 to 380 C sulfer ontent of less than 05% and should
ESSO
ESSO RONEX MP proe neutal n a heial eaton test. It should e lean
possess te pope sosy and ontan no wate or sediment
MOBL MOBL GREASE MP
GULF ULFLEX CPACS · U
SHELL RETNAX D6 D
SHELL SHELL ALVANA R
Enne o s
To apa
SHELL LVANA EP2
ers
BP P ENERGRESE L2 O pn apat
CASTROL CSTROL LM GRESE
H ee 2 ters
L ee 9 ers
GP GP F1 GREASE 530 Cooing syte·water (onl fo te engine)
VALVO-
VAL·LTH NO 2 EP GRESE 20 ers
LNE
GLO GEASE
CHEV CHEVRON MULTMOTVE GREASE NO 2
RON
CHEVRON POLY URE EP GRESE NO 2
VEEDOL MULTPURPOSE ALL PURPOSE
VEEDOL
GRESE NO 2
NL: Ni Lbicg Gs si
'1
,i
I
,
2. DISASSEMBLY JUDGMENT
EF1-002
This capter covrs th judmnt of dsassmblin g h FD g ,
DETRMINING H NEE FOR ENGINE OVERHAUL . 2-1
ROUBLSHOO NG S S 2-2
CAUS OF ROUBL N S CORRON 7
AGNOSS GUE . 7
r·
t.
'
DISASSEMBLY JUDGMENT 2-1
DETERMINING HE FO EGI OVERAUL
Whether an engine needs overhaulng DETEIORATION. IN FUE fators and o horoughly ne the
or no determned by onserng CONSUMPTION (FC) engne
varou fator nlung reucton n Detroraton of FC alo arbuable
oupu ffuly n arng eer o the oerang ondon of he REDUCON ENGIE OI
oraton n ol or fuel onumton, vehle (nludng roa onon, load PRESSURE
reuon n ol preure, an the n eght drvng hab) an oor an f the engne ol reure ro o the
reaed need for erio mantenane. tenane of ar. herefore eterora rear l, he engne nludng the
I erable however, o judge on of FC no always a gn ha lubratng system should be over
heher or no he engne atually engne verhaul requred However, hauled
requre overhaulng by ondutng the operang onton are un Engine oil pressre
varou hek a any of he above hange from he new ar pero, s °
(Oil temperatre 7 to 8
faor an ofen be orree hrough oble o deermne wheher or no At idling
nor erve operaon raher han a he engne requres overhaulng by Maintenance standad
omlee overhaul ung e FC value of the new ar 10 kg/cm 2
erod a a rerene If he FC value Repair limit
REDUCTION IN COMPRESSION dro below 60% of e referene Min 5 kg/cm 2
PRESSURE value he engne houl be over At 1,500 rpm
The omreson preure of he en hauled. Maintenance standard
gne lower a he ylder lner, 32 to 44 kg/cm 2
on, on rng an valve beoe DERORA EGN Repair limit
orn If omreon reure ro o OL CONUMP (OC) Min 2 kgcm
h repar lmt, e engne us be The OC value hange aorng o
overhauled. varou or nlung oerang
Compression pessure (Wam engine onon of vehle, qualy of
and engine rpm: 180 to 220) engne ol, e Hoever, f he OC
Maintenance stana r value ro belo 40% of nal
More than 30 kg/cm 2 value durng he ne ar ero, an
Repair be regarde a a gn a engne over
Less 25.0 kg/cm 2 haul requre Bere akng he
' Difference beeen cylindes nal eon o overhaul, alo
:; Maintenance standard neeary o hek opreon re
/
Less than 4.0 kg/cm 2 ure, blow-by ga presure and oher
i!
. I
u:
2-2 DISASSEMBLY JUDGMENT
TROUBLESHOTING TESS
MEASURING COMPRESSION Compression presure (War engine Exmple of trouble
ESSURE and engne rp: 180 to 20) Trouble symtoms ta are attrbta
The measureme1t value of te co Mantenance standard ble to ncorrect compresson pessr
pression pressure s porant n deter ore tha 30.0 kg/c2 are: low enne outpu, deteorated
minng the tme tat engne overaul s Repar
oil consumpton, deterorated uel
needed. It s terefor necessary to Less tha 50 kgc2 consuton, esson of we soke
periodcally measure and record engne Dfference between cylinders
durng h speed ravellng dfcult
comrssion pressure. Mantenance stadard
in startn rregulr ngne opeton
Max 40 kg/c2
desel knock overeatn, etc I
coresson ressure dos below te
rer lmt, the caus ust be x
amned nd the enne overauled
( ,;
, .
Factors that may cau reduction n
compession prere
Cylnder lner Cylnder ead Valve tran
Improe nstallation Improper valve tng
o nozzle Imroper vlve clearance
Crack n valve nser or Crack or break n valve
proper nsalaton
Forein atter caugt n valv
Gas leakae from cylinder
ead sket Poor alve contac
Valve stckng
Low compression. -
�
'
pressure
Bent connectng ro
Wear or daage n rng and
Bow-by or blow ole
Algned end as
ston ston r Oters
DISBLY JUDGMET 2-3
MEASURING BLOW-BY GS Trouble symptom measured and then a decson should
PRESSURE Touble symptoms that ae attibuta be made whethe the engne equies
ble to ecessive bowby gas pessue oerhaulng
Measuement of blow-by gas pessue
ike easurement of compession ae: ow engne output, deteioaton
pressue povides an impoant in n oi o fue consumption esson of
omation, in decding whethe o not white soke duing high speed ave
an engine should be ovehauled. ng difficuty n sating iegula
engne opeaton dese knock ove
B (W
heating oi eakage fom ai beathe
x )
o othe aeas, etc If the bowby gas
pessue eceeds the sevice standad,
Max. 12 mmAq
copession pessure should also be
Factors that may cau an increae in
low-by gas prer
Cyinde ine and piston Vave nake and eaust systems
'i/
Eensive scung Hafopened ehaust shutter
oged o cushed muffle o ie
Tubine side ing sicking
oken o bent beathe hose
ogged beahe
Etensive scufing Fauty coesso
Aigned end gaps Vacuu um unning wthout a beak
Piston ing Ohes
2-4 DISASSBLY JUGMENT
MEASURENT OF BOOS Ep f f
PRSSUR urbharger lure s edenced by
hould the turbcharger become in decreased engine uut, excesse uel
erative, boost ressure should be consumn r black exhaus smoke.
measured diagnose he nake and bnrmal bst ressure ndcates the
exhaust systems. necessty nsecn and ssble
When engine speed no-load
erhaul the turbcharger ad n
max. running (Warm engne) ake and ehaus sysems
Maintenance standard
80 mmHg
(Measured at the ntake duct of
the turbocharger)
F w w p
urbocharger xhaust' sstem
Interrence o blades haust shuter ha-oen
h housng uer/ing damaed r
Imeller/shat heel blades obsructed
brken Gas leakage around arts nstalle
eized shat heel at rn turbocharer
L boost ressure
Inake shuter hloen
ir cleane element cling
r leakage arund ars installed at
rear o turbharger
Inake system thes
DISASSEMBLY JUDGMENT 2-5
NO-LOAD CCLERATION Trouble sympto Slow deeleation is generally caused
AD DCLRATO TST Trouble symptoms elating to by poo governo perfomane, suh as
proper aeleraton or deceleration are impoper adjustment of damper
The ondition of an engine an be
as follows: low engine output, deterio spring or idle spring or too hgh idlin
judged by checking its aeleration
rated fuel onsumption and difficulty adjustment by otrol knob
and deeleation speeds. This test is
performed under a no-load condition in shifting of transmssion
No-load acceleration and
eceleration test (Warm engine)
Causes of slow acceleion o
Acceleration
deceleraion
Maintenance standard
Max. 1.5 sec. Slow aeleration s aused by low
Deceleration compression pessue, ncrease n
Maintenance standard blowby gas pessure, and failue in
Max 3.0 sec uel system
Ineton pump Fuel le Othes
Maladjusted netion Cloged cushed Excessve engine oil vsosty
· , tmng uel ppe
.
Malfunction of delivery Clogged uel lte
valve
Malunton o njecton
pump
Extensve sldng essnce Same as the causes o "Low
regula neton pessue on oy pton copesson pessue
Stcn Same as e causs o Hhe
blowby as pessue
Same as under Low boost
Nzzle Engne pope pessue
2-6 DISASSEMBLY JUDGMENT
MEASURING WTER Causes of hgher aidity MESURING SPECII GRAVITY
TEMPERTURE DIFFERNCE the burnt ases lea through the OF FUL
BETWEEN RADIATOR INLET cylinder head gaset into cooling Por qualiy ue not only cause
AD OUTLET water the suurous acid gas in the reduction in engine output, but also
This test is perormed to check wheth- burnt gases dissolves into water, thus causes fiure in the nozze and
er the radiator is unctining nrmay increasing the acidity o the water plunger and clging in th ue iler
It is desirable to examie temperature lement I any o these aiures is
uring the running state using a PRSR OF R observed, it is also necessar to mea-
thermister NK N RDR sure the visosity o uel in order to
Water emperature diference Fauty waer tank cap nd radaor cap udge whether uel quality is accept-
etween radiator inlet and oute can case he amn o coin aer able Genealy speakin reduction o
Mainteace stadard o be redced or "he enne ver 0% in he specific gravity can cause 5
Approx. 5 to 7 C
°
hea. herere he ater tank cap to 7% increase in the ue cnsump-
and radiaor cap shoud be checked tion, and alie ecrease in engine out-
Trouble sympm peridical put
Excessive temperature dierences can Wate tak cap type eatio bewee temperaure ad
cause engine overheating. Mateace tadad pecifc graviy
06 t 08 kg/cm 2
Pile causs Radat cap type
1) Extreme water temperature dif- Mateace tadard
ferences are caused by water scale 0.8 t 1.0 kg/cm 2
or f reign matter obstructing nor-
ma water low in the radiatr
2) Sight water temperature differ- .
ences are caused by oreign matter ENGINE OIL SPO TEST
such as mud and insects accumu- he enine ol spot test is performed O
lated n the radiator core fin, t evaluate the cndition o the engine
obstructing smooth ow of air oi, thereby jdging whether r not the
through the fns engine oil requires changing V 1.
A spot est kt is avaiabe frm the
petroleum manufacurer and the spot .
test shod be perf rmed b referring
LITMUS TEST OF COOLING to the nstructins givn in the it. -� _: .
WATER , UJ• .
L
:
Ti•1AURI (Cl
Check the pH vaue o the cooing P
water using the litmus paper {Use bue
litmus paper)
Trouble sympm
the acidity o coolin water is e-
cessively high, engine overheating or
reduton n the quantity o cooling
water may reult
DISAEMBLY JUDGNT 2- 7
CAUSE OF TROUBLE ND ITS CRECTIN
PRECAUTIONS ON TOUBLE- horough invesigaion of he and he rolem was reaire y
SHOOTING AND EAIRIG rouble prior o disassemly can smply replacing he oil seal
preven unnecessary procedures f he cause of his prolem is
1) Prior o disassembly, confir he
enablig uick and efficen epair auly ol al here is o prole
naure of he problem. Dermine
work Noe ha disassembl Howeve ol leakage is ofe a
he following pois ad h codi
wihou prelminay invesgaion seconday prole esulig rom
ions efoe ad afer he occur
ofen aes reproduco of he anoher primary cause and he
ece of roule by askng he user.
poble diffcul hus aking pimay cause mus be remove
1 Did he ouble occurred sud
ouble-shoong possble whou fail
dely?
2 Was here anyhng unusual he cas of he abov eample
4 Always sa wh a sple opera
bfore occurrence of he he caus of he oule ma e one
o
ouble of he followg
Afe aking a guess as o h caus
3 Und wha condion dd he • h wy gas pressure s
of he rouble pform ivesga
oul occu? ecessively high ad engine oil
on o epa wok sarg wh
4 Was hre ay repar wok done spirs ou due o he high pres
h sples opeaon
cenly? sue
(Pl:I_ !-1·., 5 ·Js he ay oher unusual ) Always cosd h caus of he Misaliged crakshaf due o
"'; phenonon? oubl wa o an bag shell
Conf th naue of h pobl h sa pol wll occu
h shop (y h svc padly f h sympos oly
chanc hlf) ae coced whou vg h
Rconf h ae of h po al cas of h oul B sue o
l coplaned of y us and sek ou h o of h oul
pf ss sg various esg ad ov coplly
qpen n h shop Then ake Exapl: An ngn was ough o
a guss as o h cause of h he shop caus of ol lakage
oul fo h cankshaf fon ol sal
DIGI IE
h dagoss gud s a abl whch HOW TO USE THE GUIDE scon hough h do mak
ca usd fo skng ou h cas Op h pag of gd co " If h a o an on
of ol whou dsasselg h spodng o h ol sypo applcal "Caus of oule
g o h ass of h sypos coplad of y h s s h m avng he lags
of h pol and h slt of 2) Chck all of pos lsd n h u of do maks should b
chcks pfd h shop pg gad as h cal caus of
3 If h s y applcal n h ol
h chckn pos h caus of h cas s havng no do
h oul ay assd n h ak ca gadd as o
llowg an ng h cas of h oul
• Each h "Sypos Note
ad chckng pos sco If more than one cause is ssmed,
cospons o on o o repar peraton should bgi wth the
s n h Caus of oul simpest peratio.
2-8 DISASSEMBLY JUDGMNT
:.
z
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DIFFCULT ENGINE STARTING u C C
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I v I I L
Cuse of trouble
Discharged baery
E
""
I
Poor connecion of connector nd erminl
Breaks in elecricl wire
·.
u Faulty sarer
iu
I Fauly sarter SW n starer relay
Fulty air heater
ck of fuel
Fulty feed pump
ncorrectly insalle fuel pipe
Faulty injecion pump
E
u
"
I"
Faulty nozzle
Cloged fuel filter element
u Ar in fuel sysem
Incoect inecion timn
Broken or dmaged fuel ppe
Cloged gaue filte
"
Dmged rin ger
Damaged or seie roing enine par
.
0
High engne oil vicoity
o ncorrec vlve clernce
I
ndeque comression pressure
0
0
I ncorrect alve min
C
e
C
Cloge ar cleaner elemen
Fauly cluch nd subsequent power rin
(Check by connecting nd isconecing he cluch)
DISASSEMBLY JUDGMNT 2-9
"
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u a
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u : u u
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BLACK EXHAUST SMOE :
0
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a 0
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D
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Cause of troble f L L L : - . L
""
Accmlaton of ludge i a heae
-
loged i cleae eleme
>
Hl-opeed ntke hutte
"
Turbochre ile (jam, etc.)
Oil leakae fom compresso de of turbochae
Excesve ijecio quaniy
Uneven plger wer
Malfcton f delivey valve
(
Fulty ozzle
u
u
Poo fuel qulty
Excessively dvced jecto tm
Falty boo compeo
( .
We o po i o cylde le
-
D 0
.
Excesive o i ol p
WHITE EXHAUST SMOKE
(
Dd m
E mpe oo lo
e�
C
Ee ol leaka down hoh valve sem
We o po o cylde le
C 0
c Excesv l pa
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Icoec vlv cleace
2- 10 D! AS EMBL Y JUGNT
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: 0 : E E
0
. .
> C 0 " " E
: 0
t
4
C
C C C
o ·
'0 t 0 '0 '0
C C C 0
C 0
3 c - _
U U U U V V
Cause of trouble
Incorrect djustmn of lik or rod
Fuel leakage from inject ion pp
Uneven injection quantity
E Mlunction of goernor
Uneven injction ressure of nozzl
Improper fuel spray of nozle
L
Improper djustment of idl spring
Improper djustmnt of damper sprin
Malfunction of deliver ale
Air in ul system
I
Improper placement of ale seat
Improper vale clearance
0
I
Incorrect al timing
C
'0 Incorrect compression pressure
C
U
Engine temperature too low
Detriorted enine mount rubber
. Improper justmnt of idlin
0 Rusted control wire
DISASEMBLY JUGMNT 2 - 1
�
C
·o
"
>
-�
0
.
u
"
.: C
. a
C
.
· E
.
C
C
0
DECRASED ENGINE
0 C
" 0
C
"
a
0
·
C
t
E C
"
POWR 0 0 0 ·.
> C s
E E E E
" E
"
.
E 0 "
"
" E . " i
0
C
0
·x
"
t
C
·;
u
.
=
E
"
" " 0
C
0
E 0
C
i
>
.
)
.
.
> 0 0
C
>
" E
0 0
: C
. :
C
,
C
,
u
" 0
0 u
,
: 0
0 0 C 0 C 0 0
Cause of trouble : a I I V .
I
1
Impop ul qualy
Imppe adjusment o in-
econ uantty
logged uel le element
Wae o a n uel system
:, Low fuel pessue (ov
i E
,i .
ae)
!:
Impope uel spay m
nzle I -
L Impope necton tmng
Maluncton deley
ale
Maluncton o eed pump
alunctin o necton
pump
Faulty bst compensat
logged ai cleane element
Thin t nake a
-
E
" > t
.
Accumulatin cabon
a eate
Halopened intake sutte
"
lgged o cued exaust
- ppe mue
Haopened exaust sutte
Tuocage malunct
Wea on pstn ings and
cylinde line
0 on, stcn o bken
0
piston ring
Seed pston
·0
Won o seed ale stem
Imppe seatng o ale
nset
Impope selectin ea
while traveling
Imppe adustment
cntl nae .
0
Poo etunng engne
stop wie
2- 12 MBLY JUG E NT
DI AS SE
C
·2
C
2
<
<
<
C
�
.
·o
E
C
u
C
EXCSIV OL CONUMPTON C
E =
<
. ,
u
< 0 0
:
" <
C C
-
"
<
C 0
E
< -
E
C 'o
" <
E
< <
; 0
.02
. 'i
< 0 C ·; : "
0 0 C "
E -�
< <
"
0 "
E
<
C
-�
0 C
<
-�
<
" C .§
" ; <
V
.E ;
0
" 8
0
: C
"
< "
C
<
" 0
< u
. .S u C 0
> C
0 E ·o
< 0 u 0
: 0
C <
C
<
C u E
<
C
u
C
C
c
·;
C " i t 0 i ;
C C 0 C 0 C C
Cause of trouble
0
u L L 6
0 :L . L
Worn piston rings nd cylinder line
Aligned piston rin end gaps
Insuficient piston ring tension
Impoper break-in of piston ring
<
0
Inversely fitted piston rings
C Broken or seized piston rings
i
C
Worn piston rng
Scufng of cylinder liner
Worn vale ste or guide
Worn le ste seal
' Worn or broken seal rin
0 <
Oil return hole obstructed by carbon
1 Improper installation of seal ring
Lekage of engine oil
Excess of engine oil
Improper qality of engine oil
0
Cloged air cleaner element
DISASSEMBLY JUDGENT 2-13
i
"
·o
. - O
C
:
"
I
<
.
EXCESSIVE FUEL CONUMPTIO
= � � �
U, <
e .
: :
C "
n
" < < C
<
.
E . .2 <
.
0 0
0 <
: C
1
E E t
" E
0
�
0 n O · O
E : <
<
>
: = =
: : I
.
C <
.5
V � 0 < 0
.
. C >
E
. 0 0
0
a
< 0 0
<
< < < o I
C < C C
' �
.
O
'0
0 0 0 O 0
<
C C 0 0
Cause of tle = U U Q -
Maladjsted nozzle njecton pressre
!
E
Improper fel spray rom nole
Maladjsted njection qantity
a Improper seatng of delvery valve seat
·
L Imroper njeton tmng
Falty boost ompensator
<
Worn o seized piston, or piston rng
0
Wo cylnder liner
<
C Improper seatng etween vave seat and nsert
0
C
U aadjsted valve learane
Clogged a leaner element
Hal-opened ntake shtter
<
.
Halopened exhast shtter
0
Cloed or rshed exhast pipe or m fler
Engine temperatre too hgh
Draed rake
Cltch slip
Sezre n drve lne
u
Inscent tre inaton pressre
Unneessary aceleraton and deeleration
"
C .
'> Improper gear shftng
"i : A
o. Prolonged idling
2- 14 DISSEMBLY JUGMNT
"
·o
�
0
C
u
.
"
u
NOISY ENGINE . .
"
.
:
" "
C
"
.
"
. 0 .
"
E ·;
" " - "
.
.
0 0 e
3 E E ; " 0
E
0 0
. ·
>
. >
V 0 J .
.
3
u
u
>
! X X 0 0 0 E
. . 0 0
:
. . :
. 4
C u
.O
"O 3 3
u
: 0 0
C 0 0 0
Cause of trouble L c .
Improper timer advnce angle
Uneven injection quantity
"
E Inection timing too early
s
nection timing delayed
neven nozzle inection pressure
Imroper fuel spray from nozzle
Malfunction of delivery valve
Poor fuel quality
Wear or seizure on rotatng and sliding ortions
nsuficient intake ir quantity
"
mproer valve clearnce, or seizure of vlve
Low intke ir temerture
0 Engine too cold or overheated
nsufficient compression pressure and compression ir
temperature
Exceive oil coming u into cylinder
DISASSEMBLY JUDGEMENT 2- 15
.
"-.
E
� :
C
;�
-
0
.g
" . e
0
<
-
:
-
0 :
0 0 0
C
c
·o0
.
0
'
C
-
-
C
- 0
--E
·a
C
.!
C : "S
3
C
u
-
-
E
"
:
:
C
C
�
u
: :
:
"
ENGINE OVERHEATS C C C > >
E - - ·
C
C
" 0 C C
:
C
:
"
> - 0 0
-- -
0
:
·
C
-
.
C
.
C
0
-E "
:
u
C
u
C C
:
0
i:,rv
j'i 11,:w-·'
> C <
e
V
0
! >
u
·
0
:
"
!'"[
,!
0 :
.1:,
0
0
- - E
·= =
C u
: 0
<
:
0
-
· u
0
" <
: 0
:
0 & ;
"
-�
C
0
0
u
i'
: 0 =
>
=
> 0 0
j1!
- . "
-
8
>
:
=
00
u
C
o C
C
3
0
--E -E -
<
0
:
:
:
:
C
0
: 3 3
<
Cause of rouble U
X
u
C
U
C
U < < < u
!'
I mprop e fan b elt te nsio n-.
5 Wrn or sezed bearing
� Air dr awn fro m suction sid e --- -- --+ - --
- - - -- -
� Improper w ater seal - --- -- --
3 D amage d impell er +
1
-
--
M alfun ction of th erm os tat -- +
- - - - -
- .-
- 1-
Waer leakage fom coolng water psage
� O verfl ow of co oling waer du e o blow ou t +- - - - - - 1 - .__ _
8 � of gas
U Accumulaon of waer scale n cylnder
blck
Clo in g by o xide of iro n
Clog ging by wate r seal-
" W a te r l ak ag e -- - -- --
- - +.
� Malfuncon of radator ca -•
Cloged cor due o accumulaon of
mud and nsecs
Impror fuel spra rom nozzle _
+
. § Improper njecon tmng
Halfpened exhaus shuer ---- 1 --- -
-
-
' i Cloed or crushed exhaus ppe or mufler --- - -
v a G as le a ka g e fr om h ea d g as k et -
Gas leakage fo m cylinder head n o zzle tube,. ___�- -----
-- --
- t-
--
•
Connuous operaon under heav load, or
oher mpror operaon
Impror selecon of gears whle
o ravellng
Incorrect ndcaton of hermomeer
ENGINE DISASSEMBL
3
. AND RASSMB·L
: ENGIN ISSSMB - ·�,"L
AND RSSMBLY '.;t
EF1-002
Tis chapter covrs ngine disassmbly and rssmbly, Refer o he cher
4 "Engn proper whn nspecng h cylnd block pson crankshaf
c.
DISASSEMBLING ENINE ....•........•........... 3- 1
Turbocharger (FOT engine only) .. .................... 3- 1
Right side of engine .....................•... ••.. 3- 1
Front side of engine .......•..............•........ 3- 2
Left side of engine ..•...•...•................ 3- 3
Cylindr head .•.........•..... , . ............... 3- 4
Engine proper .•...........•.... ..•.•.....•..... 3- 4
Engine rar P.T.. ... ......•...... ...•.. .....•... 3- 7
REASSEMBLING ENGINE . ....•....................•• 3- 9
Engine proper ... .........•......... ............. 3- 9
Cylindr head ................................. 3-13
Left side of engine ............•................. 3-13
Front si de of engine .......... .... .. ..... ........ 3-14
Right side of engine ............•................. 3-15
Turbocharger (FOT engine only) ...................... 3-17
Engine rar P.T.. ... •....•...•....•.......... 3-17
ADJUS TMET . ............•..................... 3-19
Adjuting valve clearance ......•................•.... 3-19
Adjusting Vbelt tension ............................ 3-19
Adjusting e turn witch ..................•........ 3-20
F'
' .
'·,:.;) /i
.
ENGI DSBLY AND RASBLY 3-1
DISASSEMBLING NGINE
Before disassembling the engine, be 5 Remove the turbo adapter bracket,
sure to completely drain engine oil and urbo adapter suppor and urbo
cooling water. adapter
TURBOCHARGER (FD6T ENGINE
ONLY)
1) Remove he urbocharger shield
plate and outle exhaust connector EF3·009
5) Remove the water pipe and hose
RIGHT SIDE F ENGINE
1 Remove he water hose waer nk
and say
2 ·Remove he urbocharger oil ube
nd ol dran ppe 6) Remove e ol pump outlet pipe
nd ol pump
EF3006
2 Remove he exhaus mnfold
EF3011
EF3002
3) Remove he air nke duct
7) Remove he bypass and full flow
oil filer
3) Losen he hose clamp
4 Remove the urbcharger
EF3008
EF3-004 4 Remove he water manifold 8) Remove the vacuum pipe and hose
3-2 GI DSEMBLY AND REBY
12 Remove the ol coller water nlet 3) Remove the coon fan and spacer
ppe
EF3-017
4) Remove the ar compressor's de
13 Remove the ol cooler
lvery tube ar nlet ppe and un
loader tube f so equpped)
5) Remove the belt drve type ar
compressor f so equpped
10) Remove the hydraulc pump, ol
reservoir and rubber hose (f so
equpped).
F00
FRONT SIDE OF ENGINE
Remove the vacuum hose and
vacuum pump lubrcatng ol hose 6 Remove the V-belt and an pulle
And then remove the generator
) Remove the hydraulc pump ad
justng bar and bracket f so
equpped)
2) Remove the generator adjustng bar 7 Remve the fan pulley bracket
and bracket
EFJ-06 EF3020 EF3023
ENG DISASEMBLY ND REASSEMBLY 3-3
8) Remove the tension pulley bracket ) Remove the cnk puley
and adjsig bracet. Note
If it is difficult to remove the crank
pulley assembly, drive it out by lightl
apping on he crank shaft end cover-
ing it with a brass pad.
3) Remov the gear riv type air
compreor hyrulic pump and
piping (if o equipped) EF308
) Remove the nozze tube nd e
pill tube
9) Remove the water pmp pully
water inlet pipe and water pump
EF3100
EF3029
3) emov the nozzl asembly
4) emove th timing gear ca
1 O) emove the flywheel houing
pointer cover, mh a lever with
th flywheel ring gear o that the EF3030
lywheel cannot turn and remov
the cran pulley nut uing a ocket ) Rmove the uel tube n fuel
wrench (99535 25007) EF327
ltr
5) Maure and record th backla
betwen any pair of front gar
train
Note
Insall e injection pp previo
disonted
EF3-026
5) emov the boot compenator
) Place the crank pulley tool tub (if o equippe) an air inake
(99690 000) agint th crank manifol
haft and remove th tapr cone
y tapping the tool with a ham-
mer (if aper con i quipped)
EFS023
LET SIDE OF ENGINE
) emove th air inake duct (F D6
ngin only) an air heater. EF3032
3-4 ENGINE DISASSEMBLY AND REASSMBLY
6) Remove the njecion pump conrl Note 3 Measure and record he aun f
ever reurn sprngs and breaher. Be re to loosen the rocker saft salgnmen beween he cran
bracket mounting bolts, starting from shaf and flywheel husn.
e ouide and working in.
EF3.033 E3037
7 Remove the necon pup lubr 3 emove he cylnder head moun-
catng ol supply ube. And hen n bls. And hen hok a chan or 4 Aach engne sand aachen
reove he necn u wre he enne lfers and re 99554 97001.
ve he clnder head usn a
hs.
Note
Be sure to oosen te cylinder head
mounting bolts starting fom the
outside and working in.
EF3-034
8 eove he sarng mr.
5 ase he engne usn a hs, and
un securely n he engne
sand 99550 9001
ENGINE PROPER
1 Measure and record he laeral
runou of he cluch dsc suace
EF3-035 of he flywheel.
EF3040
CYLINDER HEAD
1 emove he rocker cover.
eve he ol an.
2 Usng a puller bl (99532 9500 ,
reve he flywheel.
336
2) emoe he rocker shaf assembly
and push od F3041
ENGI DSLY A RY 3-5
7) Remove the oil screen assembly. Note
Snce the ositon No s not ste
on e shell, when removng the an
aring shell lower), write the os
ton No on a tg n nk an attach
e tag to e shell to entf t
14) emove the crankshat thrust
washer and main bearng shell
upper)
Notes
1 Keep e upper an lower thrust
EF3-042
washers togeer as a atche set
2 Keep e min ering upper an
8) Remove the flywheel housing 11 Pull out the piston together wth lower ells as a matche set for
the connecting rod each man bering cp
Note
3 Be careful not to scratch or mage
Remove e engine rear PT.O (if so Note
e man bearng shell an upper
equiped) before removing e fly- Before pulling out the piston, e sure
n lower rust washers
heel housing to remove the crbon aumulate at
e top portion of the cliner.
15) Remove the iler gear
12 Measure the rankshaft end play,
and record the results
9 Measure and record the se clear-·
ane at the large end of each con
neting rod
305
EP3-57
13 Remove the man bearng hell 16) Remove the ler gear shat
(lower) and main bearing cap
10 Remoe the conneting ro cap
and bearng shell
Note
Keep e berng shells for each con
nectng r, eng creful not to con
fuse upper n lower s hells FJ046
3-6 ENGIN DSASSEMBLY AND RESSEMBLY
17) Loosen the camshaft lating 18) Remve the cam fllwer.
pate munting blt and pul the
camshaft asemby (with amshaft
gear) ot t the frnt
Note
Set the engine with the oil pan side
acing upward so tha the m fol-
lower will not fall out when the cam
shaft is removed.
EF3-049
20) Remve the frnt en plate
9) Remve the i je
EF305
,;:·.
{�)
ND REASBLY
GI BLY f�=--- 3-7
ENGIE REAR P.TO.
FRONT�
E F3-051
1 Eye bolt Ball beaing 2 Bolt 3 Bal ang Snap ng
2 Gasket 2 Snap n� 22 PT.O cove 32 PO gar 2 Ol seal
3 Oil tu 3 Ball beang 23 Gasket 33 Ball bearng 3 Ta
4 Bo Idle gea shaft 2 Ol slnge 3 O-g Slnge
5 Drive shaft cov er 5 LoCk washe 25 Flwheel housng 35 Ong 5 ompanon flange
6 Gaske 6 Bolt 26 Gasket 36 PT
· _ holde 6 Dve shaft
7 Gasket 7 Bolt 27 ove 37 lamp
8 Idle backe 8 P 0'nte cove 28 Ol seal 38 Stud
9 Bolt 9 Ponte 29 Nut 39 ock washe
o Idle gea 2 Gasket 3 PTO plate ut
3-8 EN G DISASSEMBLY ND RESSEMLY
1) Remove the PTO oil tube and 3) Remove the PTO holder and gear 5 eove the dler gear
P.TO drve shaft cover aembl
EF3-052
EF3054
2 Reove the lywheel housng
EF3056
cover And then eaure and
record the PT.O. gear backlah
4 eove the dler gear hat cover
And then eure and record the
backlah between the dler ger
ad crank gear
I
·�
i/
-.
-;
EF3053
EF3-055
ENGI DASBLY AND REABLY 3-9
REASSEMBLING ENGINE
When reassemblng the engine, be sure 4) Insert the camshaft and tighten 6) Raise the crankshat using a host
to install new gaskets, packngs and 0- the locating plate mountng bolts or rane and et ino the cylinder
rng, and apply engine ol to the sldng Tightening torque blok
surfaces of each component part of 1.3 gm
the engine.
ENGINE PROPR
1) Intall the ol je (pson cooling
oil et)
Tightening torque
30 to 40 kgm
EF3060
5) Insall he upper man bearing shell
Notes
Apply a cat f engine oil t he
sliding suface of he main beaing'
shell, and install e shell in is
iginal position
2 When e aing shells ae e-
placed the uppe and lwe shells 7 Inall he upper thrus asher on
must be eplaced as a set eah de f te No. 6 journals
and meaure the rankshaft end
EFJ-049 play o ensure ha thin
repair limt.
2 Insll he front end plae.
Note
Tightening toque
The thust washer has a m stamped
10 to 13 gm
on i whic should face te cylinde
bloc side hen installed
Install uppe and lwe wases w
i,1' e me ticness and have the ma
;
•:
, facing e cylinde bl side
Maintenance standad
006 t 4 mm
Repai limi 0.40 mm
Kind of thust washes
EFJ50
Symbol A B C 0.20 .5 0.40 .5
3 Inet he am folloer nto e Thkness 0.00 -0.03 0.06 0 0
3 3 32 3.4
ylnde blok (mm) 0.040 0.070 0.100 0.0 0.0
EFJ0
EP7
EF3062
3- 10 ENGI DSSMBLY AND RSLY
8) Install the lower shell to the main 9 Tigen the main bearing cap bo
bearng cap and attach the cap to Tighening orque
the block. Be sure to install the 17 to 17.5 kgm
lower thrt waher o eac ide
of the No 6 main bearing cap
ARROW
MARK
EF366
EF3-063
CONNETING R PST
EF3068
Notes 10 ntall the pper bearng hel an
1. Apply a coat of engine oil to the bo o the connecting rod 2 Do no install the pison ring in
sliding suace of he main bearing such a way a is gap faces he
shells an install hem in eir oe irection of the piston pin and is in
original positions Be sure to apply a coat of engine oil to a vertical direcion
2. There is mark embosse in the e sliding surace of the bearing shell
main aring cap as shown in e an re-install in its original posiion
figure below The bearing cap
must b insalled with this mark
facing the fan side
0 � -'
t
-�
� - I EA4113
EF3·064 12 Attac e lower bearing e to
te connecing o cap
ote
3 Be sure to install rus washers Apply a coa of engine oil o the sli·
wih e mark facing the bearing ing surface of the bearing shell
EA411
cap Do not confuse the fron of
the hrust washer wih the rear 13 Attac te connecting rod cap
Tighening torque
5 o 20 kgm
11 Ung a piton inert too (99631
oe
Z5001 , iner te piton together
Make sure that the mark smpe on
wit the connecting ro no the
e cap agrees with the mark on the
cyliner liner
connecing ro
Noes
1 Make re a e arrow mark
stampe on e top of the piston
faces e fron of the engine an
the cyliner number sampe on
the large end of the connecng rod
faces e side with the injecion
pump
E3-065
E5037
ENG DISASSEMBLY AD REASSEMBLY 3- 11
14) Make sure that the side clernce
t the connecing rod's lrge end is
within the mintenance standrd.
Maintenance standard
0.10 to 0.30 mm
' I
-' ' (
h
' 17
.
FS01
\
o·, 18) lign the injection pump ger
� timing mrk nd idler ger timing
mrk (B nd BB) nd insll o the
' FS038
EP3-47 fron end plte with O-ring
Notes
15) Insll the idler shft When remounting to the engne when
Tghtenng torque 30 to 40 kgm only the njectn pump has been dis-
mounted from the engine nstall as
follows:
urn e flywheel n the forward
drecton and set the No pston
to tp dead center on the com-
presson stroke (When e No
pston s t to top dead center on
the compresson stroke, the exhaust
valve s fully closed and there s
valve rush Moreover the 1/6 mark
of the flywheel s matched wt the
ponter of the flywheel housng)
Note
F306
When nstallng the njecton pump,
confrm at the scrbed lne of the
16 Align the idler ger iming mrks njectn pump bracket and e
ih he crnk ger nd cmshf scred lne of e frnt end plate
ger iming mrks nd inser he are matched
idler ger onto the idler ger shf
Then insll the idler ger ple F307
Tghtenng torque 20 kgm
2 Cnfrm at each scrbed lne f
the njectin pump s perfectly
matched
) Match e scrbed lne at the
pump bdy and bracket
F02
17) Check the idler ger end ply 19) Confirm h he iming mrks
Mantenance standard for ech ger coincide when he
003 o 012 mm injection pump i inslled F304
3- 12 ENG DISALY A REAY
() Match the scribed line of the
injection pump bracke and fron
end plate
) I EF3043
25)
EF3-072
Mainenance standard
3. After confirming he above iems, Less than 00 m
install by aligning the posiion of
the inection pump gear so ha
the ebossed V mark at he check
window at e op of he timing
gear cover and the scribed ine a 2 I
the top of the ooth of the inec
ion pump gear coincide. Tightening orque
When assembled in the above man· 10 to 1.3 kg
ner, he B mark of the gear train
idler gear and the B-B mark of the
inecion pump gear will coincide.
26
0
EF3041
�
2 I
24 I Note
f engine rear P.TO. is equipped, in
sal e engine rear P.T.O. fore
Tightening torque insalling the flywheel.
S 15 o 0 kgm Tighening orque
0 EF3-06
1 7 to 75 kg 15.0 o 155 kg
Notes
1 f engine rear PTO is equipped
20 insall the idler bracke before
installing he flywheel housing.
. When insalling a new oi seal drive
i ino place in the flywheel hous
Maintenance standard ing. Be sure o apply a coa of
0.05 to 05 mm engine oil no grease to he sealing
Repair limit 030 mm lip in advance Be careful not to
EF38
damage or deform the oil seal.
ENG DISASSEM BLY AND REASSEMY 3-13
28) Measure the latera runout of the
urf ace of the fywheel which con-
tacts the cutch dc. Make ure that
the meaured vaue i wthin repair
imit
Maintenance standard
Less han 0.15 mm
Repair limi 018 mm
EF3-085
EF3-038 Notes
1 The tighenin order is shown in
4 Inert the puh rod into each cam the figure
follower. 2 The @ in the figure indicaes
t ightened togeher with the rocker
shaf bracket
29 After the "runt of the uce f
of the fywhee which cnct the
cth dc h bee checked, bed
e ock waer
EF3-086
7 Tighten the rocker haft brake
EF3083
bolt
Tighening orque
5 nert cyinder hed bot at the 35 to 40 kgm
rocker haft bracket, nt the
rcker haft emby ung cylin LEFT SIDE OF EGINE
CYLINDER HEAD
der head bot a a gude, and
1 Pace each pito at t topot Inta the tartng motor
thread in the bot
ener potn, nd ake re that Tightening orque 70 kgm
the pt earace at thi
i,{
,
tn wth pefed ante-
J ance drd If the cerance
i,
t with the t, debe
the to ad heck each portn
Mainenance sandard
+020 o +060 mm
Ji·
'l
,1
EF3035
6} Tghte the yider hed bot
form derbed bew, ng
the cynder hed bt oket 2 Intll the injection pump bri-
wrench (99664 ZS000 At th cating ol uppy tube
time, tghten whie beng carefu
that the ba part of the vave
ER4·121
rocker adjtig bot d the puh
rod don't move ut of poition
1 1st time: Tighten to a torque of
2 Ital the cder hed gaket 6 kgm
Noe 2 2nd ime: Tighn o a orque of
Insall te head gaske assembly wi 10 kgm
e embossed art numr facing u- 3 3rd ime Tighten to a orque of
ards 15 kgm
4 Finally, check te ightening orque
3 It the cynder head. of the 4 or 6 center bolts
3- 14 ENGI DISASSEMBLY D REASSELY
3) Install the breather with a gaske, 7) Install the fuel spll tube to the
and then nsall the njecon pump nozle holder wth he connecor
conrol lever return sprngs. bolt through copper two gaskets
E306
3101 Insll he waer pump nserng he
ruer rng beeen the pump an
E3-033 8 Insall he nozzle tue
engne
4) Insall the ar ntake manfold and Tightening torque 2 kg
Tghtenng torque
hen install the boost compensaor 10 to 13 kg
\t'1
tube (f so equipped na.!
Air intake manifold mounting
bolt tightening torque :')
FD6 1.6 to 20 kgm
FD6T 09 to 12 kg
E3057
9 Insall the nozle tue clamp
Insall the waer ne ppe an
tghen he clamp
EF3032
5 Install the fuel fler and ue
E3058
0 Insall the rocker cover wth a EF369
aske
Tghtenng torque Insall he enson pulley adusng
08 to 10 kg bol and racke
6) Insall the nozzle assembly
Tightening torque
25 to 35 gm
FRONT SIDE O ENGINE
1 Insall the crank pulley assemly
and tghen the crankshaf nu o
he specfe torque usn he sock-
e wrench {9955 25007
Tghtening torque
E3030
5 to 56 kg E3077
ENGIN DSASSEMBLY AND REASEMBLY 3- 15
9 nsall the gear dve type air com
pressor, hydraulic pump and ppng
if so equipped.
EF3·078
6) Install the fan pulley bracket.
E3100
RIGHT SDE OF ENGINE
1 Confrm that the rubber rin s
nserted at the cylinder block
10) Insall the generator adjustng bar mounting surface of the oil cooler
and generator bracket and then install the ol cooler to
the cylinder block together with
Generator bracket
the oil cooler water outlet pipe
tightening torque
40 gm Tightening torque 2.5 kgm
Note
Be careful not to damage the -ig
E3- 023
when inserting e water outlet pipe
into the cyliner block
7) Install the belt drive type air com
prssor and piping (if so equipped).
:,
,
EF3-20
E3099
E308
11) Install th generator and V-belts.
2) Install the oil cooler water nlet
pipe (water pump outlet pipe) be
8) Install the n pulley, fan spacer
tween th oil cooler to water pump
and cooling fn
through a gaskt (wate pump sid
and Oring (ol cooler side)
12) Insall he vacuum hose and
vacuum pump lubricating oil hose EF308
3- 16 GINE DSBLY A RSBY
3) Install the hydraulic pump ad 1 0 Install the water manifld through
justng bar and bracket (f so a gasket
equipped. Tghtening toue 15 kgm
EFJ009
7 Install the oil pump thrugh a
gasket And the install the oil
pump outlet pipe through a gasket 11 Tighte the hse clamp
and O-ring
EFJ-016 Tightening toue 20 kgm
4 Install the hydraulic pump, il
reseroir and rubber hse (i so
equipped
EFJ008
EFJ0
12 Install the exhaust maold
8 Install the il level gauge guide thrugh a gasket
Tightening tue
20 t 25 kgm
Notes
1 All nuts ae nt conventinal ones,
.·,
but ae heat esistant
., /
2 The tightening de is shwn in
te figue
3 Afte tia un of the engine e-
5 Insll the vacuum pipe ad hse tighten the nuts
9 Install the water pipe and hse
EFJ03
6 Install the byass and full low oil
filter nsertng the rubber rings be
tween the flter and oil cooler
Tightening torque 2.5 kgm EFJ088
ENGI DISASSEMBLY A REASSEMBLY 3- 17
13) Install the water tank, stay and ENGN EAR P.TO
hose. Assembly of the secial rear P.TO.
arts only is describe here Oter
oerations have been describe else
where and are omitted here.
Installng the idler gear assemby
EF3006
EF3090
TURBOCHARGER (FD6T ENGINE 4) nstall the oil tube and oil drain
ONLY) pie
nstall the turbo adapter uport Note
and bracket And then intal the Be sure to insert the O-ing between
turbo adater through a gasket oil drain pipe flages and turbochrger
nd cylinder block.
EF3091
1 Cylinder block
2 dler gear bracet
3 Idler gear shaft
4 Bearig (ier
5 Bearig spacer
6 Bearig (outer)
EF3002 7 Iler moutg bolt
2 Set the turbocharger through a ga- 8 Flywheel osg
ket and temporariy tighten the 9 Cover
nut Set the turbocharger outlet 5 nstall the air intake duct At the 0 lywheel
exhaut connector and temporarily ame time connect the earth wire. 1 dler gear
tighten the nut
Notes
1. All nuts are not conventional ones, Asemble the bearing bearin
but are heat resistant. spacer and idler gear haft to the
2. When inslling the connetor idler gear inert fom the PT.O
careful not to damge the seal ring. coer mounting section of the fly
wheel houing and intall to the
idler gear bracket
6 nsal the turbocharger shield
pate
EF3089
Adjust the clearance between
turbocharer and connector to the
maintenance andard as llow
and tighen the nuts.
Maintenance standrd
0 to 20 mm EF3-056
3- 18 GI DSBLY AN REABLY
2) Tighten th dler gear mounng Installing the P.T.O. gear assembly 2) Mak sur ha h backlash b
bolt. twe h P.TO gear and dler
Tightening torque
gea s wh anenan
10 t 1 kgm
sandards
Manenance sanda
.05 0.25
Repa lm 030
EF3-092
3} Make sure ha h backlash be
tween th dler gear ad crank gear EFJ-94
s whn anenane sandards.
Mantenance sandard 1 Drive shaft cover
0.05 t 025 mm 2 PTO gear
Repar lm 030 mm 3 O-rng
4 PTO holder
5 Snap rng
6 Orng FJ053
7 Ol ea
8 Drve ha
9 Nut
10 PO lae
11 Bal bearing (inner)
12 Ball bearng (outer)
� G
13 Oi hole (ile gear)
( '·,. "- 14 Companon lange
"
. ·\ ' ./ 3 Insa h fywhe hous o
J' , ;,� -·
/ � n "'\ -
hrough a gask
4 nsa he drv sha cov hrou
EFJ-oss
1 Insa he P.O. hodr and P..O. a gaske and nsa h P..O. o
gear assbly hough an O-rng. ub.
4) Insall he dler gear shaf covr.
EFJ4 EFJ052
EF303
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
ENGI DSLY AD RELY 3- 19
ADJUSTMENT
ADJUSTING VALVE CLEARNCE 2) Ajust the valve clearance The
mainteace stadard and adjustig
1) Properly algn mark "1 /6 stamped
pocedure are shwn below
the uter peiphery of the fly-
weel ith te pointer of the fly Maintenance standard
wheel housing and set he N 1 (Bo intake and exhaust valve)
pisto o No. 6 piston to top dead 0.3 to 0.4 mm
cete o te compression strke
3) Ate valve cleaances have bee
Wen the No 1 pisto is at tp
adjusted properly with the No 1 o
dead center o the cmpressin
N 6 cylinde positied at its top
stroke, te imig gear case pointer
dead cete of the compessio
ad ijection pump gea scribed
stoke tu the cakshaft oe
lie will almost coicide
coplete turn ad begi t adust
the emaiig valve cleaaces
�
o� Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
EFJ-095
Cylier No. 1 2 3 4 5 6
Valve arragement I Exh In Exh I Exh In Exh I x In Exh
Valve No 1 2 3 5 6 7 8 9 10 11 12
N 1 top dead cente
cpessi stoke
• • • • • •
N 6 top ead cete
cpession stroke
• • • • • •
ADJUSTNG V-BEL T TESON
1) Aust the aduste s that the belt
deflectio is withi mainteace
stada rage when the poit indi
ated by the aw in the figue is
epessed with a ce f appx
10 kg
he adusting a ew belt adust
its deflecti t nea 8 mm which is CRNK L
the lwe liit f the specid
ange
12to
12 18 mm GENERTOR WR
A WA TER P UMP UY M
GENERATOR PULLEY
PULLEY
TEN·
SION
PULEY
EF13 -001 T
EMl010
3-20 ENGI DASBLY AND RBL
EF 13-002
ADJUSTING THE TRN SWTCH
(for exhaust brakes)
Adjust the adjusting screw so th turn
switch is correctly set for proper ct-
vtion t ths specifed engne rpm.
Maintenance standard
750 pm
,
4. ENGINE PROPER
EFS-041
Tis chapter decribe the method of ceaning and inpecting the cyinder
block, piston crankshaft etc. and the metho o repcing the cyinder iner
ec
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2
RPAIR AND REPLACEMENT .................. 4- 8
GI OPER 4-1
CLEANING
Each component part must b cleaned metl plat to scrape o forign mat 2 Use steam clanr to clean the l
of dirty oil, oil sludgs, scale, carbon ter. Prform this prliminary cleaning bricating oil live n addition, us a
old gasket or adhesivs attached to it. bfor conduting fnish claning. wir to chc for clogging and
Claning mthods ar: high tmpra- For thos parts composd of a single clan with a claning fluid or com
ture steam claning light oil claning kind of material such as coppr cast pressd ir. Clean th watr cooling
acid or alkaline solution claning n and aluminum alkaline cleaning liv in th sm manner.
nutral etergent claning, ticlene fluid may usd. or a mtal pro 3 Whn claning rubr parts, use al
solution steam cleaning, and agnas duct omposed of two or more than cohol to remov forign mattr.
fluid cleaning. materials howver such as bearing Never use light oil, lamp oil or any
In cleaning, unexpected crac or dam shell and bushing claning with light othr inral oil. ote that, in
age may oftn e found out It is im oil trilne solvnt steam or magnas principl all rubbr parts should
portnt thrfor to tak sufcient fluid is rcommndd bcause electro rplacd with new ons whn ovr
care during claning not to overloo lytic corrosion may ccur du to in hauling th nin.
any dfct on a part ionization in thse typ parts. 4 After claning th parts dry th
Note by using compressd air. When
CLEANING METHOD When andling alkaline fluid, prepare a dircting comprss air to a ar
leaning can st e don with ither boric acid solution so hat cleaning ing do not allow th air prssure to
light oil or alkaline claning fluid. It is fluid accidenlly falling on o he skin cause it to rotte.
portnt to sele ct th cleaning mth or cloes, or splashed ino eyes can be Note
od and fluid est suitd to ach oc quickly neuralized. Do not use cleanin fluid to clean a
_asion. sealed pe bearing i must be cleaned
Light oil atus minimal perail LEANING PROEDU AND only by wiping.
ity and solubility for mattr adherd PREAUIONS
o th surfc of th parts, and is then 1) Beor cleaning cylindr linrs and 5 After drying apply clean engine oil
fore most suitale for cleaning parts pistons (cylindr head and pston to the parts, and kep them fre
with sliding surfcs or finely fnishd rings us fn mery papr or a from dirt and dust.
surfces. For other portions use a wire pic of mtl to scrape of carbon
rush a woodn spatula or a pic of stuck to ths parts.
4-2 ENGI PRO
INSPECTION
CYLINDER BLOCK
1 Check each porton of the cylnder
block for damage and cracks. If
aulty, repair or replace the cyln
der block
2) Inspect each stud bolt for bend and
damage on the threaded porton If
aulty, replace the stud bolt. ERS103
3) Measure and record the nsde
daeter of the clnder lner wth
the man bearng cap tghtened to
the specfied torque. From the EPS-054 7 Usng a wter leak test tool
measured dta, obtan the ax 9956 Z500 and hydraulc
mum nsde dameter, out-oround pump 99570 Z5000, perform a
wter pressure test on the cylnder
ness (dfference beteen the dmen
block and check for water leakage
son A and dmenson B n the
from the ter jacket If ult,
fgure, and taper (dfference be
repar or repace the clnder block.
tween the dmenson D 1 and
dmenson D 4 o the lner. If the Test conitions
nsde dmeter exceeds the wer Water pressure
lmt, or f the out-ofroundness or 4 to 5 kg/cm 2
taper exceeds the mantenance Test tme
stndard, replace the lner. 5 Mesure the flatness of the top sur for 5 to 10 minutes
Tightening torque ace of cylnder block. I the
17.0 to 21.0 kgm measured alue exceeds the man 8 Usng a cylnder lner tool 99600
Inside diameter tenance stndrd, repar by grnd Z500, remoe the cylinder lner
Wear limit 10040 mm ng I the mesured alue exceeds Refer to "REPAI AND RE
Taper and out-ofroundness the wear lmt, replace the cylnder PLACEMENT
Maintenance standard block. 9 Check the cylnder lner ftted
Less 002 mm Longtudinal irection surce of the cylnder for ny sgn
Maintenance standard of corroson or damage. If ulty
Less tan 010 mm repar or replace the cylinder block
Transerse rein O Measue the nsde dameter of the
Maintenance stanard lner fttng bore n two drectons
°
Less than 002 mm (that s, parallel to and t a 90
Grining tlerance 0.50 mm angle to the crankshaft at the
upper and lower portions of the
bore Keep the main bearng cap
D,
tightened to the specfed torque
whle measung Calculate the out
0 ofroundness of the lner fttng
EFS-006 bore, the alue exceeds the ain
tenance stndd, replace the cyln
der block
4 Measure the heght of the clinder EFS042
lner flnge porton protrudng Tigtening torque
above the top surace of the cln 17.0 to 175 kgm
der block I the measured alue s Straigh edg Maintenance standard
not wthn the specfed lmt, re Less than 002 mm
place the cylinder lner or cylnder
block
Protrusion o cylinder liner lange
above cylinder block
Maintenance standar (A
0.02 to 0.09 mm
E3 ·1
Ca beeen adjoining cylinders
6 Measure he nsde dmeter of the
aintenance standard
camsht bushng
ess than 0.03
4-4 EGI OP
Maintenance standad
Size dentficaton Thickness
Remarks Inlet
mark [mm]
847 to 851 mm (FD6)
A 296 -3.00 4879 to 483 mm FD6T)
Exhaust
B 293 -297 4841 to 845 mm
Thrust
Wear limit
washer C 290 · 294
Inlet
type
020 5 31-320 801 m FD6)
O.: Oversize 832 mm FD6T)
040 o.s 33 340 Ex haust
793 mm
CAMSHAFT
1 Nut 5 Locating pate
1) Measure the camshaft end-play If 2 ck wash 6 Ky
the measured value has reached the 3 Plan washr 7 Camshaft
4 Casha gea
repair limt, replce the locating
plae
ES118
Maintenance standard A) 5 easure the outsde dameter of the
005 to 025 m ournal, and record the results If
Repair limit 030 mm the measured value exceeds the 8) Measure the camshaft runout If
maintenance standard, replace the measured value has reached the
repar limt repar or replace the
camshaft
cmshaft
Maintenance standard
Maintenance standard
No 1 5733 to 5.35 mm
Less than 003 mm
No 2 5713 5715 m
No 3 5693 to 5695 m Repair limit 006 mm
No 4 5673 to 5675 mm
2) Reove the camshaft gear, and
vsually check each part
Note
If the mshaft has been reoved to-
gether wi the gear, disassemble the
at this stage ES-117
3) Check the surface of ech journal 6) Calculate the clearance beteen the EFS-014
and ca, and the threaded portion ournal and cashaft bushng fro
and key ays of the camshaft for the measured values If the cler
ance has reached the repair lmt PISTON AND PSTO RNGS
damage or any sgn of seizue If
aulty, repair or replace the cam replace the camshaft bushin If the
shaft clearance stll reaches the repar
4) heck the whole camshaft for any lmit even when the new camshaft
sgn of cracks usin the manetic bushing s instlled, rnd the ca
flo detectin method or red check shat ournal, and nstall the under
method If ulty, replace the cm size bushin
shaft Maintenance standard
002 to 011 m
Repair limit 015 mm
7) Measure the heht of the cam pro
fle If the measured value exceeds
the wear lmt, replace the cam ER2
shaft
1 1s ng 8 Beang she (u)
nd ng 9 Bang sh owe)
3 Oi ng 10 Bo
Pson 11 Connng od
5 Pson pn 1 Conncng od a
EF046
6 Sna ng 1 ut
7 Bushng
ENGIE PROPER 4-5
Disassemble the pistons, and keep Piston pin otside diameter
the component parts grouped by Maintenance standard
clinder numbers. 33.9 t 300
Clearance beeen piton pin and
Note piston pin bore
When overauling, all the piston rings Maintenance tandard
of all pistns should be in principle t 003
replaced as a set Wear limit 005
2) Chek the peripher of each piston
for scuffng If aulty repair or re-
ES-169
C ® ©
place the piston 6 Measure the end gap of each piston
3 Check each piston ring for uneven rin and record the results If the
wear. If ulty replace the piston measured alue exceeds the ear
ring. limit replace the piston ring.
Measure the outsid diameter of he Maintenance standard
piston and record the results 0.30 to 050 25
Measurement should be made at 5 Wear 1
m position from the bottom side
of the piston at a right anle to the
piston pin axis alculate the clear- CONNECTING ROD
ance between the iston O and heck the connecting rod or
clinder liner I If ault replace cra·cks and damage. If ault re
the piston or clinder liner pair or replace the connecting rod.
Oide diameter o piston ) Inspect the small end bushn for
Maintenance tandard damage If aulty repair or replace
99.86 to 9990 the small end bushin
Clearance ben piston and 3 Measure the inside diameter of the
cylinder small end bushing and record the
R5·50
Maintenane standard results alculate the clearance
010 to 0.17 between the small end bushing I.D
and piston pin O.D. If the calculate
7 Measure the inside diameer of the
alue has reached the repair limit
piston pin bore and record the re-
replace the bushing
sults
Maintenance standard
E
00 t 005 mm
MEAURING
DRECTON
E Repair limit 010 mm
F008
Measure the clearance beteen the
piston ring and ring grooe and
record the measured alue I the
measured alue exceeds te ear R4
limit replace he pison rin or
piston
1t ring EPS-16
PISTON PIN
aintenance tandard
0.07 to 0 Check the piston pin or damae on
Wear limit 0.4 its periphery and stepped ear If Fit the bearing shells to th con-
(FD6 ony) ault repair or replace the piston nectin rod and connecting rod cap
2nd 3rd (i so eqipped rin pin hain the same clinder number
Maintenance standard easure the outside diameter of the markin and tighten the cap o the
0.04 t 008 mm piston pin, and record the results specified torque then measure and
ear 04 Calculate the clearance beteen the record the inside diameter of the
Oil ring piston pin OD and the piston pin large end bearing shell Calculate
Maintenance adard bore I.D. If the calculated value e the clearance between the crankpin
002 to 00 mm ceeds the wear limit replace the OD. and bearing shell ID from he
Wear limit 02 mm piston or pison pin measured values. If the clearance
4-6 GINE PRO
has reached the
t he repair limit, replace BEND
he bearing shell If the clearance 1
st reaches the repair limit even
when the new bearing shells are in- 2N
w
staled, grnd the crankshft pin, u /
and nstall the undersize bering
<
a
= OIL
shels. :
U
a
Tightening torque w
z
11.5 to 130kgm
130 kgm �/
Maintenance standard .
< EF5-035
004 to
to 0.10mm
Repair liit 015 mm
GEAR TRAIN
Check each
each timing
timing ge for
for damage
damage
and wea on the teeth If faulty, re
6 I the measured side clerance a
pai or replce the ger
the large end of ec connecting
I the backla
backlash
sh beteen
beteen timing
timing
rod during disassembly o the en-
gears has reached the repir limt,
gine proper is incorrect, replace the
repir or replce the ger
connecting ro.
Maintenance tandard
Maintenance standard
0.06 to 0.16
0.10to
0.10to 0.30mm
0.30mm
Repair limit 0.30m
7 Install the connecting
connecting ro to the
EP5-17 3) Measure the idler
idler er assembly
assembly
piston, nd insert the pston pin
end play an record the results If
Note the measured value hs reached te
Make sure that te arrow mark stamp- repair limit replace the iler shaft
ed on e top of the piston face the an plate or iler ger 1 ,.
front of the engine and te cylinder
Maintenance standard
number samped on e arge end of
0.03to 0.12 mm
e connecting rod facs te side wit
Repair limit
limit 0.30 mm
e injection pump
5) Mount the connecting rod tted tted
ith the connecting ro cp to the
conncting rod agner, an insert
ARROW
the piston pin into the smll end MARK
bushng. Mesure the clearance t
the aligner pin (A or (B) to check
the bend and twist o the connect- EFS047
ing rod. If the clearance mesured
mesured
at pin (A) or (B) exceeds the limit, 4) easure
easure the inside dimeter
dimeter of thethe
CONNETING RO PISON
replace the connecting rod. If the idler ger bushing n outside
EF3·068
dimension beteen pin (A and pin dimeter of the idler ger sht, and
(B) is other thn 50 mm, clculate
clculate recor the results. lculate the
the ben or tist by using the 8 Usng a piston
piston ring tool 99630
99630 clearance from the measured values,
ollowing equation: Z501 ) nstll the piston rings. and if it exceeds the repir lmit, re
Bend or tws Note place the bushing
20 Be sure te manufacturer's mark faces Maintenance standard
= -,
Dimension
Dimension between pin (A) and B) upward
upward . 002to 0.06 m
x measure vaue (mm Repair limit 00mm
0mm
Connecting rod bend
Maintenance standard FLYHEEL
Less than
than 005 mm heck he clutch is is contactng
contactng
Connecting rod twist surface for dmge. If fulty repar
Maintenance standard or repace he fwheel.
Less than
than 008 m hek the rng gear teeth for for dam
dam
(When the distance beeen pins is age deormaton or excesse wear
E 022
200m) If au replace the ring gear
ENG PROPR 4-7
3) Check
Check the ball beaing for amage,
amage, 3) Check the bolts securin
securingg the amp
amp 1 Drive shaft cover 8 De shaft
e to the cank pulle for looseness. 2 PTO gear 9 Nut
otating noise o an signs of PTO plate
3 O-rng 0
seizue. If faulty eplace the ball If fault, etighten the bots. 4 PTO hoder 11 Ba bearing (inner)
beaing. 5 Snap rng 2 Ba beaing oter)
4 If the lateal runout
runout o the clutch
clutch ENGNE REAR P.T.O 6 Oring 13 Oi hoe (ider gear)
isc cotacting uface of the fly 7 O a 4 Companion flange
) Check the compani
companion on flage
flage an
wheel measure at the time of is beaing for cacks o othe amage
assembl reaches the repai limit, ) Reasembl
Reasemblee the oil seal
seal to the
If ault, repai or eplace the com PTO hole
epai or eplace the flwheel panio flange. 2 Intall the
the ive shaft to the
the com
Maintenance standard 2) Check the oil seal fitting
fitting surface
surface of paio flange
Less han 0.15 mm companio flage fo amage If 3 Assemble
Assemble the companion
companion flange
flange of
Repai limit 0.18 mm fault, epai or eplace the com item () to the P..O hole of
paion flage item .
.
5) Measue the
the dimensio
dimensio A If it it 3) Check thethe tooth
tooth surace
surace of thethe 4 Assemble
Assemble the O-ing to the rive
excees the ear limit, replace the P.T.O gear for amage o wea If shaft an the press t the ball
flheel ault, epai o eplace the P.T.O bearing (oute A then lock ith
Nominal dimension 215 mm
gea. the snp ring
Wea limi 95 m
4) Fit the PTO gea an compan
companion
ion 5 Assemble
Assemble the PTO
PTO gea, aligning
aligning
flage onto the rive haft, an the oil hole of the rive shaft ith
check each plie for pla. If the oil hole of the P.T.O gar
ault, eplace the PTO gear an/
or compaion flange
5) Check the oil sealseal lip potion for
EFS018 amage If ult, replace the oil
eal
FLYWHEEL HOUSING AND Note
TIMING GEAR CASE n pinciple he oil eal should be e-
placed a ime of oehauling.
1) Examie
Examie the flheel
flheel housing
housing an
timing gea case o cacks an
6 heck
heck the ball bearing fo
fo irregular
irregular
amage. If ult, replace the
otation, noise, or an sigs of ES-048
housing, plate, cover a case
themal iscoloratio. If ault, re
2 heck the oil sealseal flage
flage porti
portion
on
place the ball bearing
an lip potion for cracks, hae
7 If the backla
backlah
h of the
the PTO gear 6 Pes fit the
the ball beang (inner)
(inner) to
ing a eformation If ault, re
meaure at time of iasembl the rive shaft
place the oil seal
eache the epair limit, eplace the igten the
the PTO gea mounting
Noe ut through the P.TO plate an
P.TO. gea.
In pinciple, he oil seal should be install the Oring to the PT.O
eplaced a ime of ovehauling. Repai limi 030 mm
hole
·._:1-'
, 3 Inspect
Inspect each tu bolt for
for ben
ben an
an Reaembly precautions Tighening oque
amage o the theae portion If 145 to 250 kgm
ult, repai or replace the tu
I\
\
bolt
1�
4 If the eccet
ecceticit
icit
between
between the
cakshaft a flheel houing
meaure at the time of isassem
bl i fult, pefom centeing, I
,
/
1/
/
_/
a eplace the staight pi
Mainenance
Mainenance s andad
ess han 020 mm
CRANK PULLEY AND DAMPER
/ l \
J ' , \
heck
heck the cak pulle
pulle fo cacks
�
I
a amage If ult, repai o re
pace the cak pulle (
2 heck the ampe
ampe amage,
amage,
E3·094
cacks, a eparatio fom the
isc If ult, replace the amper.
4-8 ENGI OPR
REPAIR AND REPLACEMENT
REPLACEMENT OF CYLINDER ightening torque Ga beeen adjoining
adjoining cylinders
cylinders
LINER 7.0 to 7.5 kgm Mintennce standard
Inside diameter ess tan 00 mm
) Using a cylnder lner tool {99600
{99600
25001 , remove the faulty cylnder Wear limit
liner and insall a new one. 0025 mm
EPLACENT O ASAF
Out-of-roundness and taper
Notes BUSING
Maintenance standard
1 Prior
Prior to instaation
instaation,, be sure to re Less than 002 mm Drive out bushngs
bushngs No and No
move rust, carbon, and scale from Protrusion of cylinder liner flange toward the engne rear, and then
the iner fitting surface and liner above cyinder block drve out bushngs No. 4 and o
fange contacting srface of the Maintenance standard toward the engne front usng cam
cyinder block. 0.02 to 009 m bus remover 990 Z0
2 Apply soapy water to the liner fit
r a
ting surface and the rubber ring,
� t § :
and make sure that the rubber ring
is free from ists or an other
damage
CYLINDER NO. NO 3 NO. 2 NO 1
NA TOO
SSMB
F·00
Drve n bushngs
bushngs No and
and No 3 2 9994 Z0
usng cam bush replacer @, © {for No. 4
and as below. 999 04
Drve n bushngs No and No 4 fo No
usng cam
cam bush replacer and 4 999 20
fo o
9990 0 r
(Tool kt cam I 9994 Z00
9997 00
bush replacer or No. (for No. and
NS
No.
MOV
F-024
3. Make srue
srue that mark
mark (Tp or R)
faces engine front (if so marked)
NGN FON
"p or A
NO NO 3
F05
Note
Press fit with e notched part of the
bushing facing the right side of the
block (as viewed from
from the rear of the
EFS-053
engine and confirm that the block oil
Liner staled c
gallery an the bushing oil hole are
Afer replacing
replacing he cylnde
cylnde lne, aligned.
make ure hat he nsde dameter
ou-ofroundness taper and flange
CORREION OF CRANKSHAF Grnd te
te cranksa
cranksaft
ft pn so that he
he
projecion are all whin he man
enance andards Grind he crankshaft
crankshaft journa
journall so hat clearance beween te undersie
he clearance beween he undersze bearng shell D and te crank
Note
bearing shell D and he journal shaft pn OD wll thn the
Before eaurng these tghten he manenance standard Be sure o
main bearing ap bolts to the secified OD will e wihin he manen
ance sandard remove the balance eght before
torque grnding the pn.
ENGIE PROPER 4-9
Notes Taper ournal portion and pin ELAEMENT OF ONNETING
. Finsh the fillets of the journal and portio) OD SMALL EN BUSHING
pn n accordane with the drawing Maintenace stadard
1 e g
g cme
cme
shown below Less tha . mm
w e cmfe e
2 Whe grinding
grinding the
the journal
journal and
and pin,
pin, Out-o-roudness (journl portion
cectg m c
be sure to keep the out-oround and pi porto)
w
ess and taper witi maiteance Mainteace stadard
Less tha . mm Note
stadards.
B ure t aln ol hol Whn
Clearace beeen joural 0 the bushg s pressed i ompletel,
and ma earig shell 10. ere w b a mm protrusion at
kL
Maitenance standard e top
.5 to .2 mm
Clearance ben pn .0 and
bearig shell .0 0 X
Manteace standard
EPS-33
.4 to mm
EF052
Gg me f
· 2 Mee e e
e me
me e
e
Sze ct mk (Re.) Remk fe g e
[mm] mee e I
STD Gg
G g eee cce be m
mc t m
025 US 7567075690
7567075690 STD: S e
e me f
050 US 7520 - 7540
7540 US Uee Ma sdard
.3 to .5 mm
075 US 717075190
RELAEMENT OF ILER
Gg me GEAR BSING
Se efct mk ck (Ref) Remk 1) e e e
e ge bg
[mm] t e wt te b e
e f e ege gg
STD Gg t eee
w e t f te e
025 US 6167561695
6167561695 STD St te
050 US 61261
61261 S Uee he e bushg s lush with the
bss e rt sde o the ege,
07 US 611756119 dmes "H dcted the igure
w w be 5
REPLACEMENT OF FRONT OIL 3 Pe e
e e mg
mg
SEL AND COLLAR ge ce e me wy
1 Remve
Remve te e c
c by te
g cg em Appy a cat ege t the ut
2) Ug e c
c ece
ece sde perpher e car
< RONT
9918 5002), e e e ES38
c te ck 2) Mee
Mee e e mee
mee f
eftte
eftte b e
. mee f e e f
cece
cece betwee em
�
. - .-
te mece
m
e me f e
Mtece stdard
COLAR
3 to .6 mm
OI SA
ET14·067 E14·068
4- 10 ENGI PRO
CORRECTION OF FLYWHEEL
Grnd o machine the flywheel so
that the runout of the conactng sur- Kobelco Engine Parts
face wll be wthn manenance
manenance email: EngineParts@HeavyEquipmentRestorationParts.com
standard.
standard. Howeve, the gndng tole
ance s 2 mm If dmenon A excee
exceed
d Phone: 269 673 1638
the wea lmt replace the fywheel
assembly·
Flywheel depth (A)
Nominal dmension 21.5 mm
Wear imit 95 mm
EFS-018
REPLACEMN L
SEL ND CLLR
1) Remove the ol eal
eal and colla
colla by
by
tappn o focng them
2 Usng an oil seal and colla
colla epla
eplace
ce
(99691 ZS000, pe the ol seal
colla onto the cankhaft
3 Pre the
the ol eal onto the tmng
gea case n the same way
w ay
Note
Apply a coat of engine oil to the out-
side periphery o the oil sel coll
T4070A
DISASSEMBLY AND CLEANING ..••.•••••.•.. 5-1
INSPECTION . .....•..•...• •...... 5-2
REPAIR AND REPLACEMENT •.•••........ 5-5
REASSEMBLY ••••.•••.•••...•..•.•.. 5-8
:1,
,1:;
-
.;
,
i!:"
�i
CYLINDER HEA AND VAL E MECHANISM 5-1
DISASSEMBLY AND CLEANING
SASSEMBLY
CINDR HD
I 1 Engine slnger (ront)
10 2 Push rod ppe
3 Ol ppe
4 Splt collar
5 Upper sprng at
6 Iner valve sprn
7 Outer valve sprng
8 Vale stem seal
9 Loer sprng at
10 Vale gde
11 Head bolt
12 Cylder head
13 Head gasket
14 take vale nsert
20
15 Itake alve
16 Exhast valve sert
17 Exhast valve
18 Water jet
19 Water et
20 Egn slger rear
1 Slee
22 O-rg
23 Nozle t
1) Measure the distance between the SPLIT COLAR TOOL ROCKR HFT
valve head and the bottm surace
f the cylinder.
Note
Crbon sould be removed from e
sketed surface of e cylnder and
e valve prior o measuremen.
E-104
1 Stopper bolt 6 Bshg
3) Remoe the upper spring seat, vale 2 Lock ut 7 Isde rg
spring (outer and inner vale stem 3 Rocker bracket 8 Exhaust vale rocker
seal and lower spring seat 4 Adstg rew 9 Bshng
4 Remove the valves rom the bottom 5 take ae rker 0 Rocker shaft
surfce of the cylinder head
Remove the rocker shat stopper
Note bolt
All te parts removed ould be 2 Remoe the rocker shat bracket
grouped together or eac ale valve rocker and nsde sprng
ES05-2
NOZZ TU
Remve the nozzle sleee sng
2 Remoe the split collar using a the nozzle holder rnch 996
slit collar tool (99624 500 550
5-2 CYLINDER HA AD L V ME
CLEANING
) Wash eah pat wth lh o or
clean with steam them wash n
water and dry thoroughl
2 Scrape arbon from eah par usn
fine emer paper or wre brush.
Not
During claning, grop all parts ac-
cording to val so that th original
2) Usng the nozzle tube remover EFS-014 combination can b rproducd at th
(99655 Z5500}, drive ou the tim of rassmbly
nozzle tbe rom the botom sde
of the cyinder head.
INSPECTION
CYLINDER HAD or no waer leas from the water
jket. I uly repar or repae. . : )
1) I the heht of the valve measured
pror to disassemby exeeds the Tst of condition
speced manenae sandard n- Watr prssur 3 kg/m 2
spet both the vave and valve nsert Tst tim for mints
o any abnormaly. If neessar
replace aulty parts.
Maintenance standard
Intake valv
1.32 to 1.84 mm 3 Inspe the botom surae o the
Exhaust val ve lnder head for any daon of
0.82 to 1.34 mm rakn or oher daage. If any
War limit abnomaly s found repar or re
Intak val 2.8 m pae he lnder head.
Exhaust valv 2.3 mm 4 Chek the ontang wdth of the
valve inser and the ontat pattern
2) Measure the flatess o the der wh he vave. If uly repair or
head, and reord he resuls. I te repae.
measuremen exeeds the repar Maintnanc standard
lmt grind the ylnder head. If ntak
ylnder head flaness has worn be 22 to 25 mm
yond the wear lm shoud be Exhaust Inspe the water ae or au
replaed. 20 to 22 mm mulation of water sae and rus. I
Longitudinal diection Rpair limit 3 mm neessar, lean the lnder head
Maintnanc tandard
Lss than 005 mm
Rpair limit 020 mm
War limit
030 mm (tolranc)
Tansvrs dirction VAVE MECHANSM
Maintnanc standard 1) Eame the valve sprin or breaks
Ls than 005 mm or other amae. If fau Ity, replae
Rpair limit 020 mm the sprng.
X X
War limit ES-85 2 Measure the squaeness of the valve
0.30 mm (tolranc sprn and reord the results I the
? >j 2 j 1 0 J 9 : q � ]
,
lmt s exceeded replae the vave
r · c - . 0 ' �f
i r 5) Un hydraulc pump (99570
sprng
9 0
1•�0' 6 ", jG f Z5000 and water leak test tl as
(JI� _,- : .� O • C
r . (
1,�- : • .y�·J' 0 �' · , -J, .'
semb 995 Z5002 perorm Innr and otr
the water pressure test n the cl Maintnanc standard
EF6-022
ner head ad determne whether Lss than 2 m
CYLNDER HA VAL MEISM 5-3
5 Check the contacting suraces of Valve guie insie iameter
SPRING
_.1 SQUARENESS the valve spring seats (upper and Maintenance stanar
lower and valve springs for cracks 9.00 to 90 mm
wear or other damage f necessary Clearance beeen valve stem
replace faulty parts and valve guide
6 Check the vave stem for wear or Inke)
other damage f necessary replace Maintenance staar
f the valve stem shos significant 0.02 to 005 mm
wear also repace the vave guide Wear limit 015 mm
7 Check the valve stem end for dam- (Exhaust)
age or uneven wear f faulty repair Maintenance stanar
or replace the valve. 005 to 009 mm
ES-86 8) Measure the hickness of the valve ear limit 19.85 mm
3) Measure the fee length of the valve head and the outside dameter of
spring and record the resu Its. the valve stem and record the re
Note
suIts f faulty replace the vave.
The value of the free length is men- Outside diameter of valve stem
tioned for reference. Judge the need (Intake)
or replacement of the valve spring by Maintenance standar
measuring its spring tension. 8.9 to 8.98 mm
Wear limit 8.83 mm
Inner
(Exhaust
Nominal imensions 54.26 mm
Maintenance standar
Outer
8.93 to 8.95 mm
Nominal imensions 57.12 mm
Wear limit 8.83 mm ROCKER ARM AND ROCKER
Valve head thickness SHAFT
(Intake)
1) heck the contacting surfce of the
Nominal imension 2.0 mm
valve stem end and valve rocker for
ear limit 1.8 mm
damage or uneven wear f faulty
(Exhaust)
repair or repace
Nominal imension 1.5 mm
2) Measure the inside diameter of the
Wear limit 13 mm
Msurg fe lngth valve rocker bushing and the out-
4 Measure the tension of the vave Note side dameter of the rocker shaft
spring, and recrd the results f the Since e valve guide will be eccenri and record the results. alcuate the
limit is exceeded replace the vave lly worn when the valve stem is cearnce from the measurements
spring eccentrically worn, simultaneously re obtained. f each value exceeds the
place it when the valve stem is re ear imit, repace the bshing and
Inner
placed. shaft
(when compressed to 40. 5 mm)
Maintenance stanard Valve rocker bushing inside
12.35 to 13.65 kg diameter
Wear limit 11 kg Maintenance standard
Outer 0.0 to 0.04 mm
VALVE SEAT Wear limit 0.10 mm
when compressed to 43.5 mm) CONTACTNG
Maintenance standard SRFACE WEA ON Rcker shaft outside diameter
THCKNES VALVE STEM
25.65 to 28.35 kg O VAVE Maintenance standard
HAD S89
Wear limit 3 kg 19.98 to 20.00 mm
Wear limit 19.90 mm
9 Determine the clearance beteen
the valve stem and valve guide by
measuring the external diameter of
the stem and the interna diameter
of the guide f the measured value
exceeds the specified ear limit,
relace the vave guide as necessary
Note
his clearance also be determined by
simly inserting the valve into the E6-105
S88 valve guie.
5-4 CYLIER D AN L V MCHA
3) Examne the vlve rocker sprng 6 esure the rocker shft runout
nd insde sprng for brekes or nd record the resuIts If the
other dmge. If fulty, replce the mesured lue eceeds the repr
srn lmt, repr or replce the rocker
4 Mesure the free length of the shft
nsde sprng nd record the results ntenance stndard 4·4
Note Less tn 0.0 mm
Te value of te free length is men- Repar limt 0.10 mm
toned for reference. Judge the need
for replacement of te vle sring by
mesuring its spring tension
10 esure the outsde dmeter o
Nomnal dmenson 60 mm the cm follower nd record the re-
sults f the mesured vlue eceed
the wer lmt replce the cm fol-
lower
ES-91
Mintennce stndard
19. to 19.98 m
Wr limit 19.5 m
11 esure the outsde dmeter o
7 Check the rocker sht brcket fr
the cm ollowe nd the c fo-
bends, crcks or other dmge nd
lower bore n the cylnder block
Msurig fee length the ol pssges or cloggng If
nd record results Clculte the
necessry repr replce or clen.
clernce usng the mesureents
8 Check the contctng surce o the
obtned t eceed he wer
djustng bolt nd push rod or
5 esure the tenson of the nsde lmt, replce the cm ollower
wer or dmge nd the threded
sprng nd record the resuIts If portons or dmge. If necessry Clearnce beeen cm followe
the lmt s eceeded, replce the replce fulty prt(s nd cm follower bore
sprng 9 esure the push rod runout nd Mintennce stndrd
(Wen compressed to 35 mm) record the mesurement If the re- 002 to 00 m
Mntennce standrd pr lmt s eceeded repr or re Wear limit 02 m
2.2 to 32 kg plce the push rod
Wear lmit 1.7 kg 12 Check the cotctg suce o
Mintennce stndrd
the cm profe nd cm llower
Less than 05 mm for dmge or uee er f
fulty, repr or relce
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
ES88
CYLI HD AN L VE M 5-5
REPAIR AND RPLACEMENT
CORRECTING CYLINDER HEAD 3) sing valve sea grinder, repair he CHECKING AIR IGHTNES
Using a surface grinder, grind he sea suace of he valve inser OF VALE
lower surface of he cyinder head. Maintenan standad fer compleing he lappng opera
° °
he amoun of ginding shoud no ntake· 30 00' to 30 30' ion conduc an air ighness es o
° °
exceed 03 m he cylinder head xhaust 45 00' to 45 30' deermine wheher air leakage occurs
should be replaced if is heigh exceeds beween he valve and valve inser f
the specified wear limi air eakage is noed, aain lap he valve
Nominal dimension (B) 90.0 m and valve inser
Wear limit (A) 89.7 mm Note
f e contacting width of the valve
VALV INSRT ANGL
and valve inset exceeds the speciied
wear limit, corect o eplace the valve
P610
inset
REPLACING VALVE INSERT
EF6-024
) sing a valve inser remover (9966
Z5500), remove he inake and
LAPP THE VALVE exhaus valve inse
fer repairing or replacing he valve
or valve inser be sure o perform
· ORRING VALVE AND valve laing
ALVE INS ) pply grindin compound uniform
1) sing a valve refacer or oi sone, ly o he sea o f he valve
repair he valve sem end nser he valve ino he valve guide.
Wih he lapping rod coing ino
conc wih he valve head, lap he
valve by roing i while lighly
aping he valve inser SCON AA
2) sing a valve refcer, repair he 08
valve face oron 09
Maintenan standard
° °
Intake 29 30' to 30 00' 2) Using a valve inser relacer (99665
°
Exhaust 4 30' to 45 00'
°
Z5000), cold-fi he exhaus and
inake vave nser o he cylinder
3 fer compleing he lapping opera head.
ion wash he lapping compound
away, and hen apply engine oil o
he seaing surface, and perform
lapping wih oil
4 fer ol lapping coa he conac
VA
ing suface of he vave wih read NS
lead and repea lappi� operaion
in he same manner as previousy VALV
G U D
done wih he grinding compound
and check he condiion of he
valve surace epea laping unl
he valve surface is properly cor
reced 6-009
5-6 CYINDER HAD A VL ME
Cold-fittng pocedure 2 ing h d p REPLACNG ROCKER ARM
(99666 ZS000}, d h l BUSHNG
• Kep h al int in dy ic
han iv minu. U al gid ino pl nil h l nd ppo h m, pl a
l wll po h oolng f o h ool j oh h hing n o d o
o h lind hd Alo h 2 m gin h bhing nd
h l id o h i di h bhing o
Note ppndila o h lind ha
Do not touch cold vave inser and d ote
ote Mak the bushin gap positon on he
ice directy.
Before drvin he vave uide into ocker arm po to removin the bush-
Irs h ylind hd in ho pace cean t competey and appy a n
coat of engne oi to it.
w unil i mpa xd
°
8 C
Tak h l in nd ln
d had, nd i h l in ALV
UDE
ino h lind hd RPACER
3) ing h l in l
i (n h ha l id onl
ing uling ol 99670 AVE
UDE
ZS00
ote
Be carefu not to exceed a pressue of VAE
NSERT
1,500 kg when caukin and do not
cauk he insert at the same spot that
was cauked previousy EF6-012
6112
h n bn h l 2 Co in p h bhin lign
d nd hn h n m on h o m ih
nnn ndd h
�.
h bhing gp, nd di h bh
gd nd no h ing ino h o
nd hd hn png h
18 gd 99662
Z00 o
Af drvn n he bushin confim
'
Caan bn vav uid
ha th o arm an bsin oi
and vav sm
ET143 hos a and
Mannan sana
•
Inae: 2 o mm
Exhaus o 9 mm
Ousd dam o h am
+2
9
REPLACING VALVE GUDE +006
1} ing a l gid mo 99667
ZS00O di o h l gid
om h boom id o h n
d hd
OL HOE
·, VALV F-05
GUIDE
RMOVR M h inid di o h
p-id bhng nd h id
VALV d o h h h
_ NSRT
ln bn hm i l han
ALV h minnn ndd, h
U inid dim o h buhing
Manenanc standard
P6·8 02 to .06 mm
CYLNDER HEA A VL MEIS 5-7
REASSEMBLING
CYLINDER HEAD
1 2'
2 9. 30, (_
EF6-026
1 Push od Vlve oe bshng 2 Nole
2 Adjsting rew 2 Inae valve e 2 0-ng
3 Loc nt 13 Exhas valve e 2 lve spng loe sea
4 Roke sha 4 Roe shaf be 24 Inne vle spg
5 Roe ove bol Cy nde head ol 2 Oe alve spng
6 Roe ove 6 Vlve spng ppe sea 2 nae vale ge
7 Gase 7 Spl ola 2 nae vale nse
8 Noze olde ds seal 8 nsde spng 2 ne vale
J
9 Nole hode sleeve 9 Cylnde hed 29 Ehs lve ns
0 Noe holde ss'y 20 Vale sem seal 0 has vale
31 Exhas vale gde
Before reasemblng, be ure o apply 4 Aemble the valve prng nner
engine oil to each liding urface. and outer and uper rng eat
1 Inll the lower prn eat Note
2) Ung a te eal replaer (99674 When installing the inne and ote
Z5000 ntall the valve tem eal spings nstll them so that the side
o the ale uide which hs a salle sping inding
pitch faces the lowe sping seat side.
STEM SEA
REPLACER 5) Uing a plit collar tool 99624
Z500 ntall the plt cooler
VALVE
STEM T COAR TOO OCKER SHAFT
SEAL
Iner roker haft braket ono
the roker haft and lok he ha
VALVE to the bracket with the topper
GUIDE
bol
Note
et
Inst all t he roc er s ft t t he bk
F617 so tat t e oil hole in t he rc k ft
er sh
ER6-04
n fac e downward.
Notes
. se new valve stem seals.
6 Meaure te dtance beeen the BRACKE A
valve and the lower urface of the /
2. lways ssemble e vlve stem
seal b pushing he seal in b hand.
lnder head
Neve drive it in wi a hamme, snce beteen valve and
e. clinde head
aintenance stndad
3 Inert th ntke and exhaut valve
ntake 3 to 8 mm
reetvel to their original poi- 60
xhast 8 to 3 mm
tion
5-8 CYLINDER HEAD AD VAL E MECHANIS
2) Install the xhaust valve rocker, 4 Appy sealant o the circumrnce
inside spring, ntae valve rocer, of one ptch of the thaded nozze
A
and roce bracet B to the rocer sleeve
shaft in that order 5 Usng a nozzle hold slve nch
Note (99656 Z5501), instal h nozzle
Pay careful attention to the direction seeve.
of the valve rocker. Th sid of t Tightening torque 35 to 40 kgm
valve rockr with th adjusting bolt
threaded hol must b at rigt ot
sid. Bfor coating wit seal ant toroughly,
remov any oil and dirt on the thread-
3) Inrt roer shaft baet C onto ed portion o the nozzle sleev
the rocr shaft and loc wth the
stopper bolt.
Appl a thin oat of etainin om
.BRACKET B
pound 75 (10133 90000) to the
suace of nole holde which
maes onat wth the head.
3 Usin a nozle tube settin tool
asseml (99651 5500) drive in
te nol tube
BRACKEC
EFS02B
NOZZLE TUBE
1 Apply a thin oat of soap wate
to the O-ring and nstall te Ong
to the nole tue at 8 mm om
the uppe end so as to pevent
cutting and tansfomaton when
divn in the nozle tube
:•; '.
Jc
·1
Kobelco Engine Parts
,.
email: EngineParts@HeavyEquipmentRestorationParts.com ,\Ju :i.
Phone: 269 673 1638
6. LUBRICATION SYSTEM
Te lubrcating system conssting of an oi pump, oi cooer, short vave -
semby, oi ter and other compoents, and ow of oi ater the main
e are iusrated in the ubricating syste diagram.
LUBRICATIG SYSTEM DIAGRAM ..................... 6-1
OIL PUMP ........................................ 6-2
OIL COLR AN SHOR VALVE ASSEMBLY ........ 6-4
OIL FILTR ...................................... 6-5
Full-flow & bypass oil filter ............... ............ 6-
PISTO COLIG OIL JE ........................... 6-9
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LURICON SYSTEM 6-1
LUBRICATING SYSEM DIAGRA
I
GEAR TRAN
DER GEAR
OIL PRESSURE
SWITCH
OL COOLER\
SORT VAVE
REGULATO
VALVE
RELIEF
VALVE
TO O AN
iI
,iI1 EF7·013
"dI
i·j J1/ ,I
'
1•. :
r. !·I
,I
L:' alve opening pressure
Maintenance standard
il pump relief valve
.5 to .5 kg/cm 2
il filter short valve
.8 to .2 kg/cm 2
il cooler short valve
28 to .2 kg/cm 2
egulator valve
4 to 4 kg/cm 2
il jet cut-o valve
.8 to 22 kg/cm 2
il pressure switch operating
pessure
Maintenance standard
.4 to 6 kg/cm2
6-2 LUBRICON SYT
OIL PUMP
DISASEMBLY
1 Nut
2 Lock washer
3 Pump drive gea
4 Gasket
5 Oil pump ase
6 Gasket
10 7 Key
8 Drive shaft
9 Pump gear (drve side)
10 ump gear (diven side
11 Relie vave
2 Valve sprig ·:\i
13 Gasket '!.lV
14 Pug
15 Oi pup cover
16 O-rig
17 Lock washer
18 Bolt
19 Org
20 Lock washer
21 Bolt
22 ock washe
2 Bolt
24 ock washer
25 Bolt
26 Outlet ppe
26 EF7·014
1) Remove the cover. 5 eove the ump drive gear
2 Measure the clearance betwee the 6 emove the gears rom th case
pump gears (drive ad driven) and 7 emove the plug, O-rig, alv
the cover, and record the results sring and reief vave
4 Measue the acklsh etwee the
drive ear ad driven ear, ad re
cord the resuts
3 Measure the clearace between the
tooth end of the pmp gears (drive
ad drien gears) ad the case ad
record the resuts E-006
LUBRICON SYST 6-3
CLEANING AND INSPECTION
1) If each lerane nd bcklsh of 2 Check the interior surfce of the Mantenanc standard
the pump gear mesured at the time ase and the ger-side surface of the Case sde 0.03 to 0.07 mm
of disssembly rehes he repair over or crks or dage If Cover sde 003 to 008 mm
limit, repir or rele. faulty reir or replce Rpar lmt 020 mm
Clearanc btwen pump gear 3) Calculte the clerance between the
and cover outer dimeter of he driven gear 5 Exmne the relief valve and alve
Maintenanc standard shaft and he inner dameter of the cning urfce fr dmage or
004 to 0.10 mm
bushng If the alue hs reached uneven wer. f ulty replace the
Repar lmt 05 mm the repar liit relace the drven vlve or over ssembly
Clearance btwn pump gear ger assembly. 6 Mesure the trength of the ale
tooth end and case Mantenanc standard
srng nd reord the resuts If
Mantenanc standard 0.03 to 0.08 mm
fulty relace
004 to 0.0 mm War lmt 0.20 mm Mantnanc standard
Rpar lt 0.20 mm 266 to 29.4 g
4) Calculate the clernce betwee the
Pump gear backlash Remars
outer dmeter of the drive shft
Mantenanc standard When comprssed to 46 mm
nd the inner dimeter of the over
6 to 27 m nd cse bushings. f the vlue hs
Repar lmt 0.50 m rehed he repir limit reple the
over or cse ssembl
REASSEMBY
1 Lock nut
2 ock washer
3 Oil pump drve gear
4 Key
5 Case
6 Key
A·A SETION 7 Drve gear
8 Drve shaf
9 Drven gear
10 Bushng
11 Drven shaf
12 Cover
13 Rele vave
14 Vave sprng
A B
15 Gaske
16 Plug
B- SECTION
EF7-015
6-4 LUBRICAON SYSTEM
Before reaembling, apply clean en- Clernce between pup ger Repi liit 0.20 m
gine oil to ech otating or iding u nd cover Pump ger bcklsh
face. Mintennce standrd Mintennce stndrd
1) Intall the elief vale valve spring, 0.04 to 0.10 016 to 027 m
gaket nd pl Repir liit 0.15 Repir limi 050 m
2) Inert the dive and diven gea Clernce between pup ge Cover tightenin toque
into the ae, then ene that eah tooth end nd cse 16 to 20 kg
eaane and baklah meaed i Mintennce stndd
within the epai lmt, and intall 004 to 010 mm 3) Intall the pmp dive gea
the over throgh the paking
OIL COOLER AND SHORT VLVE ASSEMBLY
DISASSEMBLY
EF7·016
1 O-ing 11 Elemet 21 Valve prg
2 Water pe 12 Pakg 22 Plug
3 Nt 13 Cove 23 Og
4 Rbber g 1 Blt 24 Pakg
5 Lck washer 15 Gasket 2 Pakg
6 Pa waher 16 Rbber rg 26 Regulat valve
7 Hg 17 Rbbe g 27 Valve prg
8 Og 1 Rbber rg 2 Pg
9 Blt 19 Pakg 29 k aher.
10 Pakg 20 Shrt valve 30 lt
LURICAON SYST 6-5
1) Remove the water outlet ppe 4) Perorm a water pressur test on 7} Examne the vave sprng or breas
2 Remove the cover. he element. I lty, replace the or agng. alty, replace the shor
3 Remove the element. lemnt valve assembly.
4 Remove th plgs, valv springs, Test standad
8 Measure he strength of the valve
shor valve and regulaor valve. Direct hydaulic pessure of
sprng, nd record the results. I
Loosen he short valve assebly cap, 10 kg/cm2 to the element to
aly replace
nd remove the valve sprng and short check for any sign of waer Maintenance standad
valve leakage. Shot valve 942 kg
(When compessed to 54 )
CLEANING AND INSPECTION Regulato valve 13.5 kg
(When compessed o 44
) Use a caustc soda solvent to clean ATTACHMENT
the nsde of he ol cooler hosng
nd the xteror of th element RESSMBLY
completely removng scales or any When rassembling be sure to replace
oher oregn matter Then, rns ll rubbr rings gaskets and packng
and dry completely Insall h short valve assmbly
HYDRAULIC PUMP
Compltly remove carbon, sldges, (99570 25000) ote
c Whch my have accmlted Apply a coat of engine oil o the slid-
R-108
:1. i the elemen's oil passge ing suface of the shot valve, and en
, } Alwys clan each prt o the short sure that the valve itself moves
5} Chck h hosing r dge I(
(i valve ssembly wth cleanng sol-
vent nd hen rnse and dry com
ulty repir or rplce
6 Emin he condition o shor
smoothly without binding.
plely
vlve nd valv s conacing sr
Note c r dmge r neven wr
Remove all traces of the gasket from alty replc h shor valv s
the pump body. smbly
OIL FIER
FUL-FLOW & BYPASS OIL FT �
DSSSMBLY
�
I-4
Centril byas o ftr and ow o ftr EF 7-01
6-6 LURICA SYT
1 Flter case 10 0-ring 19 Gaske
2 Lock nut 11 Oil filt er bracke 20 Plug
3 Spnde 12 0ring 21 ock washe
4 Rotor cover mounng nut 13 Element 22 Bol
Rotor assembly 14 Reainer 23 lemen sprng
6 0rng 15 ock waser 24 Filter case
7 Clp 1 Bolt 2 Cener bol
8 0rng 17 Short valve 26 0rng
9 0rng 1 Vale sprng 2 Dra plug
f/l
I /
V
EF7-018
Dep type bas oi fter and l ow oi fer
Cener olt 9 0ring 1 lug
2 0ring 10 0ring Sprng
3 Filter ase 11 lemen 19 iter cs
Sprng 12 Plain waser 20 0rng
5 lae 13 Flter cove 21 Cener bolt
6 Rubber seal 14 Shr vale 22 0rng
Elemen 15 Vale sprng 23 Drain plug
8 asket 16 ock waser
LUBRICAON SYSTEM 6-7
Note CLENING AND INSPECTION 4} Chek f bent ct bolt and
Drain oil form the filter prior to dis-
Clean all the disassembled pats cogged oi passage f nsay,
assembling
except those made of ubbe wit epai o epace
cleaning fuid then wash with 5 Check fo damage o esi a
1) Disassemble both the full-flow and wate and dy them thooughly on the contating suf of ah
bypass filters, beginning with thei 2 Inspect te element fo damage f valve and valve seat f necessay,
cente bolts it is damaged, it should be eplaced epai o epace
2 Remove the vave sping an shot as a unit Also eplace the element 6) Measue the stength of ah vave
vave. when the next specified inspection spng nd ecod the esults
peiod coesponds with the e aulty eplace each sping
placement peiod Stength shot valve spring
3 Check the body and cove fo dam Maintenance standard
age cacks o weakened welded 1.04 to 204 kg
joints f faulty epai o eplace (When compressed to 577 mm)
REASSEMBLY
When eassembing be sue to eplace
all the packings with new ones
1 lock nut
2 Case
3 Spinde
4 Rotor assemby
5 O-rng
6 Orng
7 Camp assemby
8 Bo
9 O-rng
10 enter bo
11 Eement
12 ase
13 Washer
14 Sprng
15 Orng
16 Orng
17 Pug
18 Pug
19 Gasket
20 Sprng
2 Vave
EF7-019
Centfugal bypas oil filter and ow oil te
6-8 LUBRICON SYT
1 Ceter bolt
2 Oring
3 Sprg
4 Pate
5 Rubber sea
6 Eemet
7 Fter case
8 O-ng
9 Gasket
10 Fiter ver
11 Oig
12 Eemet
13 Ceter bt
14 Washer
5 Sprig
16 Fiter as
1 Org
18 Dra pug
9 Org :1;
0 Pug l1i
21
22
Orng
Sprg
:w
:
·,;'I
2 3 Srt ale 1!_;
:/Ji
[:1 i!
1
EF7·020
Depth tye bypas o ter and fu ow oil flter
1) Insta the short valve, valve sprig Center bolt tightening torque 3 stal the ra plug through the
nd ug. 4.5 kgm O-rg
2) nset the sg washer eleme
etc. nto he case The stall the Note Tghtenng torque 2.3 to 2.7 kgm
cae to the fte cove through the Appy a coat of engne o to the sd-
cente bot ng contact of the short vave, and en-
sure that he vave oves smoothy
wthout bnding.
LUBRICATION SYSTEM 6-9
PISTON COOLING OIL JET
DISASSEMBLY INSPECTION REASSEMBLY
Loosen and remoe the connector 1) Clean the connector bolt assmbly Fit th connector bolt and aske o
bolt. B careful not to los th gaskt and oil t and inspct the inction h oil and install to the cylindr
when remoing th oil jt hol o the oil jt for clogging block
When cloggd, unclog with a pice Tightning torque 30 to 40 kg
or wir or compressd air
2 Inspct th cutoff valv at th con-
nctor bolt Chck the oprating
condition by ushing th al and
chck th valv spring r brakag
or a dcras in tnsion and rplc
th connctor bolt whn dctiv.
Valve spring free ength
Nomina dimnsion
15.9 mm
Vave spring tnsion
Maintenance standrd
EF3-049
074 to 082 kg
(when compressed to 13 mm)
:, i
7. COOLING SYSTEM
D '
EFS-003
Te coolng systm consts of a water pu, hemostat adiao wate
ak ad n v.
COOLING SYSTEM DIAGRAM ........................ 7-1
WTER PUM 7-2
HRMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
ADIATOR AND WATER TAK ....................... 7-4
FA AD A DRIVE .............................. 7-5
COOLING SYST 7-1
COOLING SYSTEM DIAGRAM
WATER NK
/:
,
RDIOR
EFB-004
',
!l:
:r
!':
' I
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· .
·!
;
,.
7-2 COOLIG SYSTEM
WATER PUMP
EXTERNAL EXAMINATION o the eal aembly I the eal is 2} Check or tererence of he m-
AD CORRECTION damaged, t hould be replaced. I peller wth the vehce body I the
traces o greae leakage are noticed, bearg's axal or rada play s ex
1} If any trace o watr leakage is
check the condtio o the ball cee, replace the two ball
notced at or around the ater
bearg I necessary, replace aulty arigs as a ut
dran hoe on the underside o the
part
vehcle body, check the codtio
DISASSEMBLY
/�
)
1
2
3
Fange
Snap ring
Ba bearing
4 Spaer
5 Ba bering
6 Shaft
7 Body
8 Greas nppe
9 Seal asmby
0 Impee
Packing
2 Cv
3 Sew
EFB-005
v 3} Press out the ball bearngs and
spacer.
1 Remove the coer ad press out the 2} emove the ap rig ad press out
flange the hat assebly ro the pel
ler sde ad remove the mpeller
B006 S08
4 Remove the eal aemby from the
body
COOLIG SYSTEM 7-3
CLEANING AND NSPETION 1 Pres in he ball bearings an spacer ress ft the flange
into he shaf. At this ime press ft
1) Remove water scales and rust from
the ball bearing (impeller side) fully
he body and impelle, and clean all
unil conacts te beang soppe
he pars excep hose made of rub-
of the shaf.
ber wih cleanng fluid, hen ah
ih waer and dry hooughly.
2 Check the impelle and body or
u corrosion o crache. If faul
y, eplace
3 Check he eal aembly fo
amage If fauly, eplace.
4 Mesue boh he ine diameer of
he impelle and he ouide dame-
e of he haf o ee f hey ae
whn he pecfe mainenance
andad values.
ES012
If eiher pa i beyond he peci-
e alue eplace he pulley an/
o haf.
5 Uing a pes, nsall he impeller
Maintenance standard hle easung ih a fele gauge
Sha OD o ha he clearance beeen he
13.03 to 05 mm impelle and he body in wihin he
Impller D anenance sandad.
299 to 30 mm EFS-010
Maintenance standard
Fitting toleran
2 e he shaf assembly no he 03 to 080 mm
: I
002T to 006T mm
boy and insall he snap ng
Remarks
T = Tight fit Note
B sure to apply grease to the outer
5 Inpec he shaf fo bending wea periphery of the shaft assembly
an amage o he headed po
on If fauly eplace o epa
6 Chec he ball beaing' sealed plae
,
i'I f noise, play, hemal scolora-
I on o amage If fauly eplace
1
' RASEMBLY
iI :1,' 1 1
.,1·
I
j."
6 fe assembling he wae pump,
apply geae hough the grease fi
ing.
ES-011
3) Press he eal assebly no he
1 Fange 6 Shaft boy
2 Sanp rng 7 Spac
3 Bal beaing 8 Sa assmbly Note
4 Gas poo 9 Body Apply bonding agent to th outer peri-
5 Bal eang 0 Imple phe of the seal assemly
7-4 COOLIG SYT
THERMOS
REMOVAL Valve opeing temperature
°
76.5 C
Wear limit
° STIRRING BAR
Less than 715 ,
°
More than 815 C THERMOMETER
THERMOTAT
82.0
Wear limit
°
Less than 770 C
°
HOLDING PATE
ore than 870 C
EFS-014
88.0 C
Wear limit
°
Less than 83.0 C
1 Water manifold 4 0-ng More than 93.0° C
2 Gasket 5 te outet
3 Therotat 6 Bot
Valve lit
°
76.5 C
aintenance standard
ore than 10/90 mm/ C
Remove the water outlet and remove - "/ _
Wear limit -.�,; -
the thermostat.
Less than 9/90 mm/ C ?�(,
OURC
S
°
82.0 C
aintenan standard
ore than 10/95 mm/ C
Wear limit
INSPCTION
Less than 9/95 mmfc
Check the operaton of the thermo- 880 C
stat, usng a t simar to that n the aintenan standar
follown illustratn If the valve INSTALLATION
More than 10/100 mm/ C
openng temperature or valve ft ex- Wear limit Poston the thermostat in the housing,
ceeds the wear lmt repace the Less than 9/100 mm and wth the gasket n place, connect
termostat the water outet
RADIOR AN WER NK
FLUSHING TH COLING 4) Remve any drt and dust accumu Water tan cap an radator cap
SYSTEM lated between te radator cre fns
Measure the operatn pressure f the
and tubes
1) Pour cleanng solvent nto the coo vave If the measured value ecees
ng system, an aow the ngne to the specied value, repace
INSCTIN
le for appromately 30 mnutes Radiator ap
Note Radiator unt and water tank unt ore than 1.1 g/m 2
Close the radiator shutter (f so equip- 1 heck the eteror for dents, cracks 0.8 to 1.0 kg/cm 2
pe) in order to maintain the tepera- and other damage If faut re Wear limit
ture o the cooling water above the place ore than 1.1 g/cm2
opening temperature o the thermo 2 Plug all openngs wth wooden taps Less than 0.7 kg/cm 2
stat. p the entre radator and tank Water tan cap
unt nto a cntaner of water and aintenan standard
rect the specfe ar pressure t 0.6 to 0.8 kg/cm
2 Thruhly ran the ushing fu
the water t etermine f ar leak Wear limit
an fll he adatr and engne th
age is notced If air leaae s n ore than 09 kg/cm 2
clean tap ate and un the engne
agan r adtonal flushng tce repar or replace the raiatr Less than 0.5 kg/cm 2
3 Flush epeately wth tap ater un an/r tan unt
tl the ate aned m the cl Seciied air pressure
ng system s cmpleey clean 05 k/cm2
COOLIG SYSTEM 7-5
Antifeeze density
Cec the density of te ntifeeze,
si density tester f the density is
too low, add ntifeee ntil the speci
fied density is reached
Specifed densi
45 to 60%
ESB-11
ES2
FAN AND FAN DRIV�
EXTRNAL EXAMINATON 3) Chec the fan pulley for deforma 1) Remove the nut and press out te
1) Check the cooling fan for dents, tion, cracs and dmage. If falty shaft from the bering spport
bending, cracks and damage. If replce
·fulty repair or replace 4) Chec the tension pulley for de
frmation, cracks and damage If
2} Check the crank pulley and V-belt
fr deformtion, crcks ad dam fulty, replace '
e If falty replace
DSASSMBLY
Fan pulley bracket assembly
F8·06
2) Press ot the saft from the
bracet
3 Remoe the snap ring nd pess ot
the bearings and space
1 Nut 7 Bal bearing
2 Sprng washer 8 Snap rng
3 Plan asher 9 Connecer
4 Bearng uppr 0 Bracke
5 Bal earing Shaf
6 Spacer 2 Scre pug 07
7-6 COOLING SYT
Idler pulley assembl 2) Check each part for damage and Tension pulley assembly
cracks If fauly repair or replace
3) Ceck he ball bearing for excessve
play noise uneven rotation, dis-
coloraion uneven wear and
damage If fauly replace
REASSEMBLY
Always discard old oil seals and insall
new ones hen apply a coat of grease
o heir sealing lips Aslo coat he bal
bearing wih engine oil
EFS-018
Fan pulley bracket aembly
1 Grease nipple 4 Ider puey
EFS-021
2 Snap ring 5 Bracket
3 Bearng assemby 4 Tenson pey
rease nppe
2 .Snap rng 5 race
3 Bearng asseby
1) Press out he pulley and bearing
assembly from the bracke.
2 Remove he snap ring and press out
the bearing asembly from the
1) Press he bearing assemby ino he
pulley
pulley and install he snap ring
2) Press he pulley assebly into the
bracke so tha he distance from
he pulley fron edge o he bracke
rear edge is 865 mm
1 Nut 7 Lock washer '
2 Bearng support 8 Pan washer
3 Ba bearng (sa 9 Spacer
4 Ba bearng bg) 0 Snap rng
5 Brket Shaft
6 Connector 2 Screw pug
EFS019
1 Press he shaf ino he bracke
2 Insall he snap ring ball bearing
(big ) spacer and ball bearing
CLENING AND INSPETON ( small o he shaft in hat order FB022
1 Clean all parts excep hose parts )
Insert e bearing suppor and
made of rubber wih cleaing fluid insall he snap ring and nu
hen wash wih waer and dr 4 Install he screw plug and con 3 Install he grease nipple and apply
horoughly nector, hen apply grease grease
8. FUEL SYSTM
;!
'·.]
EF9-56
FUEL INJECTION PUMP •.........•...•.•.....•..• 8- 1
Separatng each component .•.••••..•.•••...•..•.. 8- 1
njecton pump prope .•.•..••............•.•....• 8- 5
nstallng each componen •••••••.•.••••...•••.• 8-11
Fuel feed pump and pming pump ••.•••..•.••••••••.• 8-13
Type RAD lmit speed goveno ••.•.•••..•••••••.... 8-16
Ty RFD, RV mecanical goveno .•..•..•..•••..•.. .. 8-19
Type RLD mechanical goveno ...•.••••.•......•.. 8-24
Tme 8-27
ZZLE AND OZZLE HOLDER ..•.•.............••• 8- 30
FUEL FILTER AND OVRFLOW VALVE •.•...••...••.• 8-32
ADJTING AND TESTIG INECTO PUMP .....•••••... 8-33
njecton pump muntng and pepaaions •.••.......••.. 8-33
Pecautons when adusng the LD govenor ...•.•...•... 8-33
nial njecon timng ••••• · • -33
Adjusment of fuel njection •• .••• . 8-34
Adjustng goveno (Type RAD goveno) .•..•.• 8-40
Adjusting governo (Type RFD goveno) •..•...• -41
Adjusting goveno (Tye RSV goveno) •.•••.•.•.•• 8-43
Adjusting goveno (Type R LD goveno) •..•...••.• -45
Testng tme • •••• .•••••.••... 48
I'
FUEL SYSTEM 8-1
FUEL INJECTION PMP
DISASSEMBLY PRECAUTIONS 4} Teporarly nstall the timer ith
1) Spread a clean sheet of oil paper the sprng wser and round nut.
over the work bench and provide a 5) Disconnect the cam and tapet.
receptacle containng clean lght ol. Dsconnect the ca and tappet by
2) Prior to dsassembly visually check rasng the plunger to top dead
r mssing art. When dsas center of each cylnder by
sembling, check for foregn matter turnng the camshaft and nsertng
insde the pup and clean if neces the plunger sring holer
sary 15931200 hon n te igre
3) Drain out all ol n the pump. between the adusting bolt and nut
4 During dsassembly, do not aly of each tappet.
EF9057
unreasonable frce, asolutely
avoid rough handlng, and always
use the recommended special tools. 3 Put the pump proer n a unversal
5 Dsassemble by arrangng the arts vse 5794-0020)
order by cylinder so that they
can e easly reassemled.
6) Never exchange· part whch ae
cobned such as plunger and
i!
·:
barrel delvery valve and delivery E9-011
valve seat, and nozzle needle and
nzzle body Removing th govnor
7) Dsassemble major parts (rerred (with th typ RAD govno)
to n 6 above) and mmerse them n
lght oil carefully. Remove the closn cover.
Removing th feed pump
) Loosen the dran plug of the pump
body and dran the ol.
2) Remove the ed pump assembly.
SEPARATING EACH
COMPNENT
Removing th timer
Loc the tme couplng wth the
specal wrench (57964320) and
EF906
L-type handle, remove the round
nut and remove the ter asemly
usng the extractor (579266210. 2) oosen te loc nut wth the
specal wrench 59140500 and
remove the unglech and idlng
3 Remove the plate cover. spring assembly.
EF9·02
E903
2 Reove the tmer bracket.
8-2 FUEL SYSTEM
3) Remove the speed adjusting bolt 7 Screw the extractor 157265110
cap and lock nut loosen the or 157926510) on to the thread
tension of the governor spring by ed part of the fyweight holder to
loosening the speed adjusting olt. pull out the fyweight. The y
weight should not be disasseled
as a rule. When the yweight is
faulty replace it as an assebly
RSV
4 Remove the cover fro the
housing, slide the plate sprng of 4) eove the dlng subsprng
the link connected to the control SV
rack down fro the top wth a
screwdriver as shown n the figure
EF9065
and dsconnect the lnk fro the
hole at the font end y sliding the Removing the governor
lnk to the left and rgh
(wth the type FD, SV, governor) ,jl
'
. ,
1 eove the cap nut and idlng su
sprng. FD
ER9·225
EF9·063
5) Remove the start sprng from the 5 Loosen the lock nut wth a socet
spring ee with needle noosed wrench FD . 57910100
pliers. Then reove the sprng eye. RSV .. 15710500 and reove
the idlng sprng assebly.
2 emove the cap nut and daper
sprng asely FD
EF9-064
6) emove the round nut and spring
aher usng the socket wrench
(157915-0100.
Remove the closing cover 6 Reove th governor cover.
ER9132
FUEL SYST 8-3
7) Remove the starting spring from 4 Remove the cap nut stenng he
the spring eye, and loating lever idling sprng asseby ih the
link from the control rack. Then wench
emoe the goenor assembly.
Removing the governor
(with the type R L D governor)
1) Reoe the cap nut stened to th 5) oosen the lock nut stening he
guide scew of the goenor shat idling spring assembly wit the
wh the wench wench and emoe the idling
8) Loc the time with the special spring assembly with the screw
wench (157912-0920) and emoe drie
the ound nut and lock washe
fom the flyweiht with the tpe
andle 1579101120) and socket
wench (157915-0100
EF9-101
2) Remoe the loc nuts stened to
the goerno shaft with wenches
6) oosen slightly the nut stening
the central lee with the wench
7) oosen the lug · th hole or
o
adjusting the toque cam with the
9) To pu II o the flyweight assebly wrench
screw the extracto 157926-5110 8) Reoe the seen bolts stening
57926-5120 or 1579265310 onto the goeno coe with the screw
the theaded art of the flyweight de o the special wench
holder. 157913-0100) o the ratchet
handle (157910 0120) and remove
EF902 the goeno coe.
3 oosen the nut stenn the guide
scew with the wench
10 Reove he seting scew and
sepaae the spring ee from the 9) Exac the goeno spings out
EF93
eno housing the goveno sha.
8-4 FUE L SYSTEM
E9-107
EF9 E95
10) Extract the governor shaft to 14) emove the snap rng fstenng 18) Remove the Uy e
gether with the spring seat out of the sensor lever wth long-nose
the goveror housng. plers
E908 9 Reove togethr he fu oa
control shaft and the sprn
11 Remove the start sprng out of 15) Tae out the sensor levr
the rack connectng lnk wth long
nose plers
2) Remove the round u aeng
E909
the fyweht by usng the speca
16) Remove the nut astenng the ful
wrench (15915-10 and th
12) Remove the bolt conectng the load settn lever wth wrench
L-type handle (159101120 At
control rac wth the rac connect th time, stop th turnng o th
ng ln wth wrenchs. cam shaf wt h secal wrenc
(15916542)
E90
7 emove the ude plug on the
13 Remove the nut from the sensor opposte sde of the full load ettng
ever lever wth wrench E94
FUEL SYSTEM 8-5
21) Extrac he flyweigh ou of he
cm shaf b using he eracor
(157926-10, and emove he
prn ee fom he govenor
houing.
JECTION PUMP PROPER
OISASSEMBL Y
EF9·066
1 Taper roler bearig 13 Delivery vave hoder 25 Gasket 37 Bolt 49 Bush
2 Adjutig shim 14 Delivery gasket 26 Pipe oint bot 38 Camshaft 50 Roler
3 Camhaft rig 15 Delivery vave sprig 27 Taper roller arig 39 Key 1 Piio lamp screw
4 Gasket 16 Delivery gasket 28 Oil sea 40 Cotro piio 52 Lock washer
verfow vave 17 Delivery vave 2 Bearig over 41 Cotrol sleeve 53 Nut
6 Gaket 18 Plunger assembly 30 Srew 42 Upper sprig seat 54 O-rig
7 Gasket 19 Pump housing 31 Oring 43 Plunger sprig 55 Plae washer
8 Pg 20 Rack gude srew 32 imer brake 44 Lower spring seat 56 Lok washer
9 Gasket 21 Contro rack 33 dustig shim 45 Lok ut 57 Nut
10 Bolt 22 Joit adapter 34 Camshaft rig 46 Guide 58 Pipe oit bolt
11 ok ate 23 Gasket 35 Center arig 47 Pi 59 Gasket
12 Lok pate 24 Coector 36 Gasket 48 apt 6 Gasket
61 crew
8-6 FUEL SYSTEM
1) Remove th scrw plug at botto 5 Losen th stting scrw tightning
of th housing using th L-typ th govrnr housing and rv
handl {1579101120). th housing fro th injction
pup housin by tpin th ft
an right sis f th housing
lightly with a n at
9 Rv th plungr spring, uppr
spring sat an cntr slev
> EF9070
2) Remov the setting screw of th
center bearing 6 Insrt th tappt insrt
(1579210120 fro th scrw pug
ho, cmprss th ungr sprin
by pushing th tapt u at th
ungr spring sid an pu th
pungr spring hdr ut
10 Rv th lck pat
EF9-067
3 Remov th baring covr
lt·.r•,
'
J< :.
TAPPET
INSERT 901
': !;,
7 Aftr puing th punr spring
hoer, insrt t tt ca
(1579316120 fr t baring EF9·072
insrtin h of th pup husng 11 Rov th ivry vav hd
and pu th tppt ut and ivry valv sring
EF908
4} Pu ut th cahaft tgthr with
th cntr bearing
EF9-018
E2
8 Aftr removing th apet insrt
th plunger insrt 1579214120) 12) Rmov h dlivery valv an
EF9·9 fro the scrw lug ho and pull gakt by thrding the dlivery
the plunger with the lwr spring valv xtractor 159200320 nto
sat. th dlivery vav.
8-8 FU SYTEM
When the "pull back funcion is
improper, fuel cutof at the nozzle is
not good, resulting in after rip. If
tightness a the valve sea is in
aequate, changes in the aoun of
fuel injece arise, leaing to reduce
engine output.
S93
ES9-36
Tappet
Check he ppet, roller pin, nd 1Bearng covr 2) Fit the washer an shi plae
neele rollers, looking r wear, 2 Oil sea the camshaf an frce he inner
scoring, an oher efecs f eects 3 Outer race
race into position with a press.
are fun, replace i wih a new 4 Extractor
5 Nut
ppe
appet aembly
Contol rack and control sleeve 2 Pull and replace i wih a ne oil
Reove he ppe guie pull the
1) Check he control rack, making seal
roller pin an remove the roller
sure that it is sraight an tha he 3) Fiing bearing ouer race into
bushing an roller
teeh are no aage. f eecs governor housing
Loosen the ausing nu an reove
are un, repair or replace he se he wopiece guie, as shown
the ausing bol nu from he tappe
subject par in he fgure, to press he ouer race
2 Check the clearance of he conrol ino the bearing hole provide in
sleeve an plunger collar an re the bearing cover The guie is a
place when he wear limi is ex special tool (1579258120)
ceee
Maintenance standard
0.03 to 0.08 mm
Repair limit 0.12 mm
Springs
When pluner or elivery spring e
fcs are evien, replace the subec
spring
1 Adjustng bolt 5 Rolle i
2 Adjustng nut 6 Roller
3 Tappet 7 Roller bshn
4 Tappt gude
BEARING COVER
EF9·196 REASSEMBLY
PART REPLACEMEN Befre assembling he fuel injection
pump, clean parts thorouhl and
Oil seal and bearing outer rae apply a thin coat of engine oil to
1 Use the ouer race exracor roting an sliing parts
(157925-0120 an remove he 1 Moun the pump to the universal
ouer race rom the bearing cover Inner race of camshaf bearing vice
Install the outer race exracor n 1) Place the inner race extractor 2 Assemble the plunger barrel
tihten he nu to force the flare (157925-4120) over the inner race Assemble the pluner barrel b
porion of the tool beween the of the bearing an pull the inner aligning he knock pin rven nto
ouer race an the oil seal Hold the race fom e camshaf A the the housing an the roove of he
bearing cover an ap th knurle same tie remove the him plate barrel wth he barrel escape hole
prion of the tool with a hammer. an washer facn he fron of he housn
FUL SYTEM 8-9
F9·02
EF9-079
6 Holding the control rack so that the
hole at the end of the rack is at the 9 Install the upper spring seat t the
3) Insert the new gasket to the de governor side, insert the rack into control sleeve Assemble the
livery valve. the pump housing. plunger spring to the hsng
Push the delivery valve and gasket Install the rack guide screw
uniformly into the barrel by
pping lightly from the top using
the extractor (157926-0120) with
the deliery alve assemled
E901
1 0 Install the plunger to the special
tool plunger insert (15921120
7 Tilt the pump housing onto its side and assemble to the barrel.
EF9-022 and set the punch mark at both At this time, the loer spring seat
sides of the control rack to the must be installed to the plunger.
4 Place the delivery valve spring atop ame dimension from the ends of Notes
the delivery valve the pump housing. 1. Since the plunger and barrel are
Install the de ivery valve holder and precision manuactured as pair,
tighten unifrmly at each cylinder they ust not be atched wi
at the prescried torque using a those of anoter cylinder
torque wrench 2) Assemble the plunger with te
matching mark facing the front
Tightening torque (cover side) of te pup ousing
3.0 � 0 � 3.0 � 35 kgm
EF9080
99
8 Install the control sleeve ith the
gap of the sleeve (with pinion
assembled is cing straight up @
ward At the same time, move the
control rack to the left and right MATCHING
and conrm that the tilt of the gap MARK
5) Install the lock plate to lock the
delivery valve holder. is the same at the left and right. EF92
8- 10 FUEL SYSTEM
11) Assembl the tappt to the pump of the barng n ths case st
housng usng th tappt camp masue th end play of th cam
(157931-6120 and tappt nsrt shaft wth th masurng dece
(157921-010 th same as whn and then adjust to 0 to 002 m
disassemblng. Push the tappt tsf ddng th end play qually at
forcefuy and nsta th pung th ont and rea wth th shm
sprng hoder.
Maintenance standard
EF9069 0 to 002 mm
Repair limit 01 mm
TIMER SDEQ
EF9·083
EF9·018 Agn the cent bang st scrw
hoe wth th set scew ho at th
12) Assemb th pung and tppt botto of th pump housng and 8 Tempoay nsta th automatc
f ach cnd and con that tghten wth a scrwdve te and move the tappt hold
the contro ack sds as
wh tunng the camshaft.
13 Ft th govrno housng to te
9 Tghtn th rack gud screw
pump housng though a gasket and 20 Whnv an njcton pump has
shm (RFD and RSV typ ony, ben dsassmbed care shoud be
and then nsta wth th· stng execsed to be sur that no bnds
scre. xst to hamp fe ovemnt of
the conto rack. Ths can b asce
'
taned b masung the esstance I -·
EF9-067
wth whch th ack s opatd (·.
16 nsta th bang cov to the Th tstng shoud b carred out
pup housng b pacng th cams at vaou
Not
hghs
Since the oil seal may be damaged by Rack friction resistance
the key grove of the mshaft when Below 150 g
installing the bearing cover, insall the
seal uide (157920-8700) to the
SHIM GASKET
threaded par of the mshaf.
21 Con that th contro ac
opates the ong shft
vous soothy. f th prscbd
shft voume cannot b obaned
14 Install the cashaft toeth rbu th njcton pump.
th the beang t th pup
housng so that th "assmby Maintenance standard 21
mark s at th tm sd (Ths 17 Measure th end play of the cam
o an be facltated by coatng shaft wth th masung dvc
the cente barng th a sma (105782420) Adjust the nd
amount of grease and stng t to pay by changng the thcknss
the amshaft.) of he adjustng shm at th nsd
FUEL SYSTEM 8- 1
INSTALLNG EACH 5) Lock by hoking the special Installing he goenor
COMPONENT wench (157916-420) to the timer (ith the type RFD, RSV, goeno
and tighten the yweight with the
Installng the timer sping washer and ound nut. 1) Instll the start spng mountng use
Align the scribed line of the injection Tightening torque 6.0 to 70 kg m sping eye to the goeno houng
pump housing with the scibed line of
the injection pump backet and tight
en with the nuts.
Next, install the time assembly with 2) Install the lyweight assembly to
te ound nut the camshat though the woodu
key, and tighten the round nut th
the lok washe in place
Tightenig toqe
6.0 to 70 kgm
EF9-014
'·I
.
6) Install the stat sping to the
governo husing side sping eye
with needle nosed plies.
EF9-084
Instaln the feed pump ER9175
Fit the eed pump assebl onto the 3
stud bolts o the pump housing and
instll with the nu.
3) Install the governor cove to the
goveno housing wih the gasket in
place. At this point attach the
stating sping to the spring eye on
the govenor housing) and insert
the loating leve link guide into the
hole in the control rak
7) Connet the sleeve to the lyweight
and the link to the control ak and
lock the pin with the plate sping.
i ; Then install the goveno cove.
i·
:i�
Insn the ovenor
(with the type RAD governor)
1) Inset the stat sping munting use
sping eye t te sew at e
bottm igt te contl k
inside he goven using nd
EF9063
tigten e se.
2 Tempoily instll the utomtic
time to the dive sie shat.
3) Tempoaily instll the lyweigt 8) Push the speed adusting sew to
assembly to the cmsht. set the goveno sping.
4) Align the key with the key goove 9) lnsa' te dampe spring idling
the camshat nd inset the spring ungleich spring etc. in ode
flyweight assembly when adusting the injection pump
8- 12 FUL SYT
4) Instal he dlng spng asembly Inslling the governor 5 Instal the sensor leve.
with the socke wench (RFD ... (wth the type RLD governor)
15791 4-0500, R SV . 15791 4
Insall he star spn mounng use
0100. spn eye o the overno housn.
2 Insll the flyweht assemby to
he camshaf hough h e woodu
key, an hen he oun nu wh
he lock wsher n pace.
Tightening orque
EF9-113
6.0 to 7 0 kgm
Insa he ack connectng nk o
he contro ack and nsta the sta
sprng.
5 Instal the damper spn assemby
(RFD, dln sub sprn and cap
nut.
EF9014
E9110
3 Instal the full oa conro shaf 7 Ftn the govenor o the pump
EP9·104
an spn. Have the ono ack se of
supporn ever pue ou owa
he ovenor housng an hn
moun the seeve. Next adm he
bal jon {on conro ack s no
he so of he oatng eve. Ths
sequence makes ease o ac
the govenor cove assembly he
pump.
ER9-225
6) Insta the closng cover togehe 4 Ins he Utype leve, gue pug,
wth the O-n or gaske. fulload se eve etc.
99
FUEL SYSTM 8- 13
8) Conrmation of he governor FUEL FED PUMP AN PRING PUMP
housing and the cener of the gover
nor cover SSSB V
When the governor cover is to be
uil into the governor housing
upon completion of the shim
adjustmen of the shifer, fasten he
guide screw afer confirming hat
the governor shaft is insered in the
faucet porion of the housing so as
to slide and rotae smoohly. If he
governor shaf does no roate
smoothly oosen the governor
cover fasening bol and rebuild the
governor
GUIDE SCREW
EF9·120
9 Conrm ha he llowing conrol
rack positin can be otined after
the governor cover is attached and
the idling and he set of th gover
nor spring are loosened nd he
idling and the set of the governor
spring are loosened and the control
lever is manipulaed o he ll
speed side in such stae th he
control lever and the full load stop
lever are not limited by he sopper
bol and the conrol rac is insered
to the non-inection direction rom
the pump driving side Then con F-085
firm tha th control rack reaches
he following mximum position
smoohly when the control rod is 1 Pipe jont bolt 14 Pston sprng
released: 2 Gasket 15 Pston
3 Adapter 16 Push rod
Shif volume of the control rack
4 Check valve sprng 17 Fd pmp hosng
95 o 21 mm 5 Check valve 18 Tappet
6 O-ring 19 Tappet gde
7 Prmng pmp over 20 Roller
8 Prmng pmp 21 Roller pn
9 Check valve sprng 22 Snap rng
10 Check vave 23 Gas�et
11 Gasket 24 Flter
12 Pg 25 Ppe ont olt
13 Gasket
8- 14 FUEL SYSTEM
1) Place he fuel ed pump in vice, • Apply wench o he Hex Check valve
remove the plug, gske nd pull seion he boo of he If he vlve se is scoed o ex-
ou he pison spring nd pison. cylinder nd emove he piin cessively won, eplc he chec
pup ssembly
�
vlve wih new on.
• Remove the chec vlve sping 2 If excessively won broen re
nd check vlve. plce wih new pin.
Piston
If he periphery of he pison is
excesively won or coed replce
he pion wih new one.
2 If excesively wn boen e
plce wih new pring
Clearance between housing and
EF9-086 piston
2) Removing he ppe Maintenance standard
EF908
• Pce he ed pump in vice
003 to 0.06 mm
upside down.
Wear limit 0.15 mm
• Remove he pison eining INSPECTION
snp ring nd pull ou he ppe
Feed pump housing Tape
nd push od.
Chec vlve se cnc es f he peiphey of he ppe is
A eel e i insered in h chec won o coed eplce i wih
vlve in he fuel ed pup new one.
housin. 2 If he inside or ousid i dmged
When hi conc of his se i o excessively worn eplce h
imprope he oil ed cpciy will ppe olle wih new one.
decese nd he· pump housin Roller and pin cearance
sembly mu be replced (wih Wear limit 03 mm
he puh rod.
2 The puh od hle
If he puh rod hole i excessively
EF9·087
won, p of he fuel fm hi
e my ene he fuel injecion
pump cmsh chmbe.
3) Disssembling he piming pump When he push od hle i wn
I i ecommended h he piming excessively eplce he husing nd
pump no be dissembled unle puh rod.
he rubber se in he pison pr of Then ensure h reince i en-
he ump hs becomes decive o couneed when he hub is
he pison sized or ruy. pplied o he push od.
FUEL SYSTEM 8- 15
REASSEMBLY
EF9·089
· .: I i
, I
·Jj
1 Plug 5 Push rod 9 pe jont bolt 1 Check aIve seat
2 Piston sprng 6 Snap rg 10 Adapter A rom fuel tan
3 Pston 7 Tappet 11 Check valve B To fuel flter
4 Fe pump housng 8 Tappet roller 12 Check alve sprng
Bere assembling the ed pup, re 2) Pressue test
place old gaskets with new ones. ih the ed pump opeating at
1) Insall the push od an tppet in 600 pm the time equired or the
the housing a place clip in the pessue to ise to .8 kg/cm 2
housing to lock the ppet should be Jess tha thirty seconds.
2) Insert the piston piston spring,
gasket and tighen the plug.
Note
Coat the threads of the plug with the
adhesive agent. EP97
3 Install the dischage side check
valve, check valve sping and gasket, 4) Airtightness test
and tighten adapter nd priming Close o the outlet of the ed
pump. pump and apply air compessed to
2 kg/c to the inlet. With the feed
2
EP9-116
pump immersed in light oil air
leakage should be less than 0
ccin
3 Piing pump est pocedue • Measuing procedure
FEED PUMP TEST PROCEDURE Fit a pipe to the inlet side of the Fill he gaduated cylinde with
Standad fuel ed volue ed pump nd opeate the piming light oil, invet it in the light oil
With the ed pump opeating t pump at SO to 00 strokes pe continer, and use it to ta ai
600 rpm ow though the fuel inute with suction height of one escaping fro the ed um
lte of the teste ove a 5-second meter. Fuel should be dawn up There is no problem if the size of
peiod should be more than 300 cc. within 2 strokes. bubbles coming fom the jnction
8- 16 FUL SYTEM
between the pum housig and the COMPRESSD AIR
2
2 kg/cm (28.47 psi) CYLINDER
push rod is less tha that of mllet .
grains.
When larger bubbles contnue to
escae, replace the feed um
FEED PUMP
EP9-18
.TYPE RAD IMI SPEED GOVENOR
BL
EF990
)
1 Plug 22 Bolt 43 Nut
2 Governor housing 23 Nut 44 Busing
3 Bolt 24 Gasket 45 O-ring
4 Sprng eye 25 Cap nut 46 Adjusting sm
5 Bolt 26 Damper sprig 47 Cotrol lever
6 Sart sprng 2 Gasket 48 Lock waser
7 Flywegt assembly 28 Nut 49 Nut
8 Lock waser 29 Gaske 50 Ungle spring assembly
9 Collar 30 Cap nut 51 Nut
10 Gude ever assembly 31 Plug 52 Sprng gude
11 Colar 32 Closng over 53 Idlng spring asmbly
12 Spe stting lever 33 Bolt 5 Sroke adusing bo
13 Limer 3 Bolt 55 Sliding lever
14 Tenson lever 35 Lock waser 56 Lever saft
15 Lnk 36 Bolt 5 Adustng shim
16 Snap ring 37 Orng 58 Sleeve assemly
1 Speed adusng bolt 38 ul load sopper bol 59 Round nu
18 Gasket Nut 60 Key
19 Govenor over 40 Nut 61 rain plug
20 Tension lever sat 41 Bol 62 Gaske
21 Plug 42 dlng sopper bolt 63 Adaper
FUL SYT 8- 17
1) Remove the left and right plugs
from the top o the governor cover
and wthdraw the tension lever
shat.
EF9094
5 Disassemble the bushing and plate
2) Separate the sped settng lever E095
bearing as shown n he gure,
frm the governor spring and with- taking care not to cause damage to 1 Control lever 4 Snap rng
dra the speed adjustng bolt n the 2 Lever shaf 5 Sldng leer
the chrome plated suace at the tp 3 Nut
IH governor cover o the shiter
.I'"",·
l Flyweight asemb
'
i
•I
1 Clamp the yeight assembly n a
I
,·- " .
vse Use the governor sprng ex
- SLEEVE
tractor to remove the adusting nut
(with b securing the governor
springs Then remove the outer
_.- i Ir,. sprng seat and the governor sprngs
(inner, outer, and central
l. _ j
EF9-092
3 Remove the lower end o the loat
PATE BEARING
ng lever o the guide lever assembly
rom the supporting lever and pull
out the gude lever asembly, etc as
one pece toward the bottom o the
governor cover
1 Ajutng nut
Ur rng eat
Outer rng
4 Cenral rng
5 nner rng
6 Exracor (1579-010)
se a screwdrver or chsel to
remove the knock pn of the bell
crankshat rom the lyweght
holder Do not bend the pn
SHFER
E913
EF9·093
6) Remove the lever shat nut and
4 emove the snap rng nsde the lock washer and pul the contro
sleeve whch connects the sleeve lever assemy out o the cover
and the shifter o the guide lever housng and the sliding lever toge
assembly usng needle nosed pliers, ther with the lever shat nto the 1 Knock pn
and remove the shfter and sleeve nsde o the cover housing Bellcranka
8- 18 FUEL SYTEM
3) Bring the tool of a press nto con ly, the overnor must be checked wth Conrm that the dmenson from
tact wth the bell-crankshaft and a pump tester the end of the bshn wth the
foce out the shaft to complete sleeve asembled to the flyweht to
governor dsassembly. Ths step RASMBLY the end of the overnor hosng s
may be accomplshed by sn a wthn he 3 to 3.4 mm range. If
punch hammer. lyweight ambly not wthn hs rane, adjut to
Assemble n reverse sequence of ds wthn the prescrbed lmts by n
assembly. The only reqrements are creasn or decreasng the shm be
nsrn that clearances confrm to tween the shft and sleeve bshng
the mantenance standards and observ Note
n the follown cautons Measure the above dimension with the
The flyweghts have been machne flyeight lifted fully
balanced Do not use the flywehts of
another governor Be sure to replace t
as a set
Goernor cove
EP9·122 i,I'.,i
·,r
INSPECTION
Reassemble parts n the reverse order
.,
i!
(!:)
of dsassembly Observe the ollowng
Sleeve pont
1 Assemble the flyeght assembly to l:;
Inspect the contact srces and re ,
the camshaft wth the rond nut ";!,
place when damaged, excessvely and a lock washer
,:
: 1
worn, dscolored, etc :;
Round nut tightening torque :f!I
I�
·I' 1
Flyweight 6.0 kg-m i':·
Wear s accelerated f the level of 2 Press the plate bearng correctly n
lbrcatng ol n the governor case s the sleeve and frce the bushng
low If wear s evdent, replace the nto the shfter
yweght assembly. EF9096
Check the pn and bushng play and
replace an assembly when play s
' overnor housing
lyweght
3 hm fl!,\
ecessve
Flyweght pn and bushng clearance f. :-·7
I
Maintenance stadard
I. PLATE
4 Assemble the tenson lever and
spee adjstng bolt to the governor
0.02to 005 mm
I BEARING
Wear limit
008 mm
cover At ths tme, nsert the pn
press ft to the tenson levr nto
L _
the roove at the top of the sldn
Each lever
SLEEVE lever
Check the tenson lever, speed settn
lever and gde lever hole and pn
clearance and replace of repar to wth
n the mantenance standard when the
play s excessve.
enson lever, speed settn lever
gude lever hole and pn clearance
Maintenance standard
0.02to 009 m
Repair limit SHFTER
02mm
Governor spring 0 SHM
Vsually check the sprngs makng EF9-097
sure that there are no deects and that BUSH
the sprngs are not weak or contactng 5) Install the overnor sprng to te
each other o determne whether or speed settng lever and nstall to the
not the goernor s functonng proper EF95 tenson lever.
FUEL SYSTEM 8- 19
6) Insert the collar to the left and
right pin holes at he top of the
guide lever.
7 nsert the floating lever into the
groove at the bottom of the sliding
lever and attach the guide lever,
tension lever and speed adjsting
lever to the governor cover by in-
serting the ten sion lever saft
EF9-099
998
TYPE D, RSV MECHANIAL GOVRNOR
B
EA9·12
RFD goveor
1 Gasket 17 Bracket 33 Sleeve assembly 49 Bushing
2 Governor housing 18 Screw 34 Shim 50 0-ring
3 Lever assembly 19 Gaske 35 Set bolt 5 Snap ing
4 Pug 20 Governor cover 36 Woodruff key 52 O•ring
5 Gaske 2 Pug 37 Damr spring 53 Cosing cover
6 Spring eye 22 Snap ring 38 Nut 5 Sub spring
7 Staring spring 23 0ring 39 Cp ut 55 ut
8 Guide lever assembly 24 Bushing 40 Gaske 56 Gaske
9 Guide lever collar 25 Pug 41 Leve shaf 57 p nu
0 Foating ever ink 26 Plate 42 Siding eve 58 Conol ever
11 Snap ring 27 Tension leve 43 Snap ing 59 Sim
2 ension lever 28 Pug 44 Lever 0 0ing
3 Iling spring assembly 29 Woodruff key 45 Washer Bsng
4 Nut 30 Fyweigh assemby 46 Colar
5 Swive ever 3 ock washer 47 Sim
Governor spring 2 Round nut 48 il sea
8-20 FUEL SYSTEM
For RSV goveor
ER9-259
,
1 Joint bolt 33 Round nu 63 Lock washer 94 Se scre
2 Gasket 3 Seev 64 Bo 95 Gaske
3 Gaske 35 Sdng ever 65 Gasket 96 Cosng ce :·.,
,1
4 Adapter 36 a baring 66 Coar 97 o ,.
5
6
Nut
Set screw
37
38
Shim
uide ever
67
68
Gasket
Bo
98
99
ock ase
Bo
j;· ) '
"('
;,:
7 Gasket 39 Se bo 69 Pug 10 Gaske
8
9
1
Governor ousing
ug
Bot
40
41
42
Tenson ever
Idng spring assemby
Nut
7
71
72
asket
Tension ever saf
ug
10
10
13
Damr prng
Nut
Gaske
Jj; i:!
1Fi 1 :
11 Sping eye 43 Coter pn 73 Shim 14 Cap
12 Bo 44 Shim 74 0-rng 15 Cover
13 Starting sprng 45 ink 75 Bushng 1 Lock waser
16 Swive ever 46 Snap ring 76 0ring 17 Bo
17 Governor prng 47 Shm 77 Snap rng 1 Gaske
18 Limter 48 Sm 78 Contro ever 19 ug
9 Gaske 49 oer pn 79 Shm 11 Nu
2 Foatng ever nk 50 Bo 8 Woodru ke 111 Screw
21 oating ever 51 Snap rng 81 Coar 11 Cap
22 Coter pn 5 0rng 82 Sm 113 Nut
2 in 53 Busng 83 Bo 114 Gasket
24 Lever 5 ug 84 Contro ever 115 Bot
25 Lock waser 55 an washer 86 Sim 116 Cap
26 Cotter pin 56 Shm 87 O sea 117 Gasket
27 dapter 57 Spring 88 ushng 118 Nut
28 Gaske 58 ush rod 89 Governor over 119 ding sub sprng
29 Bot 59 Lock washer 9 Bot 1 Bo
ywegt aemby 6 Gaset 91 Se scre 121 Gasket
31 oodru key 6 Diapragm 92 Nut 12 Nut
2 Lok wser 6 Gasket 93 Nut
FUEL SYSTEM 8-21
Gverr cver aembly 8} Ro th snp ngs fo th
nsd of th gno o
1) Ro th kt stting ts
(RFD}, pugs nd tnson
shft.
ER9235
5) Ro th sdng th th EP9-133
shft
9) R th ushngs nd O-ings
EP9-16 h nds f h sw
2) Wth th sw sd, o shft nd th sw
th ftng fo th sdng Do nt th sw
nd st pnst n unss s nss)
s quppd Thn o h
s fo th otto f th
gno nd th guid
nd ftng
EP9-130
6) Ro th no ot,
onto nd k
:!
B mr (If ee
EP9-17 1) R th dphg .
3) s th sw , th
nson hough h tp f th
gn wth th fngs nd
hn h gon spng
P9131
.,
ER936
2) R th k nut, dphg
nd spng
4) o· th nut RD), ot E9·3
(RSV}, control lever and shim.
7) Ro th nd sh
ER93
) R th push d h
EP919
EP93
8-22 FUEL SYST
INSPECTION
Inspec the pars or cracks, damage,
abnoral hreads, rus ec. and repar
or repace when uy Moreover,
never re-use Orings, gaskes and oher
consumabe pas repace hem n
sead.
Inspecon pons for each man par
are given beow
Guide lever and shifter
If he shfer end (on he dng sprng
E9236
sde) s worn or f he chroepang
is peeng repace he gude ever Goernor coer assemby
assemby
Check he connecon of he shfer 1 Inser he swve ever n he gover 4) Inser he sdng ever ogehe
and gude ever fr excessve pay If nor cover, press n he Orngs and wh he ever shf, and nsa he
necessary, repace he gude ever bushngs on boh sdes and ock shm and ever Then ghen he
assemby h he snap rngs ock nu RFD or bo RSV o
he sdng ever shaf
Swe ever and bushng SWIVEL LEVER
NAP NG
Check e swve ever sha/bushng
r sdng sae If au or
shaf/bushng cearance s excessve,
repace
Governor sprng
Check he governor sprng fr damage
muua conacng of he sprng and E9-15
broken sprngs
However, judge he quay by per
frmng a governor es wh a pump 2) Inser he shm and coar o he 5 Ins he governor sprng beee
eser sve ever shaf he swve ever knuce ad e
enson ever nsng he enso
ever n he governor cover
REASSEMBLY
Boost compentor {If so equpped)
1) Insa he push rod o he ever
2 Insal he sprng daphragm and
ock nu
E912
3) Insa he key, conro ever and
ghen he bo o he sve ever
shaf
6) Corm ha he dimenson fom
he end of he bushng wh he
seeve ssembed o he fwegh o
he end of he governor housng s
ER9-237 whn he manennce sndard If
no whn his range, adu o
wihin he prescribed ims by in
creasng or decreasng he shm be
3) Insl he aphragm cover een he shf and seeve bushng
FUEL SYST 8-23
Note
Measure the above dimension with the
flyweight lifted fully.
intenance standard
RSV 19 mm
RFD 33 to 334 mm
EP9-127
� E9136
8) nsert the tension lever shaft 10) nstll the idling sprin in te
through the tenson lever to the tension lever At this time, mke
guide lever and secure the bush to sure that the dstance between te
the governor cover tension lever en and push rod end
is 15 ± 01 mm and secure the
spring with the lock nut (RSV)
EF9·096
1 Govenor husing
2 Flyweight
'd 3 Shim
7) Install the sleeve assembly together 9) nstall te bracket and tighten the
with guide lever assembly into the bolts to the governor housing nd
governor cover and install the float-
plug RFD)
ing lver to the sliding lever nd
boost compensator link (f so
quipped).
8-2 FUL SYST
TYPE RLD MECHANICAL GOVERNO
SSSB
1 Adapter 30 Floatng lever 59 Lock nut
2 Gasket 3 1 Snap rng 60 Lock nut
3 Governor housng 32 Nut 61 Lock nut
4 Sensor lever 33 Lok waser 62 Gasket
5 Snap ng 3 Control leer 63 Plug
6 Fullload ontrol aft 35 Adjustng shm 64 Lock nut
7 0-ng 36 Oil seal 65 Rack ap
8 hm 3 7 Spng eat 66 Cap nu
9 Reun sprng 38 Start sprng 67 Idlng png ubassembly
10 Fullload set lever Governor sprng nner 68 Lock nut
11 Gue plug 40 Governor sprng outer 69 Gaske
12 Scew 41 Gde lever 70 Cp nut
13 Uhape lever 42 Gude scew 71 Bol
14 ancel spring 43 Woodruff key 72 Bracket
15 Lok waser 44 Adjustng shm 73 ping
10 Nut 45 Shte 74 Torque am
17 Fullloa set bolt 46 Busng 75 Snap ng
18 Nut 47 Bolt 76 nap ing
19 Governor saft 48 Fweght assembly 77 ping inne
20 png ee 49 Lock wasr 78 Adustng nut
21 Bolt 50 Round nu 79 Plug
22 Rak onnetng o 51 Seeve ubassembl 80 enson leve aft
23 ok washe 52 Snap ing 81 Gake
24 Nu 3 Pin 82 Governor ove
2 Rack ap 5 enon eve haft 83 Bolt
26 ontol leve shaft 55 Cnel png 8 ud
27 anel pring 56 Fullpe et ol 85 Rod
28 upoting leve 57 Lok nu 86 ping ouer
2 nap ing 8 ding set bolt 87 ok ew
FUEL SYT 8-25
1) Remove the pug. 4 Remove the pug to which both
ends o the shat oing the
spporting pont of the tenion
eve assemby are pessed n
E9127
EF9-121
8) When the torque cam is to be e
paced, etract the snap ing ith
2 · Remove the gide screw together te ongose pe
E924
wih the ock nt out of the gove
no cove 5) Ex tact the shaft
E9128
E922 95 9) Remove the nut fastening the
conto ever and remove the
contro ever
6 Etract the tenson ever aemb
3 Remove the snap ing connecting
the toqe cam with the od of the
tension leve with te ong-nose
pies
E9126
E9·3 E929
7 tract the gude eve together
with the bshng tact the 10) tact the eve semb to te
cance spng at the same tme insde of the goveno cove
8-26 FUEL SYSTEM
4) Whe the rod r adjustig the
torque cam of the tensio levr or ) Abnormal abrasion of he torque
th spring is to be replaced, loosen cam surace
the nut with the spcial wrnch 2 resence or absec of th play of
(579133620) d remove i the pin t th conection tween
th torque cam adusting rod ad
the torque cam
G
hec the govrnor spring r damag,
mutual contacting of the spring ad
bro sprigs
EF9-130 However udge the quality by per
frming governor test with a pump
1) The lever assembly consists of the EF9136 ster
part s shown i the gure and is
connected by th snap rig
INSPECION SSMBLY
S G
nspect th shifter and the sleve to ) nstall the rod r adusting th
se whther thre is abnormal abrasion torque cam and springs to the ten
of the bearing for the sleeve or sion lever
whethr thre is abormal abrasion or
sizur in the pin hole of the shifter.
Abnormal abrasion or seizur in the
EF9131
shifter pin
2 Aborml brasion or seizure i E913
12 Whn th sleve replacement th tensio lever shaft portio
becoms necssary, rmov th 3 resc or absence of the play in 2 When th shter isassembld to th� i•."
snap rig and extract th pin !:
th governor sprig sheet sleeve assemly, the sleeve is press '<
4 rsece or absence of th play or ed against the lyweight holder s
seizure i the pin fr driving th that the lit o the flywight be
torqu cam coms th state of and it is so
adusted that th size 1 from th
G k governor covr adhred surfac· to
resenc or absnc of abnormal th center o th pi hole o th
abrasion or sizur in th ball oint shifter may b maintenanc
E9132
portio. standard b means o he adusng
shim
13) Remov the snap ring conncting G Maintenanc standard
the sleeve ad th bearing with th rsc or absc of ormal 28.8 to 292 mm
lon-ose pliers abrasio or seizure in the bush of A functional diclty wll occur f
the tension levr shaf portion th dimnsio is set to tae a
2) crtch of the oil seal in the control vale o the specicaon:
lver shaft portion • oo large a valu of causs
th flyweight to opn part oo
F wd, maing the slider come of
resnce or asence of anormal th sleev to ru nd wear he
abrasion in th r portion cotacg surace of he sleeve
his wear is vidncd y a
S suc oset
resence or asence of abnormal • o small a value of preve
abrason in t for portion or he th flyweight o move or
claw oo maig the maximum lit
FUEL SYSTM 8-27
9 Insall the plug to the tension leve 10) Connect the torque ca to the
shat ens od of the tension leve
Afte the plug of the tension lever 11) Install the guide scew and lock
shaft is pressed in the goveno nut.
cove coat the peiphey of the 12) Instll the goveno shaft, spng
plug with sealing agent Unless seal seat spings and loc nts
ing agent \ used, the lubricating oil 13) Install the idling sping an loc
ma lea out nut
L, 29t0.2
=
EF9-137
3) Instal the sleeve to the tension
leve.
4) Assemble the oating lever and
control leve shaft
5) Instll the leve assembly to the
.
inside of the governo cover
',
E924
·i
TMER
:j
.:I DISASSBL V
,;i
J
;i
I'
!i
E9-130
6) Install the contol leve
7) Install the toque cam
8 When the cancel sping r inte
gating the guide leve with the
tension leve is bilt in, it is con
venient to se a diver having a
ditch at its on end as shwn in EF9·4
the figre
1 Round ut 6 Flyweght 11 Lock washer
2 Lock waher 7 Tmer flange 12 Nut
3 lyweght holder 8 Thrust washer 13 Drve gear
4 Tmer sprng 9 Adjustng sh 14 Lock washer
5 Adjustg shm 0 Lock pate 5 Bolt
Use the time disassemly eassel
tools (set tool 10590-020} when
disassebling and eass�mbling the
atomatic tie
E919
8-28 FUL SYT
1) Clamp he base (57924-160) in a 7 Separate te mer prng an
vce and ntall e bung flyweght holder
5794-1700.
F914
EF9·47
Remove te lock plae, autng
EF9-142 m an tru wer
8 Remoe te adjutng m fro
te ole a e pn part of te me
Place te tmer aembly nto te
flange
bae and algn te hole of the
fywegt older wt te pn of e
bae
3 Remove the 6 bol and lock
waher and remove te njecton
pump drve gear
INSPECTON
Flyweight and flyweigh holder pin
F95 eck te clearance beween te
yweg an te ywegt holer
6 Moun he thru bung pn. If ether part exceely worn
799 to te treaed par replace t
: i
of te bung gue, compre te
prng w e pecal wrenc Timer spring
7963 , an remoe te
mer fange by pryng w a leer eck te mer prng Wen ec
wle looenng te ru ung are edent, replace e prng
Bushing and roller
9143 eck the ne an outde ameter
of te bung and te ne ameter
4 Unbend he lock waer and re of te roller If eter part exceve
move the nut and lock waher ly worn replace bot part a a unt_
EF9146
FUL SYT 8-2
iEASSEMBLY
IMER
THR UST W A SHER SPRI
ADJUSTING
SHIM
NU
FLYWEG T
DRIVE
ODER GER
GE
EF9·148
1) Clamp the base and bushing guide 3) Inert the shim into the hole at the Note
in a vice and place the flyweight pin part of the timer fange. Conirm that the spring are enered
onto the bae by aligning it with 4) Cover by matching the timer ange into each pin hole of he flange and
the pin hole of the bae. ark and direction of the key holder ully.
groove of the flyweight holder,
hook the pecial wrench to the
fange hole and instll the thrust
buhing to the threaded part of the
bushing guide
i
l.i
I:
:1
1,
1
!
i
E9149
;,]
2) oat the hole of the flyweight with
greae, instll to the flyweight
holder, inert the timer spring 912
support (157932-0200) at the
botto of the spring and place on
the fyweight. 6) nert the thrut waher and lock
plate without the adjuting him
9-5
entered and tighten with the nut
) Turn the pecial wrench in the ) Measure the lock plate and thrust
direction in which the pring i waher clearance with a thickness
compressed, thread in the t hrust gauge, select the adjusting him so
buhing and remove the spring that ti clearance becomes spec
upporter. Next, inert the spring fied value and inert the shim
into the hole of the flange with a between the thrust washer and loc
lever and install the flange com plate
pletey by threading in the thrust
bushing fully Maintenan standard
002 o 010 m
8-30 FUEL SYSTEM
8) · Align th "0 mark of the drive
gear and the mark of the time
fange and install with the 6 bolts
and lock nuts
EF9-154
E9153
NOZZLE AND OZZL HOLDER
DISASSEMBLY 2 Cleanin nozzle
Remoe carbon from around the
openings _b using the corne of a
hard piece of wood Do not use
waste or an other material to push
carbon into the openings
) Remoing carbon in openings
Use the pin ise (9977 Z5 and
EP915
wire to clean the opnings
• Allowing too much wire to
protrude at the tip of the pn
ise wll permit te wire to bend
3) Rerse the nozzle holder and inside the nozzle in which cas
clamp it in te ise Remoe the withdrawal proes dfficult Th
nozzle nut wire sould protrude no more
4 Remoe the nozzle fom the nozzle than 2 to 25 mm
older Do not drop the nozzle
needle
NOZZLE
1 Cap nut 8 Nozle 2 to 2. mm
2 Gaske 9 Reainng nu
3 Adjustng nu 10 Dus sea
4 Sprng set 11 se
5 Nole sprg 12 Inle conneo
6 Push rod 13 Pn •K
7 Body
E95 ·K
P9-15
CEANING AN INSPECTING
1 With th injection orifc down- • Carefull push the carbon into
ward, clamp the nozzle holder in a 1) Pull the nozzle needle from the the nozzle oo much rce will
vise. Rmve the cap nut nozzle body bnd te wire Proceed slowly
2) Rmv th adjusting screw and Not • Rmove carbon at the insid nd
sparat the upper spring seat Do not use he nozzle neee in of the openings with the nozzle
nl spring and push rd aoher nozze body. cleaning tool 9926 ZS
FUEL SYSTEM 8-31
Exercise care to avoid damaging DJUNG NJCON PRSSU
the surce whih the nozle uring adustment of the initial in-
needle contacts. Th use of com- j
etio pressure with the nole tester
pressed ar may clog th open lean th nozle and tster carefully not e the state of the spray and look
ings with foreign particles Al ake sure that th light oil to be used r fuel lakage If a problem develops,
ways us the spcal tool, in- n the tster contains no dr th nozzl ndle and nozzle body seat
stead 1) With the nozzle holdr austing are worn or scored If the extent is
scrw loosned atach the nozzle slght, rpair can be eected by lap-
to the ster Ect ful two or ping wth compound therwise the
thr times to rce out any dirt
� . •[ ,:e· 2) perat th lver of th tstr at
sxty strokes per minut and rad
nozzle body and needle must be re-
placed as a set
NOZZLE BODY
'· th gauge during fuel eecton
CLANING TOO
3) Eitr tghten th adusting screw
or adust by loosenng t so that the
EP9-156 inecton prssure becoms the
spcified pressure ake ths adust-
mnt usng a srw drivr in accord-
anc wth th gaug rading 4 X
RSSMBLY Mainnan standad
S X
assembly is th rrs o ds 002 to 010 m
assembly. In tightening th rtinin
nut, maintin centering and tghten FD6 200 kg/cm 2 I O
FOG 220 kg/cm 2
. ightening torque
Cap nut 4 to 5 kg-m ER999
r_i,;
Nozzle nut
6 to 8 kgm (FD6) 1 Uniform and symmetrcal
2 No symmera
8 to 10 kgm FD6T
3 Branhng
Inlet connecto 4 Tn sream
6 to 7 kgm 5 Sepped njecon
6 Mus be eveny njeed
fom he f our of ces
4) Aftr completng this adustment,
t ghtn th cap nut to a torque of 4
to 5 kgm and rcheck the initial
ncton prssur
h pointer o th prssur gaug
will uctuate during ful eecton
onsdr th cnr of th swing as
the corrct rading
EF9·6
1 Cap nu 6 Push rod
2 Gaske 7 Body
3 Adsng srew 8 Reag n
Sprng sea 9 ozze
5 prng 10 Conneo
8-32 FUEL SYSTEM
FUEL FILTER AND OVR FLOW VLE
DISASSEMBLY INSPECTION REASSEMB
Remoe· the center bolt at the top of Filter elemen 1 Istal the set sprig wher ad
the coer assembly, ad sepaate the element to the terior o the fuel
oer ssembly fom the body assem Chek loggig and make sure that the filter housig stall the oer ad
bly.
elemet is ot ruptured. If the elemet tihte the eter bolt.
s no loger servceable replae t ) Be sure to disrd the old gasket
ad pakg ad stall ew oes
Ovelow valve
1) Chek the ale sprg replac it
f a det s oud.
2) Chek cotact betwee the ale
and ale seat If daage o wear s
edet replace the sbjet pat
3) Install pressure gauge at the outlet
of the fuel lter o at the utlet
ed f the flexble hose oetg
to the lead tube Apply pressre
(wth the pmig pup f ex-
mple) ad obsere the openg
pressure. If the measured alue does
ot all the mateae stad
ad lae shm oer the sprig or
i- 7
eplace the oeflow ale
Maintenance standard
1.0 to 16 kg/cm 2
Ef9·158
1 Overflow valve 6 Waer
2 Coer 7 Set pring
3 Packing 8 Oring
4 lement 9 Center bolt
EF9-157
5 Cae 10 Drain plug.
1 Cover 7 Cae
2 Overflow valve 8O-ring
3 Packing 9 Center bolt
4 Element 10 acking
5 Washer 11 Dran plug
6 Set spring
FUEL SYSTEM 8-33
ADJUSTING AND TESTING INJECTION PUMP
Whn the injection pump has been reasons exis use a pump tester and PRECAUTIONS WHE
disassembld, plungrs or plunger adjust the injetion pump DJUSTIN THE RLD
springs hav been replaed or other VERNOR
1) Fixing the ontrol ack
In xing the ontrol rack whn
adjsng the injection quantit of
the ineion pmp to which the
RLDK typ mehanial governor
wih a orqe cam is loaded the
ontrol lver is fixed to he idling
position h injction pmp is
acelerated o above 500 rpm the
ontrol lver is maniplaed to he
full speed posiion the control rak
position is assigned to full load
position + abo 3mm by th full
load sopper and eithr he ontrol
EF9·159
rak or he onrol pinion is on
rolled o be xed o eah ontrol
rak position o obtain the in
jion qaniy.
JECTION PUMP MOUNTNG 2 Mehod of operating the control
AND PREPARATIONS lever
n maniplaing h ontrol lever of
1) Remove th feed pmp and plate he RLD type mhanical governor
cover from th injetion pmp. with h torqe cam to he full
2) Remove th driv gear of the auto speed posiion this manipulation
mati timer install the test se shold be onduted after the
opling ass'y (05784-0190) and mp spd is inreased to above
hen install to the pmp drive side 500 r.p.m at the idling lever posi
amsaf wih the rond n and E F9-026 ion
spring washer. 3 Fix h adjsing nut or adjusting
h orque am wih the lok srew
witho il
4) Conne h nozzle pipe and fexi
ble hos
5) Remov he ap of he ontrol rak
and insall h masring devi
8260; ·
EF9-025
ITIA INJECTION TIMN
3) Insall the injetion pmp o h
bed of the pmp tesr throgh the Th sar of injion is onsidered as
fixing sand (05780050). Thn h im a whih he top of the
install h atomai imer mn plngr ors h fel intak hole of
ione em above After hat h brrl Th pmp tstr st be
onnet h copling with he pabl of dloping a pressre in th
huking devi of th pmp eser range of 30 o 35 kg/cm 2 n order to
Note ovrom tnsion of he dlivery valv
If there is no chucking device, install spring (to frce he delivery valve
one (8 cylinde tester . 157840-2720, 9027 open)
12 cylinder tester . 157840.3920 or
157840420) o he pump ster
8-34 FUEL SYTEM
Adjusing the injecion iming of he 8) After adjustment
adjustment securely
securely re
sandard cyinder tighten the lck nut o the adjust
ing bolt
1) Fix the control rack to full rack
position
2) In s tall
tall the measu
measuriring
ng device
device
(105782-4010) to the tppet of the
No. 1 cylinder a viewed from the
drie side.
7) When thethe o of uel uel ha
ha not
topped ven through the tppet Adsing inecion inerva
has been lifted 245mm or mor 1 After complet
completing
ing adjustmnt
adjustmnt of
looen the lck nut and rie the initial injection tiing of the r
position of the plunger by turning erence o. 1 cylinder timer side)
the adjusting bolt to the left f the turn the camshaft to the right (a
flow of fuel ha topped when the vieed frm the drive end and set
Ef9·28
tapper ha been lited 23mm or the injectin interval fr the re
les lower the poition o the mining cylinder b djusting
plunger by turning the adjusting shims
bolt to the rght See the ble below
3) Set the tappet to top dead center of Injection order
4 2 6 3 5 1
the cmht and et the scale o 0 I 60 0
the dial gauge to "0 Injection interval : 60 ° °
0 60
° ° ° °
I ·
) Losen
Losen the bleeder
bleeder screw of the ° °
40 300 360
Scale plate indication • 0 60 120 180 2 40
° ° ° ° °
pump nd bled the air rom the
uel ystem
5) When the drive shaftshaft of the
the tester
i lowl turned in the drive direc
tion while feeding fuel to the uel
inlet of the pump, the fuel will top 2) Adjut the cylinder injectin
injectin inter
inter
flowing from the pipe the tet vals within ± 30'
ue nozzle holder Thi i the in
jection start
sta rt poition The injection
timing is normal i the tppet h
risen b the specied value fom
botto dead
dead center.
cente r.
Specifed value 2.4 ± 005 mm Tappe clearance inspeion
After all the clinder have been
djuted, check the ppet clearance at
plunger op ded center. Thi clear
ance mut be 03mm or greter fr all F916
clinder.
1) Set te cam
cam to the top dead
dead center
poition intall the measuring ADJUSTMENT OF FUL
device to th tappet and set th IJCTION
cle o the dil guge to 0
EF9-029 2) Raie the tppet
tppet ith a screwdrier
screwdrier Tesing condions
6) When the flow
flow o uel does
does not stop and read the dimension (ppet Failure of pump to delier fuel enl
when the tppet ha ben lifted clearance) until the plunger con throws the engine out of bance s
within 235 to 245m from ct the barrel at the scale o the that roughne and los o power i
bottom dead center adust by turn dial gauge Check this clarance or eident In calibrating a pump, observe
ing the adjusting bolt each tappet the following
FUEL SYSTEM 8-35
Test conditon
�
DKKCN. 101691·9220 DKKCNo 10169·9160 DKKCN 101691·9080
101691·9080
DKKC N
N 10691920 DKKCNo 1016819170
DKKCNo
DKKCNo 101691 9060
9060
DKKCNo 101691·9180 DKKCNo)016919100
DKKC No. 0699320 DKKCN o 101601 •9150 DKKCNo 101691·9130 DKKC No 1016819150
101681 9150
m DKKCNo10691·910 DKKCN 101691·9090 DKKN 106019070
DKKCNo
DKKCNo 105780·0000
Nzzle DKKCN
DKKCN 05053760 DKKCNo
DKKCNo 105015-3700
(ON 1212T
Nozze DKKCN
DKKCN 057802080
OKKCNo 05031430 DKKC No. 1050314290
1050314290
hoder (EF851/9A
Nole
njecton
175 200 220
pessue
(kg/cm2
Feed
pump ol
16 6 16
pessue
g/cm
g/cm
Inecn
ppe
6 X 2 600 6 X 2 626 6 X 2 626
(D x ID
+: !
L (mm
JIS N 2 lg l JS N 2 lg JS o 2 lg ol
Test (ASTM No 2 ASTM N 2 (ASTM No 2
Bs L6VII o Bosc L6VII o Bosc L6II
L6II
l;J
· i :i
Test ol
empe 4045 40
40 45 40
40 45
atue °C
Note The fuel injetion
injetion pump (P/N: DKKC No. 101681·9170, 1016819150 1016919120
1016919120 and 101691-9130) have bee heked under
he te onditios
onditios scifi
scifi in the on vehile dusment sifitions All other pumps hav e een heked under the tet ondition
ondition
speifi in the stand ard adusment ifitions
Piping outline
RW
PIG PRUR
U
IR
U PUP
U EF9-001
8-36 FUL SYT
Injection adjustment tandard
RAD governor
• DKKC No. 101691-9080
101691-9080,, 1016919060,
1016919060, 1016919180,
1016919180, 10169191
1016919160
60 101691910
101691910 and 101691910
101691910
1) JIS No. 2 light o (ATM No 2
Contro rack Pump speed Injection quantty Varation
Remarks
osition mm rpm cc/1,000 strokes (%)
9.7 1000 534
534 56.6
56.6 ±2 andard
Aprox 82 300 7.1 107
107 ±15
After fue excessive
Approx. 137
13 7 100 72 98
setting for sart
Bosch
Bosch oil OL61 VII
Contro ack Pump seed njection quantty Variation
Remarks
positon mm rpm cc/1,000 strokes (%)
9.7 1000 556
556 58.8
58.8 ±2 Standard
Approx 82 300 8.2
8.2 118
18 ±15
After ue excessve
Approx 13 100 750
750 101.
101.0
0
settng for str
• DKKC
DKKC No 10160
1016019
19070
070 and
and 101601
10160191
9150
50
1 JIS No 2 ight oil (ASTM No 2
Contro rack Pump speed Injection quantity Varation
Remarks
poston (mm rpm cc/1000 strokes (%)
13 1600 57 623
623 ±3
103 1,000 541 57.3 ± Sandard
10.3 700 429
429 461 4
Aprox 89 300 68 92
92 ±15
2 osch
osch oi
oi OL61
OL61VI
VI I
Contro rack Pump speed Injection quantity Varation
position mm) rpm Remarks
cc/1000 strokes ()
103 160 601
601 64.7
64.7 ±3
103 1000 563 59.5 ±2 Standard
103 0 44.7 479 ±4
Arox. 89 300 7.8
7.8 10.2
10.2 ±15
• DKKC
DKKC NoNo 0 61
619
932
320
0
IS No
No 2 h
h o ASTM No 2
Contro ack Pump speed Inecton quantty Varaton
Remarks
oston mm rpm) (cc1000 strokes %)
9.4 1000 5.
5. 556
556 ±2 Sndad
o 8 300 892.5 ±5
±5
00 Mo han 70
FUL SYT 8-37
2) Bosch
Bosch oi OL61
OL61Vl
Vl 1
Conro rack Pump speed Injection quantiy Varaion
Remarks
positon (mm} rpm) (cc/1,000 strokes (%)
9.4
9.4 1,000 54.6578
54.6578 ±2 Standard
Appox 78 300 10.13.8 ±15
126 100 More han 72.8
RLD governor
• DKKC
DKKC No.
No. 101691
101691-90
-9090
90
1 J IS No 2 gh ASTM No 2D
Conro rack Pump peed Inecon quan Vaaon
emarks
oon mm) pm) cc/1000 oke (%)
115 1600 58
58 - 70 ±3
111 00 29 - 56 ±2 dad
111 600 37 - 2
2 ±3
97 3 102
102 - 38 ±15
2 Boch
Boch o
o O 61 VII
VII
Coo ack Pump peed Inecon qua Vaao
Remaks
oo mm m cc1000 oke (%)
115 1600 685
685 731
731 ±3
11 10 51583 ±2 Sndad
11 600 3036
3036 ±3
.,
:; ±15
Ii
:,
97 300 11752
;/
RFD goveror
• DKC
DKC No
No 01691
01691-92
-9220
20
IS No
No 2 gh
gh o ASTM
ASTM No 2D)
Cono ack Pump peed Inecon qua aao
Remarks
oon mm m cc0 oke (%)
99 100 56596
56596 ±2 ad
Apox 82 300 9128 ±15
2 Bosch
Bosch o
o O 61 VII
VII
Cono ack Pump eed Incon quan Vaao
Remak
poon {mm) pm) cc/1,000 soke) )
9. 100 587619 ±2 tandard
Appox 82 300 106142
106142 ±15
8-38 FUEL SYSTEM
RSV govenor
• DKC No. 10681-9150
J IS No 2 lght ol (ATM No )
ontol rack Pump speed Injectio quatty Vaaton
poton (mm) (pm) Rmak
cc/,0 toke) (%)
107 Boot p:
35 70
70 74 ±3
abov 3
17 andad
8
94 ±2
(aov 3)
Approx 72 3 17 143
143 ±15
±15
• KC
KC No
No 1
18
89
9
J IS o lih oil ATM No 2)
Contol ak Pump pd on quan Vaaion
Rmak
poiion m) p / ok) (%)
1 5 2
2 5
5 ±2 aad
04 9 3
3 83 ±3
Appox 7 3 138 ± 15
• DKC
DKC No 091
09193
93
J I No ligh ol ASM
AS M No )
Conol ak Pup ped Inon qua Vaaon
Rak
poon (m) pm / o) (%)
95 559 ±2 Sanda
Appox 82 3 38 ±5
• DK
DK o
o
9
9
2
2
J IS No ih ol ATM o 2
Coo ak Pup p Io quan Vaiaio
Rak
poon ( (pm) (c/ ok) (%)
9 75 5
5 53
53 ±2 ad
9 9 537
537 583
583 ±3
Appox 8 3 1
1 38
38 ±5
FUL SYST 8-39
Measuring the injection amount At the time of setting the conto Max (mn inection
rack to the "O postion, the amount of each
) Determine the "O position of the
topper bot hal aways be made njection punge average
control rack.
oose amount = injection amount 0
• RAD and RLD type irreguarity Average injecton
2) perate the control rack or pinion
Set the measuring device to O
and conr that the ull troke o amount
with the position at which the
the rack i 2
governor spring i pued o that
n addition to the above, conr Injeto amount adjutment
high peed contro i tarted at a
that the contro rac wi move
pump speed of 500 to 600 rpm by When the easured resuts ae not
soothly in the direction o maxi
the speed adjusting bot (RAD within the average injection aount
mum inection by the rce of the
type) or governor ha RLtype) and irreguarity range, adjut b chang
start spring n case the contro rack
with the governor damper spring ing the contro pinion and contr
doe not ove moothy the in
disconnected, (RAD type) the seeve combination ange
ection pump ha be checked and
peed is increased sti further the connected so that it wil ove ) oosen the pinion camp crew
conto rack i puled in the "O soothy tightening the contro pinion
position direction and the end of 3 Tip the contro ever in the top
the contro rack or the contro direction s ar as it wi go then
,. pinion i pushed uy in the no set the topper bolt so that the
inection direction and becomes
contro rac poition wi be 05
ttic s the rack "O poition
10 mm SV type ony
Note This i done in order to prevent
Since the ink mchanism and other undue force fro beng exerted on
pas inside the vernor may be to the ink echanis inside o the
damaged by stting the "O position governor in cae the contro ever is
of the ntrol rack by oprating the pued towards the stop direction
, . 1 ntrol levr, setting the "O position 4) emove the rac guide screw at the
by mans of the control lver must b rear of the pump housing insert the
avoidd. (RAD and RLD type) ock cre 57976300 in its
place and fix the contro rack at the 2) nsert the pin into the hole of the
adustment tandard poition with contro eeve and change the in
the contro ever ection amount by shifting the poi
Note tion of the punger reative to the
As for idling, fix the rack with the contro rack by moving the seeve
lock screw. itte by itte whie tapping the pin
When the contro seeve is turned to
the right the inection aount in
creases and hen it tuned to the
eft the injection amount de
'I
·:\
,.\ • RFtype
Stretch the governor pring with
he speed contro ever so hat
contro wi rt at a pup rpm
o 500 - 600 Whie increaing the
rp et the contro rod pued
toward the O poition and at the
ae tie push the top of the 5) Drive the tester and drive the pump
control rod or contro pinion in the at the prescribed peed
noinjection direction The position 6) Make the fed pressure to the pump
where the rod or opinion thus stop 16 kg/c2 and measure the in
is the O positon and the O jection aount of the precribed
position on the cale is made to be stroke (000 strokes by means of a EF9-034
atched to that O position fmae cyinder
• RSV type 7 Meaure the injection aount at
Tp the contro ever towards the the prescribed speed and rack posi 3) Ater adustment is finished, ock
noninjection ide as ar a it wi tion in the same manner and cacu the pinion camp crew
go then ath the O position of ate the irregularity by refrring to 4) Remove the ock crew of the
the contol rack with the O posi njection amount adjutment stand contro rack and inta the gude
tion of the cale ards table screw
8-40 FUEL SYSTEM
5) Rer to Injection amount adjust FUE EXCSSV 2) Adjuting idling control
SETTNG FOR
ment tandards table r standard START: 9,6 �8· 2mm When the fuel injection pump rpm
injection amunt adjustment values. 9 is et at Nb (Nd + approx 50
E
beo
5 rpm), adjust the control lever pos
=1 soA 6•U-. tion that the cntrl rack is
0 �4
ADJUSING GOVERNR w positioned at Ra While in stte,
w
adjust the idling spring assemly
(Type govenor) (located under the tensio lever s
�se0 +2
-0
·1-
beo65·
:
that the cntrol rack is psitined
RAD goveor prformanc cur 4 at R when the pump rp is
·
·30+-�.
reduced t a point of idling N
g
0 2.5t05
l7w 7 abov e9_4
9.3
EF9-13
: CONTRO RO POSTON mm)
__ ___
13,O
KKC N 116132
1 Adjusting the lyweight lift and the
full lad position. er to te
l Nb
em ·20,-.
g Nd
Tye AD-K mechanical gvernr 0 Ne
w
u.Mk,w peformance curve.
! l
l • 10�4 The full lift of the yweight is I•
' .0 L
3 divided int the lift required while
:
idling and the lift reuired at high L .,:-
speed. ncrease the fuel injectin R Re Rd
U · 5 6 abe
ave 4 pump rpm, and adjust the cntrl RACK POSIT ION (mm) -
( lever mvement until the control 9-
EF96
ack is psitined at Ra" when the
DCKK No. 101691-9, 101691960
fuel injectin pump starts t re
101691-9180, 1016919160 and
vlve at a high peed. At this point,
1016919170
set the ll lad stpper l Next,
decease the pump rpm, and deter·
L mine the flyweight lift (i.e. the full
load psitin R) at high speed
r�
"blow using the strke adjusting screw.
Then, adjust the speed adjusting
�1&00
1800 t30 lt so that the governr speed
300t0 egins t decreae, srting wit the
·.1
Q 00
beo
specied rpm of Nh
t h
30
-,- ------
3 =03 • o'
10 10 av '
D (m)
F9-62 I
3) Adusting the damper spring
KKC N 1161-1 After making the idle adustment
perate the pump rpm so that the
cntrl rack i poitined at R
L
I Rb 0.1 mm (The cntrol lever should
TTI RACK POSITIO mm) e at the same psition as r the
TT .sg idle spring adjustment then adjut
[ F95 the damper spring until the control
rack is positined at R mm
�1&ot:X
4 Adjusting stopper blt
After the damper pring has been
properly adusted, stp the pup
rttion t ensure that the control
rac is in the Rd position. From
. that psition ve the control
above aboe lever s that the control rack moves
I to the R 1 mm position At
F96 this point tighten the sopper bolt
DKC No 06000 an 10609150 until it touches the conrol lever
FUEL SYSTEM 8-41
I l J ____- M PG E
E L _
Ne _ . � Ng -- 0
w
w
300
- -
0
I . _ • O Nf - e
w t N
w
a
e
a a
8.2
a Rc-2 R Rd
a RbQ Rb COROL ROD POS
RACK POSITON (m) 165
RACK POSITON
EF9039
EF9-041
CONTOL � IDLING STOP ER 1,
LEVER
_ BOLT
ULLLOD
STOPPER BOLT
Flyweight lift adjtmet
Tempoarily set to a speed of 00 to
600 rpm with the speed contro ever
set the load control ever to the u
position, gradually increase the ump
speed and adjust the stre adjusting
bolt so that the amount o return o
E9-
the control rack from the ontrol sart
point to end point is 7 mm.
5) Adjustment of Ungleich control
With te fuel injection pup rpm
at Nb (Nd + 50 rpm) and with the
control lever pulled to the full posi
tion, the control rack position EP9179
should be Rb 1 position. Further
increase pup rm to the e posi
ADJUSTING GOVERNOR
tion, the control rack osition
(Type RFD goveor)
High peed adjutment
should then be in the Rb position RFD governor performance cues 1) Move the load control ever so that
With the fuel injection pump rpm
• Set the speed control lever at it contacts the full load stopper
set at the Nb position tighten the
Full." bolt and the control rack is posi
Ungleich spring assembly until a
tioned 99 m when ijection
osition is reached just before rack
ump speed is 1,000 rpm.
osition Rb 1" sarts to change
Further increase the fue injection
pum rp, and tighten or loosen FUEL XCSSIV
STG FOR START
the Ungleich sring assembly so 1 : ·5 . :1,2-
that the contro rack stats to move
om position Nf" in the direction
of fuel increase" and reaches posi •
1 I · 30
tion Rb" when the pump rpm is at
e DAER SPRNG
position Ng" 1 50- ST. 7 0
o.t
Ater this adustment has been
&
l20t H+�
! ,.
made set the control lever at the a 5
uo · i ot-�
full position until the pump rm is •
at Nb" when the control rack 2) o determine the starting point of
position is Rb 1". With the u high-speed control move the load
pump rpm and control rack posi COTRO ROD POTO m) 9• 64 control lever to Full" and the
tion held in these positions in speed control lever al the way to
crease the pump rm to ensure that fuel increase" With the control
the pump rm reaches position evers held in those positios
Ne" when the control rack osi gradually increase nection pm
tion is Rb." • Set the oad control lever at Fu" speed Adust the stoper ot so
8-42 FUEL SYSTEM
ha when pump speed reaces 2) Afer idling he engine aust te
1,600!�8 rpm hig-speed control damper spring so that damper
begins and e control rack also eect begins starting wi te rack
begis to move from its preset posi position of 6.7 8m.
tion {step 1 above).
Note
If the rack position is less thn
6.7 �8. 2 mm, dper effect will be
wek; if the position is greter thn
67 -8 2 the idle speed will be EP9-185
higher than specified vlue nd de-
celertion perfornce will deterio
rte 3) Aust e ile subspring by n
creasing te pump rpm util e
rack is positioe at a poin of 7
m A tis poin aust e ile
subspring tensio until resistace
3) fter adjusting te startig point of begis beginning at a rack positio
hig spee conrol determie te of .7_ mm
spee uctuaion rae by graually
increasing pump spee beyo
1600 rpm. By oing so make sure
e pump speed is less tan 170
EP9-183
rpm when e conrol rack graual
ly moves to a point of . mm
3) Adust e damper pring en he
stopper bolt Wen te pump stops
Low speed adjustmen operaion e conrol rack is posi
1) To adust te iling spring move tioe a a point of 1 mm From
the speed control lever all the way tat posiion urn te stopper bolt
o "fuel increase an pstio e so tat i cotacs te loa conrol
loa cotrol lever so tat e lever whe te rack is positioe at
cotrol rack is posiione a a pot a poi of .2 mm usig e cotrol
of 3.7 mm wen inectio pump ever Tur switch adjuste
spee is 1000 rpm I is cond Aus te stopper bol so tat te
tion adust te ide sprig ocate tur swtc is switce o at te pump
o te lower e of te tension spee 37 rpm wit te corol lever
lever so tat te control rack is positione at a control rack positio
positioned at a point of .2 mm of 7.2 mm
wen te inection pump spee is
decreased o 30 rpm. Also check
to ake sure tat wen pump
spee is less a 500 rpm e
cotrol rack is posiioe a greaer
tan 10 mm a pump spee again E9184
begins o icrease an t e rack
is positioe at a point of 3 7 mm
we te pump spee reces
650±0 rpm.
EP-10
Adjuig all-speed gvenr
1) Set te loa conrol lever to ul
2) Adust te sopper bolt so tat he
rack is posiioned a a poin of
mm when e speed corol ever is
reture all e way to ue in
crease with pump peed at 300
EP982 rpm.
FUEL SYSTEM 8-43
ADJUSTING GOVERNOR Pump spd
(SV goveo) KKC . 101699130 &
,·1o-r� 101681-150
. '!:f=
RSV governor performance curves 1,350 ± 5 rpm
KKC . 10161-120 &
J
7·.5 r---=A
03•1 101681170
BOOS TROKE o.2
9 2: � 1-
0
RO M: 750 ± 5r 00 ± 5
. 4•
� '" . ° t : f - -
.
U 1.2
CONRO ROD POO n)
ROD MI 969
DKKC No 1 016919120
u 7.t ,
CONROL RO POON ()
EF966
DKKC No. 1016819150
High-speed adjustment
1) To adjust full load stopper, move P9238
the stop lever so that it contacts the
m :f.-� stopper bolt and the control ack is
, ,st:- +--� in the specied position when the
injection up speed is 750 rpm. Cheking and adustng te speed
J 7dl variation factor
c _-,o�.J ±0.1 ackpsitin
t_.
I • -=o�f 4
KKC 1016110
5mm
1) The speed vaiation facto is ex
pressed in pecent, and is obtained
� 4±SOr": - --
KC 101681150 by subtracting the ated speed fom
I 107mm the maximum speed without lod
KC 1011120 nd dividing the remainder b te
U 7.J I '�I mm rated speed.
CONTROL ROD POSTION () K 101681170
EF96 104 m VARIATION FACTOR
=
NdNC
DKKC 1016819170
x 100 .. %
NC
� Nd 1_-_="-+."b
l Ne
bl+
t •
ROD IM: � a-f -
14±0.
EP9236
o " R ,c_
2) To determine the starting point of
RAK OTON
S9200
10
high-speed control, ove the stop
leve to "Full and the contol
ORO ROD POSIIO m
abv•
E968 lever all the way to fuel increase.
With the leves hld in thse posi 2) After adjusting the starting point o
tions, gradually increase njection high-speed control, detemine the
DKKC No 1016919130
pump speed Adjust the stopper speed luctuation rte b graduall
bolt so that when pump speed increasing the pump speed beond
reaches the speciied rpm high the high-speed contol beginning
speed contol begins and the point By doing so, make sure the
contol rack also begins to move pump speed is the specied rpm
fom its preset position (step when the contol rck gaduall
above moves to the specied position
FUEL SYT 8-45
ADJUSTIG GOVERNOR A hs me, conrm a y e
RIHT
scale panel of he adsing dece
(ype L governor) STAND
AGLE
AU
e angle of he conrol leer s
whn he prescred angle.
L governor peormance cuve
CONTROL ROD
LIMIT:
ADJT BL T
w F9
w
(60)
I
500 ! 15
3
(30)
below
225 2) Algn e cener pn of he adjus 93
4.5 6579 151l l52 ing devce o e axis of conrol
abve
CONTROL ROD POSIIN (m)
lever shaf Ths is accomplished y
EF9-170 displacing he scalecarrying op
par of e dece.
DKKC No. 101691-990
Pepaation
Befre he adjusmen of he governor,
the fllowng preparaions are made
whou il: F9·4
1 Suply lubrcang oil [ Inecion
Pump Ol (3453-020) by a
prescrbed amoun n he governor 2 Assgnmen of he idling rac pos
room and he cam room of he on
necon Pump. The gude screw of he dling sprng
Run in he eser_ Afer he runn s adjused so ha he conrol rack
operaon, check o be sure ha poson 9 7 may be obaned n he
governor operaes sascorily rescred pump speed 300 rpm
3 Befre he adusmen, he lock shown in he governor perfrmance
nu r he dlng spring and he characerisc dagram in suc se
governo shaf are removed ha he conrol lever s xed o he
The full speed sopped bol, he dlng sopper bol posiion Then,
dle sopper ol and e full load he gude screw of e idlng sring
sopper ol re loosened before is xed
hand n case he specfied conrol rack
djuent o th idling posion canno e oaned, e
idle sprng ass'y mus be canged
) Assgnmen of he idlng lever posi
on
The conrol lever is xed o he
poson where comes n conac
wh he idle sopper bol y he
etin the zeo dgee point of adjusing devce and he leng of
djusng deie he proecon of he idle sopper
Rerring o he gure showng he ol is adused so ha he conrol
op ew of e adjusng devce rack posion 5 mm of he goer
(0578260, se he angular nor performance caracersic
scale in he posiion sown, ruing dagram may be oned a e
wh he square and ghen he pump speed N = 8 o 00 rp.m,
ock nu below e lever and hs lengh is xed.
8 46 FUEL SYSTEM
Adjustment of the governor sprin 3) Wen the adustment of the contact
contact of te governor spring is fnised,
1) The projection L om the gover buid te gasket and the cap nut to
2
nor cover end surce to te guide the guide screw. e
N,
�
screw of the governor saf is 0
N2
adjusted so as to be 14 0.5 mm
±
w
w
"
and the guide screw is xed by te
.
Assignmen of the ful load cotro .
lock nut ack posiio :
If this L is out of te prescribed
2 1 Fix te conro ever to a posiion
vaue, the owing inconvenience where it comes in contact wih e
ma arise fu speed sopper bo and set
provisionay te fu speed sopper EF9•18
bot so as no to cause it to come
into the goernor contro area at
te prescribed ump speed Na =
about 1500 rpm in e governor
performnce caracteistic diaram I �
Ng �·
Nf 0
w
Na
.
EF9-176 e I .
' .
:
1 j:
0 -i . t
f L too arge:-
2
w
w
1
I
I
Governor shaf wi extend too .
I
.
itte to make he doube nut sere
_L_J-1
1 I
(mm) -
E918
the adusting purpose easi
. +-�
1
f L is too sma:
2 1,
3 Adus te fstening of the fu oad
Guide screw wi push on spring l I
seat too hard to enabe e fy Rf sopper bo in order o on te
weight to run to fuif position se of e soid ine from te state
CONTROL RAK POSTON (mm) -
of e doed ine n te goernor
2 Te contro ever is fxed o the EF9·178 perrmance cracerisic digra
position were it comes in conc
wit te ide stopper bo wit the
adusting deice and he doube
nut of te governor sf is adus
ed so at te conro rack posi
�
tions 7 .5 mm and 65 mm m be 0
2
obtained in te governor perform w
ance caracerisic diagrams 500 ± "
15 rpm and 930 50 rpm and e
±
doube nut is fxed
Wen te adusmen of te doube
nu is nised increse te pup EF919
speed and conrm th te contro mm
EF9182
rack position 45 mm of the gover
nor performance charcerisic
diagram is obtined 2 Adust te adusing nu of te
torqe cm is by te specia wrenc
(15791320 so tt te position
of te conro rack a te pre
scribed pmp speed N , N2, - in
e governor performance carac
teristic digram may be approxi
maed to R R 1 , is adus
2 - •
men is made to change the sae of
te doted ine o te stae of the
soid ine in the governor perform
ance caracteristic diagram E9183
FUEL SYSTEM 8-47
4) The works of the above iems 2) 2 At thi time conrm the scale
and 3) are alterately carried out in panel of the measuri device
order to obin he prescribed
goveror perormace characteriic
governor that the control agle of
the cotrol lever is withn he pre-
diaram, by adjuting he orque scribed range.
cam and he full load topper bolt
5 If he pump speed N 1, N2 , - the
3} Cofirmatio of the speed droop
Increase the pump speed and con
iem ), 2) ad 3) are precred i frm tha the control rack poion
the item of adusting he iection Rg is obtaed at he precribed
volume of he iectio pup, speed N of the governor pr t
lihtly tune he adutig nu of he rmace characteristic diagram.
full load stopper ol and he
orque cam o ha he precried
OOL AC POO ()
EF987
iecio volume ma e oaied
in he end. gf
Note 1
I
If the above adjustment is not con- E I
ducted completely, the prescribed in-
jecion volume nnot be obtained and
1
0
I
Note
The control rack position Rt o the
:';i is m ay cause the deficit in the out-
"
start excessive supply nnot be
p ut of the engine or the emission o
black smoke.
obtain even if the pump speed is
decreased with the control lever held
at the ull speed position
Ag
High sped control adjustmnt ONTROL RACK POSITON (mm)_
1 Fix he corol lever to a poio
86 2) Sop he rotio of he pump
eer a he corol lever positon
where coe i coc wh he where he pup speed fr obtain
full peed opper bolt and adu i e idlin corol rack position
he full peed opper bol o hat of he overnor performace
he hh peed governor corol 4 Increase he pump peed furher characterisic diagram i et (pont J
a ar at he precried pump ad cofr ha he corol ack i he goveror perfrmance
peed Nf how i h governor potio Rg s oaied. characeriic diagra) higher han
erformace characeriic diagra If he peed droop doe ot reach, he dlig precried rotatio rate
ad fix e full peed opper ol replace he overor prg ecaue roo of he poit H)
the governor pr codered to 3) The cofir ha the control rack
have ee deerioraed poiio of he srt increase
volue can e oined.
0w
"
.J
Cnfirmation of the imit of the
pum rotion rat for start volum
COTROL ACK POSION Jml
EF9·184 icrease e
_
) Whe cormi he sr exceive
upply volume, aipulae he w
h !
W '
conrol lever from the dl po
io to the full speed poo b
h _
� .H
graduall decreaing he pump ' r
speed fro aou 500 rp, ad
h2 h e
cofir ha he corol rack poi
io ca e oed a he
pump peed elow N of the gover
or performace characeriic dia
9
gra. Then oain he predeter
mied corol rack poition by
E9-85 manipulag he corol rack, or
the corol piion
8-48 FUL SYT
Confirmation of the rotation rate 2 Masure th timer advancing pr
limit for black smoke prevention frman by using th strobosop
5.51- 1073-0010 at th pump tster
Set the control lever at the idling
postion. Thn, st the pump spd to
N (below 225) rpm. When th ontrol
lever is manpulatd to th full spd
st position conrm th ontrol rack
positon Rf 12 mm at whh th
control rac poston of start inras 0 65! 00
E9192
cannot obtaind
Adjutment of the contro rack DKKC No 1016919120
liite
Atr ll adjstments ar ompltd,
remove the measurng dv control
rac (5.5) E94
f,.1:
Thread the sprng apsle so that th (3.85¢1 - -
control rc position I 14.8· m 2 f-
is obtand 3 Install using th ovr mountin
bolts so that th attach synhro
6! 3
nzr levr s ridng on th tappt of
CONTROL RACK PUSH ROD
919 th rernc cylindr {o
SPRIG
�; �'i:-·I 1
cylindr
E:-_
4 Driv th pump, st th switch o
DKKC N 1016919130 th stroboscop to O, illuminat
th sal plat with th light fro
th strobosop and masur th
SPRING CAPSULE
angular hang corrsponding t
EF9-189 th hang n spd
5) Whn th standard tming s not
withn th prsribd rang, dis
TESTING TIMER smbl th timr and replae th
timr spring or adust by mans o
1) Tmer perormance curves. adustng shis
F9194 6 Atr masurmnt, always st th
switch f th strobosop to OFF
br stopping th pump tstr
DKKC No. 101691-900,
1016919080,
101919090,
1011920,
101691910,
io50 900
9·9
101191,
10119160
1------
101691917 and
DKKC No. 101681917 10169130
(3)
( z.4tsl , __
EF919
4± 1000 35
F99
DKK No 101681915 DKKC No 10101915
9. AIR INTAKE AD EXHAUST SYSTM
Te air intake ad exhaust system consists of a turboharger, air leaner
and exhaust brake.
AR INTK[ ND ;0 . " :·,
' - � ·\
1
EXHAUST YST£M _.:
TURBOCHARGERS . ...... .. .. . . ...... 9- 1
AIR CLEANER .......... 9-11
EXHAUST BRAKE ........... ... . 913
( :·
·!l't
AIR INTKE D EXHUST SYSTEM 9-1
TURBOCHARGERS
DISASEMBLY
�
\
Compressor housing
2 Lock ut
3 Imler
4 Ba plate
5 Camp
:J 6
7
o pate
Bot
8 Thrust spring
9 Pisto rig
10 Thrust coar
11 Thrust bearig
12 Seal rg
13 Srew
14 Ceter housig
15 Gasket
16 Oil iet adapter
1 Srew
18 Loc pate
19 Bolt
20 Heat shroud
21 Retaiig rig
22 Joura rig
23 Pisto rig
24 Saft whl
8 25 Turbie housig
ER15-113
26 Bot
27 o pate
28 Camp
T048model
9-2 A INTAKE A XUT SY
OPERATIONS BEFORE meaure he pla n e adal drec
DISASSEMBLV ton and recor he resul
When disassembling or re-assemblng Maintenance standard
the turbocharger, use pecial ool k T04 model
(T04B model: 99760 Z5500 desgned 008 to 015 mm
r tha purpose Wear limit
0.18 mm
INSPECTION BEFORE
DISASSEMBLV JRADIAL PLAY
AAPTER
Pace the turocharger on a level sur
ace, and turn the impeler wih nger
p o determne wheher opeae
moothly then use the followng pro EP59
ceure o meaure bot axal and ad
al ply. 3) Unbend the loc plate, and remove
E5-06 he lck plae an clamp
Measuring play in the axial direction
Note
1) Set the dal gauge he end pla Make a matching mark mpressor
meaurng ool (9976 9000 Re hosing and back plate
place the al gauge adaper wh·
the end pla adapte 995
DISASEMBLING H
96001)
TUBOCHARGR PROPER
2) Se he end pla measurng ol o
tha the end of e aape con Po o sang dsaseml sp ea a
tacng he mpeller end f the pece of clean ol pape cardoad
sa on e work bench an mae machng
3) Meaure the pla n he axal drec mak a he connecon secon of
on and record he resul e turbne houng cene houng
Maintenance standard and compeso oung ha ere ER5
T04B model wll be no make durng easeml
0.025 to 008 mm Snce e urbocharger a pecon
Wear limit devce amle w e umo 4 Remove he compreso oung e
010 mm care ng careful no o damage he m
1 Ung a hex wench 0 mel peller
99545 Z5500 emove e l nle
Note
adape
e impeller and trine wheel are
precisely dynamilly baland and
nnot be repired Therefore they
mst e handled with extra scial
END PLAY re
ADAPTER
EP15·017
Measuring play in the radia diection
Set he dial gauge he raal pla
meauring tool (996 9000 an
replace e dal gauge aape wh ) Unbend te lock plat, remove the
te raal play aapter 995 lock plate, clamp and turne hous
96000 ing EP502
2 Ung a ex rench (9955 96000), Note
remove ol outle aaper ghten If the bolt has seized, apply "thread- 5) Pce Holng Fxe T0B
the meuring ool wit bol (T04B release oil to the olt then remove it, model 968 5500 n e n
moel 14220 9001 ) Make ure being reful not to dama the sht e te eel on h e
he euring element contac the wheel If necessa tap the turbine eel on t e eel e
cener o e housing wth a wooden hamer cn on
AIR INT A KE AND EXHAUST SYSTEM 9-3
9 Remove the pson n 2) Remove h hrust coar and
hrust bearn nd seal n
ote
Onc removed, the piston ring must
always be replaced with a new ring
when reassembling However sine
e shat wheel can be reud, be re
not to damage it
ER15-17
08 model R1520
T08model
6} Remove the mpler
• Usng a handle (993 9600), re 3 Remov the journal bearn
ove the ock nut nd then re
ote
move he meler by hand
B reul not t o amag the nter
Notes housing when remong the retaning
1. Sin ndng of the shaft s also re- rng
lated t the life of the turbo
harge aeful not to bend t 10} nbend the ock at nd re- • Usn rtnng rng plrs (99546
2 Suppo he shaft wheel by hand move the back te 5500 remove the pellr sde
while losenng the lock nuts reanng rng nd journal brn
ote
When the back plate nnt e remov
ed by han tap the nter hosng
lightly with a wooden mallet nd then
remove
7} Pul out th shaft wheel
EP15-03N
EP-15029
• Usng rtnng rng plers (9546
5500) remov th turbne sd re
p 11 Pu out th thrust sacer from
;,r
tnng rng nd journa bearng
the center of th bck ae and r
mov the ston rin from the
thrust spcer
Th ston rng can b removed b
hnd
8 Remove he hea shroud.
R5
• Remoe he wo etann ns
ocated n th rar of th cente
P150 Bmodel housng
9-4 AIR K AN EXUST SY
CLEANING ND INSPCTION
INSPECTION BEFORE CLEANING CANING Note
B extremely reful not t damage
urbocharger falre may smetimes fter sakin a the part n cean
par. Avid filing any rotatig par.
be de o falty engine parts t is detergent fr abt 20 - 30 mintes
Also sure to clean pa mpletely
hereore advsable t csey nspect remve dirt and grie wit a rgh
Failure to observe the ints ma
par or acclatn f carbn, pre brsh and then blw dry wit cm
u the parts to e mbalanced.
sence f dirt r dst bstrctin f pressed air
ol passages etc. prir cleanng s
that he case of problems may be
lcated easly
ntents f inspecton nspectn pnt
arbn accmlatin (ceck wheher parts haft wee jrna part
are jammed). tside perphery f cener hsin.
0 nside periphery f eat shrd .
0 nside wa f center hsn
rface f bades f saft whee
brcatn wear brnn, dsclratn etc). aft wee jrna part.
0 Jrna bearin
enter sng bre part.
rst clar
rst bearig.
il leaage nsde and tside periphery f trbine hsng.
0 nside perpery f heat shrd.
0 nsde f cpressr hsng
race f bac pate.
rface f bades f shaft whee.
0 ear srfce of ipeler
regn ater (ls chec fr bstrcton nsde f center sng
while cleang parts nsde f trbne case
0 nside f cpressr case
long enter hsing f hle
l inlet adapter
l otle adaper
AIR NTAKE AND EXHAUST SYSTEM 9-5
INSPECTION
1) Inspect pars vsually, replacing as
necessary
Inspecton poston Inspecton tem
Compressor housng. Scratches caused by nterference wth mpeller
Scratches on contact surfces wth ack plate
Cracks and dents
Clap Corroson deteroraton and damage
Turbne housng Scratches cased by nterference wth shaft wheel
0 Brrs caused by rst formaton
Thermal deformt and cracks
mpeller Corroson
Scratches caused by ntrference wth housng
0 Blade breakage and deformty
Gaugng n shaft holes
Shaft wheel Scratches from nrference wth turbne housng
',.;:
0 Blade breakage deformy and cracks
Shaft bnt
Dscolored journals and blades
Worn adnd scrached ournals
orn and damaged pston rngs
Back plate Worn bore
Wear and damage on conact srface of thrust collar
Scratches on rear fce of mpeller
Thrust collar Wear and scratches on conact surface
Worn and damaged psto rng grooe
Thrst bearng Thermal dscoloraton
Wear and scratches on conct srface
Center housng 0 ear and scratches on journal bores and nner surfaces of pston
rings.
Obstructon n ol hole
Heat shroud Scratches cased b contact
Thermal dscoloraton and corroson
'
9-6 A IK AN EXHAUT SYS
2) Meure he shaft wheel outside Measure and record the inside diam
diameer and record the resus. If eter of he center housing If mea·
he caculaed vaue exceeds wear sured values exceed wear imis, re
imi, replace he sahft wheel place he cene housing.
Journal part Beaing pat (1)
Maintenance standard Maintenance tndd
10.16 mm 15.80 mm
Wear limit Wear liit
1013 mm 1581 m
5035
Piton ring pat iton ring prt (2)
Maintenance standard Mintennce tandard
17.34 mm 4 eaure and record he inside diam 18.03 mm
Wear liit ee of he bac plae and he Wea liit
1729 mm disnce fom hrus colla conac 18.08 mm
surface o he bac plae end If
measured values eceed wea limits,
replace the ac plae
Inside dimete (C)
Maintennce tandard
1270 m
We limit
1273
Ditn (D)
EP15-034
Mintennce tndrd
1166 mm
We limit
11 R523
3 Measure he shaf bend and record
he resus If he measured value
has reached he mainenance sand
ard eplace he shaf wheel F15009
Maintenance standard
0011 mm 5 esure and ecord he icess of
he hus beaing If he measured
Note alue eceeds he wea limi e
Sin the turbine ide i hevy nd the place he hs beain
front end of the shft will float when Minten tndard
y V-k 36 m
magnet V-block r place another V We liit
block stop the journal part. 35
AIR NTAKE AD EXHAUST SYSTEM 9-7
RASSEMBLY
ER15-124
T048 model
Compressor husng 9 Thrust bearng 1 Bolt
2 Lock nut 10 Center housing 18 Clam
3 Imller. 11 Turbne housng 19 Lock washer
4 Pton rng 12 Heat shround 20 Bolt
5 Bolt 1 Shaft whl 21 Lock waher
6 Camp 1 ston rg 22 Bac ate
7 Loc lae 1 Bearng 23 Thrust srg
8 Sea rng 1 Retanng rng 2 Thrust ollar
9-8 AIR NTAKE AND XHAUST SYSTM
PREPARATIONS BEFORE ilicon carbide. Moreover teel
REASSEMBLY part mut be polihe it a
1) Repair light damae by polishin. poliin loth uing polihing
Aluminum par mut be polihe poer. Alay replace the follow-
with plihin clot, uing ing part.
Part name Quantity R57
Oil outlet aket
Oil inlet gake • Fit the thrut ollar ito the groove
pin of the center houin, an fit
Bolt (turbine houing) 6 the eal rin to the periperal
roove of te center houin
Bolt (center houing} 4
Note
Lock plate (turbie houing} 3 When installin the thrust llar, align
e portions inditd by doed lines
Lock nut (impeller
in the figure belo
Piton rin (haft heel
Lock plate (center houin 2
Seal rin
Journal bearin 2
Retining rin 4
Clamp (back plate 3
Lock plate (back plate 3 ER15-128
Bolt (back plate 6 1>
1
Piton ring (thrut collar
• e lock plate to intall the back y·:
I .
plate to the center houin an i ,
Clamp (turbine houin 2 ben te lock plae
Thtenin torque
86 to 04 kgc
REASSEMBLNG
0
TUROCHARGER PROPER Note
nsure that the bses are ready to be
Intall the journal bearin detached from the flanged portions o
Note the inlet and outlet
B reful not to damage the nter �+D·I
housing when installing the retainin
ring.
• Uing retainin rin plier (99546
25500 ntall the etaining rin in ER15-25
the rear of te enter houin ten
intall the journal bearin an te
outer retainin rin
Noes EP1043
1. Ensure that the on end o the re-
taining ring faces e oil outet and
nall the back plate
e round portion fas the journal • Coat the thrut bearin ith engine 3 ntall the piton ring to he haft
eaing. oil and then intall the thrut bear heel aembly uing the piton
2. Coat the inner and outer riphe in an piton ring to the thrut rin uide (T04B moel: 9973
of ournal bearin with engine oil collar 2500).
A INK A EXUT SYS 9-9
2 When tghtenng the nut, be reful 8) Seat he dial gauge to the radial
not to gve the bendng fo to the play measuring tool 9976 9000)
shaf. and replace the dial gauge adape
3. Kee the rated tghtenng torque with the radial play adapter 9976
and tghtenng angle 96000).
• Coat he impelle mounting and
crew ection of the shat wheel
and the urace o he lock nut sea DIAL G AUGE
with a thin coat of seizure pre
ventaive
• Fi the impeller into the sha
wheel and tighten the lock nut
temporarily.
• Atach the rotaing asembly to a
4) Install the hea shroud to the center holdng ixture 99768 Z00)
ousing asembly. whch has been placed in a vise EP15050
9) Attach the meauring element to
the center bearing and mesure it
radial play to detemine whether it
is within maintenance standard.
Mantenance standard
0.08 to 0.15 mm
Wear limit
ER15-117
0.18 mm
• Using a torque wrench tighten the
lock nut temporarily.
5) Place the center housing assembly Tghtenng torqe
on the compressor housing. 1 to 23 kgcm
6) Apply a coat of engine oil to the
haft wheel journal, and carefully
ert th hat wheel into the bore
n the center housing. Use Pick
(99767 96003) to compres the
piton ring and intll it while roat-
EP1551
n the whel shaft
Note
reful not to scratch or break the
piston ring. 0) Sea the dial gauge to the end
play meauring tool 99766
EP15-049
900) At thi time replace the
dial gauge adapter with the end
• Tighten he lock nut completely play adapter 976 96001 ).
with handle 99773 96000) by
°
turning nut 90 furher than the
temporary poition
EP1504
) nstall the impeller
Notes
1. Before nstallng the meller, clean EN PY
PTE
e arts and check refully the
tightenng srface for dust or for-
eign mater. EP552
9- 10 AIR NTAKE AND EXHAUST SYSTEM
11) Temporarily install the compres- 14 Insall h oil inl adaper and oil
sor housing. Attach th maring outlet adapter
elemen to th compressor housing Inlet adapter tightening torque
and masure the end pla of th 115 to 150 kgcm
shat to detrmin whtr i is Outlet adapter tightening torque
ithin mainenance sandars 184 to 219 kgcm
Maintenance standar d
0.025 to 0.080 mm
Wear limit EA15-129
0.10 mm
EF15011
OIL OUTET
Turbine housing ambly ange
(ew from exhaust outet side)
3) Attach the compressor housing t
EP15-053 the back plat by properly aligning
thir marks then righten th bolts il;:
with th clamps and lock plates in
12) Align the marks on th turbine place
housing and center husing attach
Tightening torque
the turbine housing to the rotating
115 to 150 kgcm
assembly, then tightn bolts with a
torque wrench (99537 550 with
a clamp and lock plat in place
Tightening torque
161 to 184 kgcm :,
]';
Not '!:
Apply a "gauge-preventive com ![(
pound to bolts. Do not confuse these
bolts (designed specially for high tem
1
i;:) !LH
perature use) with other conventional
bolts.
EF15-010
O OUTET
Cmpreor husng assemby angle
(Vew frm he ar ntake sde
A IK AND EXUT SYS 9- 11
AIR CLEANER
INSPECTON
Cyclone type
Air cleaner casng
2 Element
3 Clmp
4 Packing
5 Wing nut
6 Q.ring
EMJ.Q03 7 Dust cover
Sigle eement typ
l
1 Dust indicator
2 Cap
3 Body assembly
4 Inner element
5 Gasket nut
6 Camp
� 7 Vacutor vlve
8 Outer element
9 Gasket nu
10 Cover
Dua emet
9- 12 AIR INTAKE AD EXHAUST SYSTEM
1) Chec the external portion of the r cracs o damage. If fauly, re ) Vsuall chec the bod assembl
body assembly, cup assembly {dust place (f so equpped). ol pan assembl and rubber hose
pan assembly) and rubber hose for 3) Chec the element for deteroraton or cracs or other damage If
cracs or other damage. If aulty, or damage If necessar, clean or re necessary, repar or replace dam
rpar or replace. place. f the replacement perod s aged parts.
2) Check the evacuator valve assembly close at hand, replace the element 2) Chec the level of ol and o co
tamnaton If necessar add or re
palce. f t s tme for an ol chan,
Element Wor Wor nterval dran and replace ol
Oil lev.el chek
Ever 8,00 m or 20 hours of operaton 4,00 Every 1,000 km of operation
Inspect/Clean m or 100 hours n eremel dusy areas) or Oil hange
When red sgnal apears on the servce ndcator Every 4000 km of operation
Outer
eleent
Every 48,000 m or 1,20 hours or when red ) Chec the ar cleaner element or
Replace sgnal appears on the sece ndcator even after
ecessve cloggn or other damage
cleanng both he ouer and nner elements
If necessary, replace or clean t f
the perodc sece me has elap
If red sgnal aperars on the sece ndcator even
lean ed clean or replace the elemen as .
though outer element s cleaned
nner
element
ecessar
. )V �. . '
Element cleaning
,i
Ever4800 m or 1, hours or when replac- ,.
Replace Every 4000 km of ortio
' :j
n the ouer elemen
Ever 8,00 m or when repacng and cleanng
Dust cover Clean
the elemen
Nots 4) Chec sece ndcator for proper
1 When ervicing the air claner be operaton. If operatn ressure s
careful not to touh the flter par no whn mantenance standards, f ·,.
of the lement replace the aul par(s)
2 When installing the p aembly Function pressur of ser
follow the instruions closely (in-
Indicator
dited by embosing leers)
Maintenance tandard
577 to 693 mAq
Oil bath pe
1 Cleaner ca
2 Damper
3 Packing
4 Eement
5 Pcking
6 Reaining ing
7 Cover
8 Wing nu
9 Wshe
ET J-028
A INK AD EXUST SYS 9 13
EXHAUST BRK
PREFORMANCE CHECK lvr o te exhaust shuttr s con 4) Deprss the clutch pedal ad check
ctg the stopper bolt whch ses f te exhaust shutter s at th ull
When idlig adjustmnt or accelerator
th fully ope posto at this tm ope poston Also chck i th
pedal ad clutch pdal adustmnt has
(EXH B plot lamp lghted) lr s set to the ully closd posi
ben perfrmed or a swtch as bee
3) Check f th xhaust sutter s at to whe t clutch pdal s
rplaced, cck th prformance of
th fully open posto when t rleased.
th xhast brake cotrol systm as
acclerator pedal s depressed 5) Fall set te exhaust brak
follows:
Moreovr cofirm that the lver swtch to the OFF poston and
1) Start the nge and confrm hat
cotacts the ully closd poston confrm that the exhaust shuttr is
the "VAC wang lamp s x-
stoppr bolt whn the accelerator returned to the ully op positon
tgushed
pedal s elased (EXH B plot (EXH B plot lamp xn
2 St the xhaust brake swtch to t
lamp lghtd gused)
ON poston. Cofm that t
Exhaust brake sysem
ACCELERAOR
PEDAL
PUSH SWITCH
J
ON
J'i AR FLTE
1,:
NJECTON
PUMP
VACUM
PUMP
�----- ..j
EO
SH
EXHAUST SHUTTER
EF15-013
MUFFLER
9- 14 AIR I
NT
AK
E A
D E XH
AUST SY S
EM
OISASSEMBL Y
EF15-014
1 Cover Braket 21 ush od
2 Bushing 12 Loc nut 22 ton washe
3 Spndle 13 Cevs assemby 23 Gase
4 Body 14 Pan washe 2 4 Daphagm plate
5 Clevs pn 15 Cp pn 25 · Daphagm
6 Vave 16 ever 26 Diapha gm retaner
7 pndle 17 Bacet 2 7 Nut
8 Bushng 18 Cynde she A 28 Cynde hel B
9 Sea rng 19 png ude 2 9 Fle
10 Gaset 20 Spng
A IK AND EXHAUT SYEM 9- 15
Dismounting
1) Disconnect the vacum hose from
te frame ide.
2) Looen t leper mountng bolts
of te muler brackt
E509
E15017
3) ooen the clev lock nt and
remove te clevi fro t pu Dsasembn the exhau bake vave
rod
1) Reove the lver and te remoe
4 Reve te gasket an flter from the exaust brake ale asembly
EF15-015 te ower camber from e bracket
5) Clamp te two nut a te bol of
3) Reove e 4 exau utter e power chamber n a ve Ten, 2) Remove two eal rngs
ounng bol an remove e urn te connector a e op of e ·
exat brak unt ylnder ell wt a box wrnc
an reove cylnder ll A and
prng
CLEANING AND INSPECTON
) Clean all of te diasembled part
xcep oe made of rubber with
cleanng flud, ten wa wit wa-
r and dy torougly
2 Inpc te prng for breakage an
ecay If faulty, replace
E15016
E15018 3) Rplace te eal rng when ga
lakage, tc occur due o a faulty
Dsassembly he power chambe eal rng
Reove t bracket cover 6 Remove te apragm fro e 4 Inpect e bug for wear on t
2 Pull h clp pn and remoe the cylnder ell B Ten remoe te nnr and oter urface and the
clev n Ten reove te pu ro nt an daebl pndle for damage f faulty, re
cabe o te bracket daprag aebly lace eer part
9-16 AIR INTAKE AND EXHUST SYSTM
REASSEMBLY
EF15·020
1 Bo 0 Seal ring (spinde te) 9 Push rod 28 Sprng guide :;\!i,) r:;I
2 Cver Bracke 20 Lck nu 2 9 Spring
3 Busng 2 Bushng 2 Cevis 30 Gaske
4 Spnde 13 Sopper bo 22 Cip pin 31 Pisn washer
5 Body 14 Nu 2 3 Pain washer 32 Daphragm
6 Vave 5 Bracke cover 24 Cevis pin 3 Diaphragm pae
7 Sinde Fier 25 Lever 3 Nu
8 Busing Gaske 2 Cnnecor 35 Daphragm eaner
9 Sea ing body e 18 N 2 Cyinder she A 36 Cyner e B
AIR NTAKE AND EXHAUST SYSTEM 9- 17
1) Aemble the diaphagm plate and 5 Inall cylinde hell A and ping 11 When in full open oition, adut
diaphragm eaine to the dia- to cylinde hell B by tuning the the tope bolt until the dien
phagm. onneto of cylinde hell A ions "A and B ae equal
F5·021
E5025
F5006
2) Inll the gaket and iton washe 6 Afte intlling the filte and gaket
to the diaphagm to the puh od in that ode, inall 12 When in full close poition, adut
th clevi he toppe olt o that 01 to 04
7 Insll the wo seal ings to h of claance exit between the
xhaust ake valv ody valve and ody
Note
Install the seal rings so that the body
ght side is at the front as illustrated
low.
·:
3) Inet the push od into th dia
hag ebly asbld abov
and tighten with the nut Thn
culk th nut and uh od wth a
unch F5007
13 Intall th ow chambe aem
EF15-026
l to th ackt
1 Spindle 14 Connect the push od clevi and
2 S rng (spnd tght) leve with th clevis in nd cli
3 S ng (body tght) in
4 Body
8 Instll th xhust ake valve
assly to th ackt
E5-023
9 Insll th lv to th sndl
10) Adjut the valve osition
4 Cla cylind hell B in a vise nd
aeble the diphag sely
and ping to cylinde hell B
027
STOPER
BOLT
5005
E5024
9- 18 A IKE AND EXUT SYS
Note 3mm
15) Instal he bracket cover.
Adjust the positon of the clevis so
that it n be set with th push r od
pushe 3 mm to the power chambr
side. fter adustment, securely lock Remounting
te cleis with the nut
1 ntall the exhau brake unit o the
exhau ppe
2 nll he vacuum hose o he
power hamber A his ime, roll
the eal tape to the hamber hoe
de
,
10. ELECTRICAL SYSTEM
EF10·010
i\
Te electrical system coists of a starting motor, generator etc.
STARTING MOTOR ............ 10- 1
GENERATOR ........... 10-10
REGULATOR .... .... . 10-15
AR HEATER ........ . 10-16
ELECTRICAL SYSTEM 10- 1
STARTING MOTOR
DISASEMBi Y 10
i·.1
'It:.;!
u ,.·•;
1 Bolt
24 2 Gear case
3 Shift lever pn
4 Shft lever
5 Lock washer
6 Nu
7 Dust cover set
/· 8
9
10
Plunger
Sprng
Magnetc tch assemby
11 Metal ang
1 Cl
EF10-011
3 Pnon stopper
14 Pnon asml
5 Center eang
S25-4 model 16 Aatue asmbl
7 Thrust washer
8 Fed col
9 Brush (+)
20 Brush(-)
21 Brush sprng
2 Brush holer
23 Rea cover
24 Metal beang
25 oc washer
26 Bot
10-2 ELCTRICAL SYSTEM
1 Gear case
2 Pinon asmbly
3 Shft lever
4 Magnetc swtch assembly
5 Dust cover set
6 Cover
7 Thrust washer
8 Metal bearng
9 Shft lever pn
10 Clp 'Ff:•
11 Pnon stopper
·i'
12 Shaft aembl 1!
:1J
13 Thrust waher
'I 1
.·, • ir
°
il/j:
1 . i ·d,/.
14 Needle bearng
15 Ol seal i
16
17
Center bracket
0-rng
:I1l
18 Ball bearng
, !1.
19 Armature assembl
(1,
:!
, .j!
(
20 Feld col
21 Brush sprng f';
22 Brush
\
23 Brush holder
24 Thrust washer
�-
EF10·012 25 Ball bearng
26 Rear cover
27 Bolt
S25 model
1) Remove terminal nut M nd discon- 3) Remoe the agnetic switch as 5 Reove the through bolts l · ' •
.,:
nect the ead wre. sembly and separate the adjustng
plate (dust cover)
ER10-153
2 Reove the tightenng bolts of the
magnetic swtch assebly 4) Remove the plunger and sprng 6) Reove the settng screw
PlO6 4
ELECTRICAL SYSTEM 10-3
7) Remve he rear cover and thrus 1) Remove he shift lever pin 1) Remve he du cover (52
washer mde n)
THRUS WASHER
EP10-9
EP06
EF003
8) Pry he brush spring fm he brus 12) Pull he dus cver from the gear
hol_der and separate e brush. case Nex, pull ou he armature 16) Remve the gear shaft assembly
and shif lever (524 model geer wit the shif lever. (52
only) 110 model only)
E08
EF004
:;.1 9) Remve te brus lder assembl 13) Remve te armaure assembl. 1) Pull e pn sopper in he
un 52-11 moel nly direcion in ic e pinion is
l[i
!-1/ insalled and reve e pinion
,j.
! sopper clip. Ten remve he
'i pinion sopper pinion and center
bearing (S264 mdel nly)
1) Remove he ener bracke and
10) Separae he yke assembly. hrus aser (52110 mdel
only)
E5
10-4 ELECTRICAL SYSTEM
INSPECTION AND REPAIR Maintenanc standard Meaure the clearance beween te
Rear cver beaing outsde dameter of the gear shaf
Armature shft (S25-64 model) 003 t 00 mm (a the slidng porton of the pin
1) Support boh ends of the armature Cnter beaing ion an the insde dameter of the
shaft pace a da gauge gns he 013 to01 mm pinon. f the clerance excees the
slidng part of the cenr bearng Pinin bearing; wear mt replace the shaft and/or
meal turn he rmaure an meas 003 to00 mm pinon
ure he run-ou of he sf by Gea case beaing Maintenanc tandard
reading the deflecon of e da 003 to007 mm 003 to00 mm
guge ponter. Rpair limit epair limit0 mm
The bend is 1/2 of ths reading. Cntr baring 03 mm
When the bend exceeds the repar Othr0mm Measure he nde dameer of each
t replace. gear case sde bushng and calcuate
Wear 01 Artue shft (S25110 odel)
gear shaft diameter cearance. f the
aues exceed repar m repace
1 easure he arature shaf diame the bushng
ter a te "A pon. f the measur ,:
Maintenanc standad ·j•
e alue exceed he wear limt
relace he armaure ssemby 003 to00
Reir imit0mm
Maintnanc ndard
1595 to159 mm
4 urn he gear shaf and easure te
War imit1590 mm
run-ou of the shaf by readng te
A
moemen of e da guge pon
er. he bend s 1 2 of hs readng
ESD9-3 Bn repai imit01 mm
Measure the ger shaft teeth fr
2) Measure the armature shaf dame wear of damage If worn or dam�
ter at the rear sde {A cener bear EP10-2
age repace the gear shaft.
ing prt {B pinon berng ar {C
and pnon gear sde (D) If the 2 Measure he nsde dameter of ec
vaue excees he wear m re rear coer sde bushng nd cacu
Ate coil
pace he shf ae armaure shaf ameter cler
ance If te alues ecee repar 1 Col sor crcu tes
Maintenanc standard m reace the ushng. Check wth a grower tester. If te
Point A 1395 t1397 mm ron pece brates when the arm
B 2035 to 2037 mm Mainnanc tanrd
ure s urne whe s contcng
C 1395 t13.97 mm 003 to007
the armature core mounte o he
D 1395 to1397 mm Rpair imit0 mm
growler eser he rmure s
Wear Ceck e tooh rofe of he shorted and mus be repaced.
Point A 1390 mm armaure saf r wear or age
B 2040 mm If worn of daage repce the
C 1390 rmaure shaf IRON IECE
1390 mm
Ge hft (S25110 odel)
1 easure he gear shaft dameter at
he wo pons. If the meaure
values exceed he wear t re
pce the gear shaft
Maintenanc standard
ES10-21.
1595 to 1597 mm
E0·2
Wea imt 1590 mm
Col dsconnecton tes
3) Measure he inside diameter of ech Use the es cord atched o he
bearing e and cacuate the grower tester and the votmeter o
arature shaf diameter cearance. check votage induced in the ndiv
he vaues exceed the repair dua windings Bring this cord ino
iits, reace he earing eta conact at adjacent egmens of the
EL CTRICAL SYTM 10-5
commutator in makng ths check. Field col
If the same readng s realzed ·r Check for contnuity etween ter
a pars of segments, the armture mnals connectng the fled col's
s satsfactory If there s a low brushes If no contnuty exsts
eadng however, an nsulaton e feld col s broken and should
defct exsts A zero eadng on the be eplaced
other hand ndcates an open
wndng
ES098
2 Measure the outsde dameter of the
commutato If the measured values
exceed the wear lmt replace the
commutator
Noinal dimnsion
0 m (S25-64 model)
3.0 m (S25-110 model)
P1035
Wear limit
ES10-097 47 .0 mm (S25- model) 2 Check for contnuty between the
m (S25-110 model) yoke and any one of the feld cols
.
termnls If no contnuty exsts
, . 3) Col nsuaton test e feld col s broken and should
Ceck e nsulaton between com- be eplced
muto nd shaft If here s con-
nuty he amatue col nd saft
nsulaton js ault and should
herefore be eplaced
ER10-156
3 Measure and ecod he mca deph P10f
between he commuto segmens
If e measued alue exceeds e
ES10-23 rep lmt eplce e commut
o Afte undecuttng beel the
Brush and brush sprng
esue e bush heght If the
corner of e commuto w lues exceed te wea lmt e
#500 o #600 sandpape plce e bus
Mainenance tandard
Nona dnion
0.5 to .8 m 19.5 m (S25-64 model)
Repair lit 2 m 180 mm (S2511 model)
Wear l
15 (S25- odl)
Commutator 11 (S5-11 odl)
1 Wen the slng surce s ough
pols t lghl w #500 o #600
�CKSAW
DE
sandpper.
COMMUTATOR
Mesure and recod te eccencty
and ter of the sldng suace of COMMUTATOR BEVEL
the commuo If e mesured �
\1/ j
� CAT0
alues exceed the epa lm re
plce the commuao
Maintenance standard 0.05 mm NO GOO GOOES102
Reir liit 04 m
10-6 ELCTRICAL SYSTEM
2) Check brush spring tension. To do exists it ndicates faut insuation 2 hec the continity between the
so, attach the spring scale's hook to and the rush hoder shoud e re- magnetic switch teinal an
the brush spring through a coth paced terina M and replce hen here
and read the scaes indication when is no continuity
the spring is ifted off its contacting
surface
Brush spring tenson
2.45 o 305 kg (S25-6 mod)
285 o 355 kg (S25110 modl)
5-TERMINAL
Magnetic itch 3O
1 Chec the continity beteen mag
netic sitch terminal and the coil
case (metl part and replace when
there is no continty
Pinin
Chec the pnion teeth r ea o
daage necessary repace the
Brush holder pinion assembl
Ensre that the pnion de
Check for continuity beteen the
smoothy Replace hen the pinio
positive insuated and the neatie
bshing s scratche burned or
{base sides o the brsh hoder sin
otherise daaged
an insuation tester I continity ES10-29
REASSEMBLY
1 Metal ing
2 Thust washer
3 Bush
4 Bush spng
5 Feld co sseby
6 Mgetc tch ssembly
7 Adjustn te
8 Spn
Pune
10 Shft eve
11 Ge cse
2 Sht eve n
® 13
14
Pnon asbly
Pnon soe
15 Pnon stoe cp
1 Meta n
EF10-0
7 Re cove
18 Atue asseb
17 18 19
19 Cente bean
S25-4 model
ELECTRICA SYSTM 10-7
1 Magntic swt
2 Adjustng pla
3 Dust cover
4 Srng
5 Plunger
6 Shft lve
7 Shf lver n
8 Ga ase
9 Ga sa
0 Thus ase
Bsh olr
Bush
Brsh srn
4 Fl ol
5 S
6 Yok
Ball bearng
8 Bol
9 Ra ov
0 matue
Ball bang
-ng
Cn bat
4 Ol sal
5 Ndl bang
6 Thst as
non
· non so
9 Cl
EF10-06
0 al arng
Thst s
S2510 model Co
efore esemblng the starter motor, 4) Insll the dust cover 52
pply a coat of beaing grease to the model oly
llowing parts.
• Gear shaft
Bal bearing
• Amature shaft
• Magnetic swtch plunger
• Spe of bue spring ad pnon
assembly
1) Isert the eter bearing (52-64
model only ad pnon assembly to
the gear haft.
EP106
3 Insert the gear shaft assembly toge
ther wth the pon assembly, and
shift lever to the gear case (52- Instal the cente acket t te
0 model ony) gear case togethe it the thust
washer. 520 ode oy
EP10-20
2 Insa the pnon stopper Usig
snap ring pies insa a cip ad
snap the pno stopper onto the
EP1018
p E5
10-8 ELECTRICAL SYSTM
6) Inset the armatue assembly. (S25- 10) nset the bush holde assembly 1 Tighten the though bolts
110 model only
Ir
EP10-1
11 nset the bush to the us
holde and old the ush spng in 15 nset the plunge ith the sping
7 nset the amatue assembly place
togethe with the shft leve and
then nstall the dust cove S2564
model only
16 nset the magnetic swtch asem
EF10-014 l togete wt the adjust
12 nstall the ea coe
plat
8) nset the shft leve pn and tghten N
the nut wth the washe, an lock Align the set sew holes of the rear
washe to the gea case ver wth tho of the brush holder,
and algn the rear cover pn wth the
yoke hole.
E0· 013 EP09
1 Tighten the olts toethe with
9) nset the yoke assembl 13) Tighten the scews the lock washe
ER05
7
ELECTRICAL SYSTM 10-9
18) Insert the lead of termial M and Whe the L dimenso is outside emarks
tighten the nu with the washe and the maintenace standard, adjust Terminal vage
lock washe. by isertng the adjusting pate
Thee are two adjusting plates, one
LEAD is 4 mm thick and the other is 8
mm thick
� '\
I 2V
i BATTR
'/\ /\
(\
RVOUTO
COUTR
EP10-48 0·9
JUTNG T
ES10·3
ADJUSTMENT
Turn the switch on and off to en
The piio pushout positio dimen- sue tat the pinion gear pops
io by the magnetic switch is lled smoothly out ad in
the L dimensio and is adjusted to L= INSPECTION AFTER Measue the voltage equied or
0 to 15 mm Measure the satig AMBLY the piio gea to pop out To do
oto a a sigle uit Test the satig moto without an so gadually decease the esisance
Pass curent betwee the agnetic load to determie whethe all ad so that voltage applied to the start-
· switch termial S and goud igs are ithi the specifications i e moto iceases The measued
dicated below volge should be withi the main
teace sdd rage
S WITCH Mainenan sandard
Curren aintenance stanar
Specified valu Less than 18 vols
BATTERY Less han 70 amperes
(S2564 model)
Less than 110 amperes VARAB RSTOR
(25-110 mod el)
RPM
Secified value
P09
Motor than 4,0 rpm
2V
(S2564 modl) BATTR
More han ,50 rpm
2 Advce the piion ad stop at the (S25110 mel) S020
piio stoppe position
3 Meaue the L dimesio ith he
piio positioed as shown i the
igu
Maintenan standard
0.3o 1.5 mm
0.3 to 5 m
7
10- 1 ELCTRICA SYSTEM
GENERATOR
DISASSEMBLY
LT22563,LT225-56B
LT2400B,LT24015
LT22562LT22562S
LT2139,LT24014E
LR28011B
EF10·17
With vacuum pup type
1 Pey nut 10 Bearng rotetor 19 e t 28 Rea ovr
2 Lock washer 11 ang 0 re 29 e re
3 Plain washer 1 e 1 Diode 3 Brsh over
4 Fan pley amby 13 Key 2 Hoder 3 1 Bsh hoder
5 Spae 14 Roor asmby 3 Hoder· 32 Brsh
6 Font over 15 S ring 24 Dode 33 Throgh ot
7 Pakng 16 tator assemby 25 Termna assemby Vam m aemby
8 Pan etaine 17 Ba earng 26 E-termna bot
9 Ba eang 18 Se set 2 7 Termna over
ELCTRICAL SYSTEM 10- 11
LT225-59,LT235-48 1
Puey nut
2
Spring washer
LT225-66LT215-20
3
Plain washer
LT225-22C 4
Fan puey aemby
Spaer
6
Screw
5
ront over
Paking
7
Pakng retaner
8
10 Ba bearing
9
11 Bearng protetor
1 Pakng
Key
14 Rotor assemby
13
15 Sip ring
16 Stator assemby
17 Ba bearing
Sre t assemby
� i Srew
Srew t asemby
t asmby
�@1 Dode
! Hoder asmby
I Hoder asmby
Dode
23
l�3 :
Termna assemby
ermna over
E-ermna bot
26
Washer
2 7
9 Rear over
28
30 Brush over
Washer
Srew
31
33 Bush hoder assemby
32
Washer
Srew
34
Washer
E1-18 35
37 Through bot
Withou vacuum pump tye Lead wre asmby
,
:I 1) Remove the three bolts holdng the 2 Remove the brsh cover 4 Remoe the throgh bots
i
vacum pmp. Then pl ot the
vacm pmp n the shaft dire-
ton (wth vam pmp type
ony
Note
Since the pump is eqipped with an
oil al, remove the pump slowly so as
ot to daage this seal.
ER10·111
EA10113
3 Remove the brh assemby
5 Separae he front over and rotor
assembly
ER0-12 A10-114
10- 2 ELECTRICAL SYSTM
6} Remove the pulley
pulley nut,
nut, lock
lock washer
washer 10} Remove
Remove the diod
diodee holder
holder S
and plain washer.
�S W3
SW2�
X
ER10135
) Turn on switc
switches
hes SW 1 and SW 2
, ,
and increase generator speed o the
7 Usin
Usingg a
a puller, remove the pulle, raed rpm.
an and key. Rated rm
50 rpm
INSPECTION AND REPAIR
2 Se the
the variable
variable resisor a he max
resistane value, and turn on swih
) Inspect
Inspect the pulley for wear
wear raks SW 3 and turn oSW •
or damage. If faul, replae
replae 3) Holdin
Holdingg he gen
geneerator speed at the
2 Inspec each terminal for corrosion
corrosion raed rpm decease
decease he resistne
or damage If uly repair or re of the variable resistor unil the
place. generator's erminal voltae reaches
.� ER10·161
3 Measure
Measure resisanc
resisancee vaues
vaues between
terminals indicaed in he follwing
he raed value. Read the ouput
current
char with a 30-volt ester.
8 Remove the fron
fron cover and spacer.
spacer. Rated voltage 28ol
28ol
Outut urrent
LR2
LR200 -
80 amres (in)
LT24 0 -
40 amres in
LT235 -
LT235 -
I ;
35 ares
ares in i lj
LT2
LT25 5-
25 ares (mn.)
LT21
LT215 5-
ER10-133N
5 amres (in
ER1
ER10168
9 Use a soldering iron to unsolder
unsolder he Stato coil and oto coil
saor oil and diode holder solder Position of Measure he resian
resiane
e between
between the
connecions, and separate the stator Coninuiy
tes leads two oil erminals. If there is n
oil and diode: oninuiy between he terminals
+
the saor is open
op en and should be re
Note
-
When usng
us ng the solderng
solder ng iron sele A E Yes placed.
an ron with a large heatng pay Resstan
and unsolder the connetons qukly E A No LR28
LR280-0- B
whle
whle grasping the lea d wire wth
003 003 ohms
A N Yes
needle nosed pler s below the point at LT240-04
T240 -04B,LT240-
T24 0-5
5
whh the soldering iron nta the N A No LT240-E
wire so that as little heat as possible is 0 ohms
transmitted
transmitted to t he dode N E Yes
LT235-48
E N N 07 o hms
hms
LT225-63
F E Yes • 7
•
L T225-62 LT22
LT225-
5-59
59
LT225-5 6B
LT225-
LT22 5-22CLT225
22CL T2252S
2S
2ohs
ES916 Measuement of output curent
LT22
LT225-
5-66 6
ELECTRI SYTM 10-
10- 13
...
. ...
. 0.29 ohms 2) hec or slip
slip rng defection
defection
LT25-20,LT25-3 measured vaue reaches the repair
...
...
.. .. 0.48 ohms lmt, replace the roor assembl
Maintenance
Mainten ance standad
st andad 005 mm
Repai
Rep ai lim it 0 mm
F�0·48 Brush and brush sprin
1) Check the brush for ear f au
au
Checking for ground rto co
replace.
STATOR COIL
L T25-20L
T25-20L T225-,
T25-39LT225-5B
E106
L T225-63L
T225-63L T235-48,
LT225-22CLT22-2S
2) Perform a continut
continutyy test between
between R280-11B
R280-11BL L T225-
the stator col ternals and stator T240-04BT240-4E
core When there contnuty, te T240-1
col s shorted and ust be re- Noinal dimension 20 mm
place. ar limit 4 m
E1049 T22-59
Nominal dimension 45 mm
ear liit 5
Chc roto col conn
2 Check brush sprng
sprng tenson.
tenson. f ne
Slip ring cessary replace the brush spring.
1) Measure the
the outsde
outsde dameter
dameter of
of the T2-20L
T2-20LT225-2
slip rng. f the values exceed the T215-9LT225-5B
wear lmt, replace the rotor assem L T225-63L
T225-63L T225-5
bly T225-62SLT225-
3) Check the nsulat
nsulaton
on of the
the rotor T21-20
T21-20 T22-2 T25-48T240-04B
col and also check for open crcuts· LT2266 T240-4ET240-
at the slp rng secton. T22-9
T22-9T2-48 80 t 30 g
If there s contnuty between the T22-22C R280-B
slp rng and shaft or core the cl Ninal dinsin 4 22 t 34 g
or slp rn s grounded. Moreover, War liit 3
when here s no contnuty be T225-6T21-9
tween the 2 slp rngs the col s T240-04B
T240-04BT240-15
open. T22-B
hen the nsulaton s aulty or the T2262ST2404B
col s open replace the rotor as T240-4ET240-1 REPLACEMENT OF PATS
sembly Ninal dinsion 40 m
Ball bearin
Resistan War liit
LR280-11B 1) Remove thethe ball bearng
bearng ro rotor
T22-66
Ninal dimnsin 50 mm shaft fron sde and rear side usng
125 hs
ar limit 49 mm a ball bearng puller
LT22-62T225-62S
LT225-56B
BALL BEARI NG
128 ohs
oh s !EARING PULLER
LT226T2-48
LT240-14E
T240-04BLT240-1
1 hs
T22-22CR280-11B
ohs
oh s ES10-58
LT25-39
170 ohs
2) Press the ba bearngs
bearngs into
into pace on
T2-20 10-5 0
10-50
the rotor shaft front side and rear
• 8 hs
sde.
10-
10- 14 ELECTRICAL
ELECTRICAL SYSTEM
REASSEMBLY
Reasemble the generator in the re-
verse order of disassembly, being care-
l ot to mistake the nstallaton
order o the insulated wash.
1 Puey
2 Fan
3 Screw
4 Front over
5 tator ambly
6 Rear ove
7 Lead \ire asmbly
8 Brush assmbly
9 Termial bolt
10 Vauum pum
Puey ut
12 ock waser
13 Pan washer
14 Key
15 Sar ,)
-·
16 Packig
17 Packig etainer
etainer
18 Ba bearing
19 Barng protector .' . ·
20 Packig , ti
21 Rotor aembly
22 Sip ring
23 Ba bearing
EF10-9
With vacum pump e
@®
\ \ '
I
'
1 Screw
2 Pakng
3 Ball bearng
4 Sacer
,
5 Key i.f/,:·J' /j,;_
6 Pulle nut asmby
7 Packing
8 Pulley
9 Bearng potcto
10 Fan
1 Font over
12 ato assembly
3 Roto assembly
4 Rear ove
5 ea wire asmbly
16 Brush over
17 Tough bot
8 Bush assemby
9 Bal bearg
20 g
2 Die assemby
22 Insulatg bushng
SECTION A-A" SECTION e-e· SECION cc B' 23 Tmal bot
24 suatg bushg
25 E-emina bot
ER10176
Wo am pm ye
ELECTRICAL SYSTEM 10-15
EGULATOR
REGULATOR
INSPECTION Gaps in field relay
1) Inspct
Inspct each trminal
trminal for corrs
corrsin
in
. r damag If ulty, rair or r
plac th trnal
2) Using a 30-vlt tstr asur r
sistanc valus btwn trinals E F • IG
I asurd values ar nt wthin (BLACK)
(BLACK) (WHITE (BLACK/
BLACK WHTE)
spcd rang dsassebl r r
place the rgatr ER10-138
Position Rsstanc Psition f Rsstanc
tst lads (oh) tst lads (oh) ©
ER10140
+ - TZ7 TZ28 TZ35 - TL2-7 TZ28 TR2Z35
1 Screw
A IG 0 0 0 F s 0 0 0
Aduster
3 Point
F IG 45 45 F N 9 9 40 4 Adust scrw
IG E 22 22 - E 77 77 450
osn th scrw
scrw an
an adust
adust th
th
I N 24 24 600 E s 0 0 0
yk gap
IG 45 45 50 E 42 42 Maintenance standard
09 to 10 m
IG s 0 0 0 N 96 96 600
s IG 20 20 - N s 0 0 0
2) Use plrs to bnd
bnd th adustr t
adjust the cre gap
F E 77 7 7 - s N 26 26 - Maintenance standard
F N 96 96 - s 0 0 0
0.8to
0.8to 12 mm
F 0 0 0 s 65 65
3) Us plrs to ben th pnt
pnt to ad
ad
ust th point gap
Maintenance standard
04to 06 mm
ADJUSMENT 1 osen th scrw
scrw and
and adjust
adjust the
yok gap
Gaps in voltage reguator
Maintenance standard
YOKE GAP @ 0.9 to 1.0 mm
Msrmn f age regator
2) Us plrs to bnd th lwr cn ndr n d
act to adjust th core cap
1 Mak wrng cnn
cnncti
ctins
ns as shwn
Maintenance standard and turn th switch
swi tch n
08to 2 mm 2 Gradually
Gradually incrase
incrase genratr
genratr spd
untl it rachs 800 rp �approx)
3 Use plrs t bnd the uppr cn Turn o th switch
ct t adjust th pont gap 3 Gradualy nc
ncas
as gnrator
gnrator spd
spd
Maintenance standad up to th ratd rpm Rad th vlt
04to
04to 05 mm (TL2Z-7) ag ndcaton to s if the ndca
1 Low contact
045to
045to 055 mm ton s wthin th spcid voltage
2 Uppr contt (TL2Z28, TL2Z33) rang
3 just srew
4 Scw
10- 16 ELECIL SYT
Combinaton of generaor and 7 If any problem
problem is enountered
enountered in
egulator the speed characteristis readust
TL2Z·17 the voltage regulator core gap
LT215-
T215 -20 L T222, Voltage flucuaton
flucuaton grea
LT235-48LT24004B Wder re gap
LT240-15
LT240-15 Volae flcan
flcan all or
TL2Z28 lage decrease
LT225-62L
T225-62LT229, Sall re gap
LT215-
T215-39 39 ER10- 142
142
LT225-66LT2263
Pull·in voltage of field relay
5 Stop the generator
generator operation
operation and
and
LT25-56B repeat steps 1 through 3 above to ) Inrea generator
generator speed in the
LT225-62SLT2-14E see if the reglator voltage under no same manner as fr that under no
TR2Z35.......
TR2Z35....... LR28011B load is within the specified range. load and measure the pullin volt
Rated rpm age o the eld relay to determne
6 After
After the reglat
reglator
or voltage
voltage has been
been
5000 rpm
rp m f it is within the maintenane
properly adjusted chek the speed
Mantenance standard standard range
harateristis of the generator. To
2 to 30 volt do so chek r inrease in voltage Mantenane andard
when the high·speed ontat oper 14 t 18 ol (L2Z·,
ates following low-speed ontat TL2Z28)
operations The voltage should in· 9.5 o 125 l (TLZ33)
rease by approximately 5 volts Remark: a A ernal
�
w
C
<
CORE GAP LARGE
.. ·
1
. ,-·
0 r-< . NORMA
ER10·141
ER10·141 >
CORE GAP SMA
4) If the indication
indication exceeds the spei·
spei·
fied range, turn the adjusting srew ER10-143
� AC GENERATOR EED (RM)
until the reguator voltage under no 2 te pullin voltag
voltagee exeeds
exeeds the
oad is within the speifed voltage E1070 maintenane standard rage re·
range. adjust the adjustng screw
AIR HEER
INSPECTION
1 Frame Check the condi
condition
tion o the
the wiring
wiring
2 Insulating bock fr breaks.
3 Spring
4 Rbbn heae
2) Chec the heating
heating eement r ac
cumulaton of arbon I f necessary
clean
3 Check for roken or shortiruited
shortiruited
heating element. If neessary re·
place the ar heaer assembly.
EFl0-20
11. AUXILIRY EQUIPMENT
EF1-002
;�
Auxilary equpment consts of an air compressor, vacuum pump power
steerng ol pump and meter drver.
AUXILRY EOUPMNT 0
, '
AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1
Pulley drive type . . . . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . 11- 1
Gear drve tpe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
VACUM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
POWER STEERING OIL PMP . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Belt drve type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Gear drve ype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
METER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
AUXIRY EQT 11 - 1
AIR COMPRESSOR
PULLEY DRIV TYPE
SASSMB
�
�3
EF11-06
1 Conneco 14 Nut 27 Compression n g 40 Key
2 Packng 15 Lock washe 28 Pston pn 41 Cankshaft A
3 Packing 16 ylinde head 2 Snap ng 42 Canksha B
4 Unloade valve 17 Sud bolt 3 Pson 43 Nut
5 ing 18 Packing 31 Ol ng 4 Ball aing
6 Valve gude 19 alve seat 32 Bushing 45 Beang holde
7 Delvey valve holde 2 Suction valve Connecting od 46 Lock washe
8 Sping holde 21 Spng 34 Needle beang 4 Bol
9 Sing 22 Sucion valve holde 35 ock nu 48 Saght n
0 Delivey vale 23 ylnde packng 36 ock wase 49 Key
11 Packing 24 ylinde 37 Ol seal 5 ug
12 Valve seat 25 Cynde ackng 38 Cankcase 51 ug
13 Packng 26 Snap ng 39 Bal I beang
11-2 AUXIRY EQT
1) Clamp the drive gear in a vise 5) Remove th sna ring sing a na
through a copper plate and remove ring remover.
the nt and lock washer.
2) Using a puller, remove the drive
gear and key. SNAP
RING
2
9) lamp the crank cas in a vise and
arat the bearing holder from
EF010
th crank case ing the crank
6) Remove the iston pin and then saft with a copr hammer
3) Remove the clinder head assembly remove th iston ward.
and pacing, taing with a wood-
en mallet.
EF1-3
0) Remove the baring hodr
7) Remove the comression rings and
EFl 1-008 oil ring.
4) Remove the cylinder ing with
a copper hammer
E 4
1) Remove the acking.
EP11-089
8) Remove the ve bolts holding th
baring holder.
E009
AUXIRY EQT 11-3
2 Remove the crankshf assembly 7 Remove the deivery vve spring, CLEANING AND INSPECTION
fom he crankcase, pping the deiver vve, pcking vave e Cean al part except those mde
cranksha fon end with a copper and pcing from he cinder o rubber wih cenng uid, then
hammer. he wh with water and dry thorough
8 emove he connecor o the un-
loder vlve ) Inpect the clinder head and
crncae r damage I ult,
repir or repace
3) Inpect he peripher o the piton
nd the inide all of the clinder
r damge If ut, repair or re
place
4 Inpect the piton ring r damage
or uneven wer I ut repace
Meure the cearance beween he
EF11-16 piton ring an te ring grooves,
an record the resuts If the
3) Using a bearing puer, remove the meured vue reaches the wear
bl bering from the cranksht 110 imi, repace the piston ring or
piton
9) Remove the unoader vve guide Wear limit 0.1 mm
togeher with te him
EF11·17
14 Cmp the crnshaft assembly in
vie Remove he nut nd eprae
crnsh A nd cranhat B
EF1121
0) Remove the unoader vave nd
vve pring om the unoader vve EP11-13
guide
Cmp he cyinder he i vie
EF1118
a hown in the gure an remove 6) Meure the en gp piston ring,
the vave holder uing the vave n recor the reut I he
holding oo (99744 Z000 meured vlue reaches the wear
5) emve te cnecti ro n
imit repace the piston ring
need bearing om crsht A
6) Cmp the cinder he in a vie Wear limt 2 mm
trough copper pate nd remove
the deliver valve hoer Then
remove the pring hoder from the
eiver vave hoder
EF112
Remove the suction vave spring,
EP113 9
sucion vve, valve set and pck
EF1119
ing from he cylinder he
11-4 AUXIARY EQIPMENT
7) Inspect the coectig rod r 9 Measre the sde clearance of the 2 Ispec he delvery valve un-
cracks or damage If ulty, replace large ed coectig rod If the loader valve scti valve valv
or repar. clearace exceeds the wear limt sea valve sprig an vave holder
8) Measure the nsde dameer of he replace the coectg ro or r damage ad wear If alt
small ed conectng rod bshig cransha. replace.
ad record the resul. Calclae he 3 Inspect the oil seal lip r damage
Maintenanc sand ard
clearance between he iside dia- If ulty replace
0.2to 04
meer of the small ed conecig ear limi Not
rod bushg ad he oside dia- 04mm Gnerally, th ol sal should be re-
meter of the psto pi If the placed with a new one when ovr·
calculated value exceeds the wear Ispect th crashaf or cracks hauling.
limit, replace the conectig od or or damage. If ly replace
pison pn Check the ball bearg r any
sign of ueve rotio noise or
Wear 0.1
heat discoloraio. If ulty re
place
AU X IARY E QI ME
P NT 11-5
REASSEMBLY
Before reassembling, apply clean
engine oil to each rotating or sliding
surfae. In addiio, replae all
gaskes paing and O-rings with new
es
1-�:ri'
.
�
32
-·
1-.34
·_
EF11-023
1 Stud bolt 13 Deivey ave 2 4 Suction valve seat 35 Ba bearing
2 Nut 4 Deivey alve seat 25 Sprin g 36 Nut
3 Lock washe 15 Pacing 26 Cylinde head 37 Loc washe
4 Plug 6 Pisto pin 27 uctio alve olde 38 Key
5 Pug 7 Conecting od 28 Cylinder 39 Ol sea
6 Cocto 8 Needle beaing 29 Compessio ing 40 Cancase
7 Pacig 19 Cansaft A 30 Pisto 4 Bal beaig
8 Uoade alve guide 20 Spig 31 Cip 2 Casat B
9 Unoade ave 2 Sim 32 Ol ing 43 Staigt pi
0 Delivy ale holde 22 Pacig 33 Nut 44 Beaig olde
Spig holde 23 Suction vave 34 Key 45 Bot
2 Spig
11-6 AUXIARY EQIPMENT
1) Install the packing sucton valve sng a test rod measure the lft of
seat sucton valve and suction each valve Confrm that the
valve spring into the cylinder head. measured valve lift s withn the
2 Usng a valve holder tool (974 specfied values.
5001) temporarly tgten the Valve lift
sucton valve holder to te cylnder Delivery valve (A)
hea. approx mm
Unloader valve B
approx mm
S valve
approx mm
EF1120
8 ghten the delvery valve holder to
the secied torque
EF1122
A
Tightening torque
50 t 60 kgm
nstall te pston rng nto te
3 Assemble te srng and unloader UNLOADER iston
DELIVERY
valve to te unloader valve guide, VALVE VALVE
and then install the unloader valve No'te
Make ure that compreion ring
guide assebly to the cylnder ead
throug the sm I 1.• L· ·mnufaturer mr fe upwr
Tightening torque
5.0 to 60 kgm
C
� SUCTION V ALVE
10 nstall the cl to the one side of
te iston
ER11-124
6 Tghten the sucton valve older to
te specied torque usng a valve
older tool (744 001. And
ten usng a unch stae e
sucton valve older in three
locations
Tighning torque EF11-24
50 to 60 kgm 1 nsall te needle bearing and
EF11·21
Nte connecting rod to cranksaft A
D not take the ame pion that ha 12 nstall crankshaft togeter wt
previouly been taked te ey to crankshaft A.
4 nstll the packng delvery valve 13 ghten the nu to te spefed
seat packng delvery valve and torque and ske the nut n three
spring to the cylinder ead n tat locatons usng a punc
order. And ten teporarly
tghten the spring holder and
elivery valve holder to the cylnder
head
No
Make ure that the chamfered ide of
he valve seat inide crce fce the
valve
7 Install the packngs and connector
to the unloader valve gude
Tightening orque
EF9
30 o 35 kgm EF5
AUXIARY EQIPMENT 11-7
14) Install the ball bearings to the 8 Insert the crankshaft togethe 22) Install the cylinder head
crankshaft ith the cylinder into the crank-
case Tightening torque
Note 14 o 1.8 kg
Make sure tha rear bearing (small) No.
ark side faces inside and fron Noes
bearing (large) o mark side faces 1 Make sure ha the air intake pot
ouide ces o he rear (bearing cover
side when equipped on tractor)
-' 1� 2 Make sure ha the air intake port
faces to the front (pulley side)
r
'
(when equipped on bas)
EF11·26
15 Put the cylinde packing as shown
in the gre arond the connecting
od, install the piston assembly to 19) Instll the beaing holde to the
ether with the piston pin and cankcase
sten with the snap ing. Tighening orque
06 o 0.75 kg
EF1132
23 Install the plley together ith
the key and tighten the nt throgh
th washe
Tighening orque
70 to 8.0 kgm
EF1-27
6 Sgge the positions o the gap o
°
the piston rings in 180 incements EFl 130
in the piston pin diection.
17 Inset the piston into the cylinde 20 Foce the cyline into he cank
lne using a piston inset tool case, lightly tapping with a copper
(99754 96000 hamme
2 Put the oppe packing on the
! 1
cylinde
F 11028
1 Oil ring 4 Compresson ng
2 Pston insert tool 5 Cynder iner
3 Pison EF1131
1-8 AUXIARY EQPMNT
GEAR DRIV TYP
SSSMBL
>.
�,
/1!
1�
4�
;1:/
.1:
fl
,
"•
;:ii' ·
EF1-33 !
;,
jillt"l'
1 0-ng Snap ing Valve seat
i1:
14 27 3 Nut
2 Clne 15 Bolt 28 Suction alve 40 Lk washer
3 Bolt 16 Lock washe 2 Spng 41 Dive gea
4 ock washe 17 N 30 Suction alve holde 42 Cankase
5 0ng 18 Connecto 31 elvey valve holde 43 Ball beang
.6 Compesson ng 19 Packing 32 0ing 4 Key
7 Ol ing 20 Snap ng 33 Sping hole 45 Canshaft
8 Pston 21 Unloae alve 34 Spng 46 Ball eaing
9 Pston pin 22 Sping 35 0ing 47 0ing
Snap ng 23 Unloade alve holde 36 Deliey valve 48 Beaing hole
11 Conneting od 24 Bol 37 alve seat 49 ock washe
12 Metal 25 ock washe 38 Clinde hea 50 Bolt
13 Connecting od 26 acking
AIRY EQUT 11 - 9
1) Clamp the drive gear in a vise 5) Remove the bearing holder and O 1) Remove the delivey valve holde
hrough a copper plae and emove ing and -ing
he nut and lock wher. 6) Remove the piston assembly and
uppe metal
7 Remove the canksha assembly
0 ER11112
ER11·105
8 Remove the ball beaing 12 Remove the delivery valve sping
Using a puller emove the dive valve O-ing and valve seat
gea and key 13) Remove he conneco and pack
ing
14) Remove he snap ing unloader
valve valve sping and valve holde
ER11·106
9) Remove he compession ings and
JI oil ing
3 Remove the cylinder head assembly
ad O-ing 15) Using a valve holde tool (9974
25500), remove the sucion valve
holde
EP11·3 EP1112
10) Remove the snap ring, pison pin
4) Remove he cylinde and Oing and piston
16) Remove the sucion valve spring
valve valve seat and packing
CLEANING AND INSPECTION
1) Clean all parts excep those made
0
of rubbe with cleaning luid the
ash with ate and dry thorough
ly
) Inspect the cylide head ad
E11113 crankcase r damage ulty
repair o eplace
11- 10 AIARY EQUT
3) Inspect he peripery of e ison 7 Meue te nd gp ison ring, 12 Mesure e outside diamee of
and e inside wll of e cylinder and ecod e esuls If e e crnk pin, nd recod e
damage. If ul, ei o e- mesued vlue reces e epi esuls Insll e mel ino e
lace limi, eplce e ison ing connecing od and connecing od
4) Mesue e ouside dimete of te Compresson ring cp, and igen te nu o e
ison nd te inside diamee of Maintenance standard specified oque. Ten mesue e
e clinde, nd clculae of e 015 to 035 mm inside dieer of e metl and
clernce beween em Repair lmit ecod e resul. Clculae e
If e clculed value exceeds e 0m cleaance beween e mel and
ei limi, eplce e pison o Oil ring cnk pin om e measuemens
clinde. Mainteance standard If e clculaed vlue exceed e
Top 05 to 0.35 mm epi limi, eplce te metl o
Maintenance standard Repair limit cans
019to 0.25 mm 0m Maintenance standar
Repair lmit 0017 to 0083mm
028mm Repair limit
Skirt 01mm
Maintenane standard
007 to 03mm 13 Inspec e delive valve, un
Repair lmt lde valve, sucion valve, valve
0.8m sea, vlve sing nd valve older
dmage nd we If ul,
5 Inspect e ison ig dmage eplce
or uneven we. If ult, relce. 14 Mesue e valve sing ension
6) Msure e clence beween e nd free lengt. If e measued
9
ison ring nd e ing grooves, vlue exceeds e eir limi, e
and ecod e· esuls If te 8) Measure e ouside diameer of e plce e valve spring
mesued value eces e repir pison pin nd e inside diamee Free length
limi, epce e pison ing o of e pison pin boe, nd clcu Delivery valve
ison lae e clence If e calculed Matenance standar
Compression ring value exceeds e epai limit, e- 13m
Maintenance stanard plce e pison o pison in Sucton valve
002to 006 mm Maintenane stanard Maintenae standard
Repair limit 001L to 002T mm mm
0.0mm Repair lmt Teso
Oil rng Delivery valve (Whe co-
005L m
Maintenance standard Remarks presse to 9.5 mm)
003to 008mm T = Tight fit Mainteane stadar
Repair lmt L = Lose it 046 kg
010m Repair limit
9) Insec e connecing od r 037 kg
cacks or dmage If ul, eplce ution valve (Whe om
o ei pressed to 7 mm
10) Mesure e inside diameer of
e sml end conecing o and
ecod e resuls Clcule e
cleance between e inside dia
meer of e smll end connecing
rod and e outside dimee of e
pison pin If e cluled value
exceeds e epai limi, elace e
connecing rod o ison pin
Maintenance standard
002to 004mm
Repair limit
EP11-13 007 m
11) Insect e canksaf acks
o dage aul elae
AUXILIRY EQUIPMENT 11'-
Maintenane standard 15) Inspect the ol seal lip for damag. REASSEMBLY
0.45 kg If fulty, eplace
Bee esembng py cen
Repair limit
engne o to ec otng o sldng
0.36 kg Note
suce In ddton epce ll
Generay, the oi sea shoud be re-
ske ckngs nd O-ngs w new
Note paced with a new one when over-
nes
The value of free length is metioned haulng.
or reerenc. Ten, judg th ned
or replacement o the valv spring 6) Ceck e b ben ny
by measuring its spring tension. sgn uneven oton nose o
he dscooon I uty e
ce
EF11·034
1 Connector 11 Sucton valve holder 20 0-rng 29 Snap ng
2 Packng 12 Delvery valve holder 21 Cylinder 30 Pson pn
3 Unloader valve holder 13 0rng 22 0rng 31 Ol rng
4 Snap rng 14 Sprng seat 23 Ball bearng 32 Connecng rod
5 Unloader valve 15 Sprng 24 Drve gear 3 3 0rng
6 Sprng 16 0rng 25 Lock washer Meal
7 Packng 17 Delvey valve 26 Nu 35 Bearng cover
8 Valve ea 18 alve sea 27 Key 36 Ball bearng
9 Sucton valve 19 Cylnde head 28 Compesson ng 3 7 Canksaf
10 Spng
11- 12 AUXILIARY EQUIPMENT
1) Install the packing, suctio valve 8 Install the pakig ad connector
seat, suction valve, and suto to the uloader valve holder
valve srng ito the cylider head. Tightenn torqu
2 Using a valve holder tool {9974 30 to 3.5 km
25500), install the suctio valve
holder nto the cylider head 9 Install the pisto ring into the
Tightening torque piston.
10 to 12 kgm Note
Do not instll the iston ring wit its
g facin in t direction of the
iston in and vertil direction of the
iston in but with te manufacurer's
6 Usig a test rod, measure the lift o mark facing u
each valve Corm that the
measured valve lit is withi the
EP11·12
sefed values •
Valve lift
3 Install the uloader valve holder Deliver vlve (A)
valve spring, uloader valve ad arox1 mm
snap rig Unloder vlve (B)
rox 2 mm
Tightenin torque
Sucton vlve C
10 to 12 kgm
arox 3 mm
N A
OSION
E
A
10 Istall the sto wth the psto
n ad t the sap rngs
DELVERY UNLOAE
VALVE VALVE
SUCTON VAL.E
ER11-124
4) Install the delivery valve seat, O
rng, delivery valve ad valve srg 7 Usig a puh, stake the sutio
5) Install the O-rig ad delvery valve valve holder i three loatios
holder
Note E3
Tightenin torque Do not stke te sme ortion tht s
10 to 12 kgm reviousl been stk 11) Istall the ball bearing
Note
Apply a cot of 0.2 - 03 cc adesv
to three threads f the delivr vlv
holer on the sie f t clinder
hea
EP19
•' IN GAP
POION 12 Inser the crankshat assembly
EP1-23 nto the crankcase
AUX/IAR Y EQIPMENT 11- 13
ightening torque 6) Install the cylinder ead assembly
06 to 075 kgm together with the Orin
Tightening toque
5) Using a piston insert (99754 25 to 3 kgm
96000), install the cylinder to
gether with the Oring
Tightening toque
25 to 3 kgm
ER11-112
3) Install the metal into the connect
ing rod and connecting rod cap, and
install the connecting rod and
onnecting rod cap tgether with
the lock washe into the crankshaft.
Tightening torque
2.3 to 26 kgm
14) Insll the bearing holer together
with the O-ring
?I
·,
VACUUM PUMP
DISASSEMBLY ) Remove the vacuum pump from
: 1
1 the generator perpenicularly
i,
',i
lj
t1 J ·. _ ' , !
i
J
F1·036
15
2) Remove the pump cover
1Plug 6 Oi seal Rotor
2Pcking 7 Connecto 2 Vane
3 ckng 8 Packng 3 onneto
4 Vve aemby 9 Houing 14 Packng
5 ckng 0 0-ng 15 Pump coe 7
11- 14 AUXILIARY EQUIPMENT
3) Remove the rotor from the housing 3) Housing • Replace hardened or isolore oil
and remove the vane fo the Inspect the sliding surae with the seals (Inside diaeter of oil seal
rotor. At the same tie also remove rotor fr daage and replace when must be wihin 9 m.)
the 0-rng from the housin worn or daaed, especially when As a rule, replae all the ol seals at
the inside diaeter is worn or the te of each disassebly
daagd • Replae any discolred copper
4) Others packng Moreover, chek the
• Replace the 0-rn at each dis threads of each part fr daaed
assebly and replae when daaged beyond
use
REASSEMBY :+d
J.i!
Each sldin part ust be cated wth :r
1· 1
EF·038 enine ol when reassebled l'i
1 Vane -ring l.f1,l,
2 Rotor 4 Housing 1,:/
i1'/.
.1/f!·I
i
1·;:
l•
CLEANING AND INSPECTON ,' 1_
Cleaning
Remove dirty oil, dust, etal powder,
etc clining to each part and then
clean each part
Since unexpected daaged can be
easily detected while cleaning, perfr
cleaning work carefull
After cleaning, dry each part with
compressed air
nspecton
1) Vane
Measure the lengh, heght, ad
thcness of the vane and replae E9
when over the wear lit
Length
Nominal dimension
41.0 mm 1 Ba bearing 7Plg 12 Connector (exhast)
2 Oi sea 8Vave assemby 13 Bot
Wear imit
Roto 9 Hosing 14 onnctor
40.5 mm 4 Vane Generator 15 Pmp oer
Height 5 ring 11 Bot 16 Packing
Nominal dimensio 6 Paking
235 mm
Wear limi
22.0 mm
Thicknes·
Nominal dimensio
7m
2 Pump cover
Chec r aage at the sliding ) Assemble the ur vanes wth the E
surfce wth the rotor and replace end having he round char a Rotor
when worn or age the outse 2 Vane
A UXJIR Y EQNT 11- 15
2) shaped
With theoilsidegroovehavingat thethecover "+ 3) the
rotorside, Withhousing
the cover oil side
exhaust supplyinstalportl theat 5) Hold the pup perpendicular and
mounted to the geneator as shon
align with the shaft hole and insert pump
and coer
lck with the three bolts
washers. in the figure and install with the
into the housing.
also install the O-rin.At the same time three bolts and lock washers.
Tightening torque Tightening torque
0.6 to 07 kgm 06 to 07 kgm
4 housing
Align theoil sealrotorshaftshafthole hole and
figure atsate)the rightas shwn
Note
infiguretheeccentric (Lef Be careul that the oil seal is not
damaged by the pline of the shat
EFl 1·038
1 Vane 3 0-ring
2 Rotor 4 Housing
EF1141
EF2
POWER STEERING OIL PUMP
BELT DRIVE TYPE
1 0rng
SASSM 2 0rng
3 Sd plt B
4 Crtrdg ssmby
5 Sid plt A
6 Collr
7 Clip
8 Dowl pin
9 Covr
2 10 Reservor
11 Se wshr
1 12 Stud nd b o It
13 Brckt (rr)
14 Lok wshr
15 Nut
16 Nut
17 Lok wsr
18 Pull
19 Bot
/ 20 Lok whr
I 21 Brkt (front)
22 O se
½ 23 Bod
/@
4 0ring
25 K
26 Shft
,
27 Sprng
I 28 Sprg
� EF 1-3
29
30
31
Ref vv
0rng
Connto A
32 Conntor B
11- 16 AUXIARY EQT
1) Remove the pulley together with
the key.
EF11050
E1147
EF1 i-44 6 Remove the clip usin pliers CLEANING AND INSPECTION
Note The cartridge assebly i sub
Take care not to amage the sh, assebly consisting of a rotor, vane,
rotor an vane. cam ring, pressure plate, side plate,
2 Clamp the front bracket in a vise
and traight pin.
and remove the rear bracket.
1 Clean all parts except those made
of rubber with cleaning uid, the
wash with water and dry thorough
ly.
2 Insert vanes into the rotor slots,
akig sure that they re free to
move
EF1148
7 emove the cartridge assebly t
gether with the shaft and side plate
B, lightly tapping the shaft screwed
3) Remove the reseroir, lightly
side with a plastic hamer.
tappig the bri of the reservoir R1 14
with a woden mallet, and reove Note
the O-rig. If replacement s necessay eplace the 3 Ispect the vane chafer. I ulty,
rt assembly (cam rng, rotor replace the cartridge assembly.
and vane) as a set 4 Check the side plate, ad pressure
plate vane cntact surfaces, making
sure that they are nt scrtched.
eplace the cartridge assembly e
hibiting defects. If repair seems
fasble, dess the parts wth an
oilstone.
5 Ispect side plate , rotr ad side
plate B conact surces r wear If
ulty, repir the r replace the
cartridge assembly.
Repar lmt 001 mm
EF1146 Wear lmt 005 mm
Note
The above s on ctea o the n-
4) Remove e rot brcket 8 Remove the coector d ds vual pas The nal usage lt s
5) Remove he cover and sde plae A ssemble the ele valve sembly etemn b oveall jugeent o
AUXIARY EQT 11- 17
the performance after it is actually exceeds the wear lmit replace the 12) If th oil pressur fluctuates or if
istalled to the vehicle as the powe bod it is outsid pecifications, replac
steering oil pump. Moreover, since Wear limit 0.1 mm the fow control valve asembly
wear is produced by the gradual sliding CM80 and RM80
of related parts abnoral wear of one Maitenance standard
part may also result in trouble in other 825 to 9 kg/c 2
parts
9 Check the valve ping fr tigue
If tigued eplace Repair liit
Less han 80 kg/c 2
1O) Chec the pasage between the
powe sting oi pump and vave More than 90 kgc 2
6) Check the ball bearing for free play,
clogging If it is clogged pass a CK8
uneven otation and otting noise
wire though it and blow away dit Maintenance standard
Replae if fulty.
with compesed air 92.5 to 100 kgc 2
Repair limit 004 Repair liit
11) Measure the outside diamete of
the relief ave and inside diameter ess than 85 kgcm 2
7) Generall all rubber parts hould be More than 100 kg/cm 2
of the body and calculate the clear-
eplaced with new ons
ance If the calculated alue ex
8) Measure the ouside damete of th
ceeds the wear limit eplace the REASSEMBLY
shaft and th inid diamete of the
bd and valve
bdy bushin and calculat the Bere connecting eassebly dip al
claance If the calculated value Wear limit 003 m pats in clean powe steeing oil
"
,
,1
;
j,:'
;'i
1; ,
EF 11-003
1 Cam ring 11 Stud 21 Bracket (frot) 31 Lc waher
2
3
Rotor
\ane
j Cartrdge 12 Sea aher
Clp
22 Body 3 Sprng
13 23 Bhg 3 Sea
4 Doe p 14 Coar 24 Shaft Ba
5 Sde pate A 15 eervor 2 O sea 35 Sprg
6 Cover 1 Sde plate B 26 Key 36 Spool
7 Bot 17 0-ng 27 ock aher 3 Bal
8 Bracket rear 18 0g 28 Nt 38 Ba upport
9 ut 19 0g 29 Pey 39 0rg
1 ock aher 20 Sprg 30 Bot 40 Coector A
41 Coector B
11- 18 AUXIARY EQT
1) Insert the relief valve spring ad 2 Assemble t ten vanes wt te 7 Isl te Orig to the body ad
relief valve. Ad the ist con end havng th ound chamr on coat with grease Ad the istal
nector A together with the Orig te outsde the reservoir sea washers ad
and is conector B ots
Tightenn torqu gtenng torqu
Connector A 35 to 4.0 kg
7 .5 to 8.5 kgm
Connector B
35 to 45 kgm
F1102
5 Instal the clp F11055
8 sta the ear rcket
EF11-050
gtenng toqu
2) Clamp the body i a vise ad instal
25 to 30 kgm
the sring, -rgs ad side late B
9 Ista the ot bracet
gtenng torque
35 to 40 gm
10 Ista the puey together with
the key
gtenn toqu
30 to 40 gm
EF11053
6) Ista side pate A ad cover
F 11051
3) Inst the shaft
4) Assemble the cartridge (cam rig
rotor ad vae) insert the cartridge
to the body ad set the coar o
te chamfer of the rotor.
Notes
1 Mae sue that the camfered sd
of the otor spln and m n
dowel pn hole face upward
AUXIRY EQT 11- 19
GEAR DRI TYPE
SSSMBL V
1 Plug 21 Pate
2 0-ring 22 Sprng
3 Sprng 23 Dowel pn
24 Rear body
r coUol ,a,e 25 0rng
4 Sea 26 Pug
Shm 27 Lock washer
6 Poppt 28 Bot
Spng 29 Nut
8 Shm 3 Lo washer
9 Spool valv 31 K
10 Bo 32 Shaft
11 Lo wash 33 Snap ng
1 eal wash 34 Ball beang
13 Conno 35 Colla
14 Pla 36 Sna rng
1 -rng 3 Ol sal
16 Conno 38 Ball barng
0-rng 39 Font body
@
18 Van 40 0rng
19 Roo 41 0-ng
l,ji
Cam ng 42 0rng
1) Remove the ont body assembly_ 4 emove he snap ring rom he 5 Press ou he drve shf.
on body. -
EP11-14
2 Remove he ca n, vane, roo,
pte, sg, an stragh n
Note
Be sure t put alignment mks on the
cm rn nd pate.
3 Remove he O-rngs from he ron
body
11-20 AUXILIARY EQUIPMENT
6) Remove the snap ring and then CLEANING AND INSPECTION Note
press out the ball bearing. The above is on criteria for th indivi
The cartridge assemby is subassem
dual pas Th final usag limit is
bly consisting of rotor vane cam
detrmined y overall judgement of
ring pressure plate, side plate and
th pormance afer it is actually
stright pin.
installd to the vehicle as th powr
1 Clean all parts except those made
steering oil pump. Moreovr, since
of ruber with clening fluid then
wear is produced by the gradual sliding
wah with water and dry thorouh
of related parts, abnormal wear of one
l
part may also result i trouble in othr
2 Insert vanes into the rotor slots,
parts.
EP11·55
making sure that they re fee to
move
Check the bll bering r free ply,
7 Remove the oil seal uneven rotion and rotating noise.
Replce if ulty.
Note
Do not remove the oil seal unlss a Repair limit 004 mm
il lak is prsent. If it must b re-
movd, disrd and install a new on. Generlly l rubber prts should be
,;.
replced with new ones.
8) Ceck the valve spring r fatige ,)! :
E1114
If tigued replace.
9 Check the psse between the
/!1
lj:!
power steering oil pump and valve .
[
fr clogging. If it is cloged, pss ('
3 Inspect the vne chamfer. If ult,
replace the cartride sseml. wire through it and lo y dirt
4 Check the side plate nd pressre with compressed air.
plate vane conct surces, main 10 If the oil pressure fuctuates or if
sure tht they re not scratched. it is outside specictions replace
eplce the crtridge sembly ex the fow control valve ssembly
hiitin defec If repair seems Maintenanc tandard
feasible, dress the prts with n 675 to 75 k/cm 2
oilstone Repair limit
5) Inspect the pressure plate rotor nd Less than 650 kg/cm 2 ,
side plate contct suraces r ear More than 75 kg/cm 2
8) Remove the plug, O-rin spring nd If ult, repair them or rep lace the
f low control vlve assemly. crtridge assembly.
A UXJIAR Y EQIPMENT 11-21
REASSEMBLY
Bere connectig reassemby, dip a
parts in cean power steering oi
EF11·057
', 1 Plug 12 Lock washer 23 Lock waser
I
2 0-ring 13 Bolt 24 Nt
3 Flow control valve aembly 14 0ring 25 Shaft
4 Sprng 15 Connector 26 Rear body
5 0rng 16 0ring 27 Sprng
6 Plug 17 Front boy 28 Plate
7 0ring 18 Oil seal 29 Dowel pin
8 Connector 19 ollar 30 0ring
9 Bolt 20 Ball bearng 31 Ball bearing
1 Lock washer 21 Snap ring 32 Snap ring
11 Seal washer 22 Key
1) Inl the flw ontrol vave a 4 Insert the drve shaft nt the frnt 5 nstall the three rings to the ron
ey prng O-rng and plug. dy and intall the nap rng dy
2 Intall the il eal (if reved Note
6 Fx the two dwe pins on the front
3 Pres the all earing nt the drve Ater forcing the ball bearing into
dy and insta the rotor and ca
ha and nl the nap rin place, turn the drie shaft and verify
rng.
Note that it rotates reey
Be reful not to damage the oi seal
ntact suace of the drive shat with
the snap ring.
P-55
R11 ERtt-152
11-22 AUXILIARY EQUIPMENT
7) Face the rounded end outwrd nd 8 Instll the plte, sprng nd rer
insert ch vne n turn nto the body.
rotor slot. Tightenng torqu
3.5 kgm
EA11·53
METER DRIVER
DISASSEMBLY
1 Remoe the clp nd reoe the
dre ger from the houng
2 Looen the set screw t the houng
nd remoe the connctor bushng
nd drien ger
Noe
The se screw and connctor are
coaed wth lock te
3 oosn nd remoe the gree
nple
INSPECTION
npec the ger r wer nd de
nd check the bll berng pl nd
h buhng r wer nd relce
when ul
REASSEMBL
When resemblng reemble n the
reere order of deb b
rrrng to the fgure.
Reasembly precauon
1 Housing 6 Ball beng
1 Wen nsalng t v gar, pack
2 Gee pple 7 Cp
3 Pn 8 Drven e te o of housng saf w
4 Bhng 9 Bng greae Moreoer, add mre greas
5 ve gea 0 Conecto from the greas nppe after re-
asemby
2 Coat the connecor an set screw
wh ock t whn nalng thm
12. ENGI TST PROCEDUES
EF1-002
This chapter decrbes the test pocedues fo engine dianos and fo beak-
n and peformance checks, well how to check mng folowing engne
ovehaul.
MEASUREMENT OF COMPRESSION PRESSURE. . . . . . . . . . . 12-1
VALE TIMING MEASUEMENT . . . . . . . . . . . . . . . . 12-1
FUEL INJECTIN TIMIN MEASUREMENT . . . . . . . . . . . . 12-2
ENINE PERFRANCE TEST METHODS . . . . . . . . . . . . 12-2
ENGIE TEST PROCEDURE 1 2- 1
MEASUREENT OF COPRESION PRESSURE
The measurd vale of compresion 2 Be sure to set the engine stop lever
prssure is, alg wth preure in the no-injection position M
egne utpu oil conumpton 3 The nole hole should be cleaned G 30 / 2
el cnsmpon n mportant wy beforehand
of deeming the orrec ime fo L 25 / 2
egne eul I threfore, nece D
sary to percll mere 2 Cank the engne wth the tter to M
recrd egne cmprsin preure. meaue ompreon prer and 4 /2
egne rpm at the me tme
E 180 - 220
(
MEASURING COMPRESSIO
PRESSUR
1) Remove the nozze hode e
bl, n inert he compro Note
HI n";·"., gge into the nozze hole
: t Measurements should made two or
:,i
'
,
Notes three times for each cylinder while the
._;,
1. Remove all nozzle holder assem engine is still warm An average o the
blies from their cylinders and place
covers on their onings to prevent M
the entry of dirt or dust EF12-001
VLVE TIING EASUREENT
n cse of gne toble uch k EASURIG VALVE TMG
o wer or xe k oke Cec vlve clence dj
durng operon vlve tmin houl necery.
be meue aog wth the omre
2 Remove th V-e coong n n
n presure check nd npcton of coplng recycouetohe
e injecto quntty, et. n typ) and c pley 'y.
Intake valve theoretil data
°
Turn the weel n nral E12·003
Open BTDC. 5 ecton ntl te No. 1 pon t
°
Close ABD.C. 47 e top center on e ompon
Remarks roke.
Valve clearance 04 5 Se ge o tht he contct
Exhaust valve theoretil data ote
n onc w the pper
Open B.BDC 53
° I the flywheel has been rotated ex
° cessively, rotate it backwards beyond
e pn o h ne le
Close ATDC 9 d xut v.
Remarks the desired position then gradually
rote it back in the normal direction
f he eedle o he dl guge
Valve clearance egn to ove men tht the
03to 04 proper position.
v bnng ope; e
n o e neede ll top
e o Rd he ne
o he mng plte n
on d record e
meue .
) Atch e tmn pte t te end
of the cnkhf. A ch
needle pointer utzing the frot
ce munig olt, and lgn the
EF2-005 eedle t ".
12-2 ENGI TEST PROCEDURES
Note
Peorm this easurement at lest two
times, and obt ain the average vlue.
6) The sequence of measurement is as
follows:
1 Exhaust valve opens.
2 Intake valve opens.
3 Exhaust valve loses.
4 Intae valve loses.
FUEL INJECTIO IMIG EASUREET
If the engine emits excessiv smoke Tigtening trque 4) he delivery valve holder ill stop
during operaton, lacks poer, or 45 kg discharging fuel at a specifc
knocs frequently, the fuel injection fyheel position, hich ll b the
timing should be measured ) Install the timing plate and needle starting position r injetion when
Fuel injection timing pointer the engine is strted Read an
FD6
record the value indcated on the
°
BTD.C. 15 30'
timng plate
FD6T MEASURING FUEL INJECTION
Note
BTDC 17 TIMING
Perfrm tis esurement t least
1) Rotate the lyheel in the reverse tre times, and lculat e te average
drecton until th No 1 pston is vlue ·, .
:·;
PREPARATORY OPERATION 0
°
BDC on cmpression i·
1) Remove the nozzle ppe stroke
2) Remove the delivery valve holder of 2) Set the fuel control lever in th
the No 1 piston ke out the full-injection position.
delvery valve sprng and tign 3) Sloly rotat th yheel in th
the delivery valve holder to the normal drection while feding fuel
specfied torque by the priming pump.
EGIE PERFORACE TEST ETHDS
Engne errmane tests should only the engine, then chec the oil level BREAK-IN OPERATION
be conduted after makng sure hat agan
1) Crank the engne ith the starter
each porton of the engn s opratin 2) Connect pipes to the outlet and ithout fuel njecton, mang sure
normal wthout ol or atr leakage nlet of the poer steering ol that the needle of the ol pressure
during the breakin operaton pump, respectvely, and ad power gauge s movng Then, start the
steering ol to the ol reservor (f so engne
equipped) 2) Idle the engne r more than two
PREPARATORY OPERATIO 3) Durng preparatory operatons, mnutes, and make sure that the ol
1) hek ngne ol level If the engne remove the coolng n from the ressure exceeds 1 kg/cm 2•
has not been operated flowng engne, but leave the generator and 3) Make sure that ol s d properl to
reassem, sash a small amount ar leaner installed to t. the rocker shaft, njeton ump,
of engne ol to both the roker engne rear PTO and other areas
shafts and valves, idle the engne for
a roonged erod of tme, stop
ENGINE TEST PROCDURE 12-3
4) Peorm break-in operation aord Valve clearance K orretion oeiient
ing to the sequene and tie 03 to 04 Pa: Atmospheri pressure at the time
speiied in te olowing tle. o measurement [mmHg
Pw ter vapor ressure in atmos
Enine phere t the time o mesurement
]
�
1
speed Lod Period
(rpm) kg) (inute)
600 10
PERFORMANCE TEST
100% oad test
1) Run te engine, and esure nd
ir ie teperature [ ] °
2 ,600 10 reord te oowin ites at in IDING TEST
3 2,000 16
10
reen o 200 rm, startin with Peror this test with the dynamo
4 1,400 16
5
,200 rp, u to 3,200 rm eter disoneted, siutaneously
2) Te items to be eured are s
67 ein or iding seed, temperature
5
2,000 20 10
lows nd ressure o enine oil, ooling
2,400 26 10 1 ynmometer d water inet nd outet temperature,
2,800 33 10 2 Fue quantity onsumption rte olor exhust soke, hunting, et
8 3,200 Full lod 10 3 Enie oi ressure
4 Eine i teperture Idling (Water and oil temperature
in wter inet nd outet
°
Length of dynamometer arm 60 C 580 to 620 rpm)
.
0.716 m tepertures
Exust teperture Note
5) Durin the reakin eratin 7 R temerature, uidity The egine should not be stopped
period, measure te llowin nd ressure using sudden acceleration and/or de
itms, ming sure tat l dat is Oters e r lee o il, leration.
witin te maintenane stdrd e, oin wter d as Aso
e te or exhust NO-LAD MAXIMUM SPEED
Oil pressure soke d ter ertin on TEST
Maintenance standard ditions Peorm this test with the dynamo
Idling Higher than 1.0 kg/cm 2
3) uate sat output, st ·trque eter disoneted, simutneously
3,200 rpm nd ue onsumtion Te ult eing r opertion o overnor,
Higher than 4.0 kg/cm 2
ing ormlas re s lws teerture and ressure o enine oil,
' .
•,:
Cooling water outlet temperature
Maintenance standard
°
70 to 80 C
p =
2
60x 75 =
ooin wter inet d outlet temper
tures, or eaust soke, et
No-load maximum speed
Mc T WQ
(Water and oil temerature
C
:1,:1i'!; t_' .!J ·
=
°
60 C)
F 36b
°
i.!; W f
ji[! ;·
N f
=-
t Maintenance standard
ess than 3,450 rpm
000 Fr 3,600 br
Ii ! '�
detected t any spot.
'.,\/!1; Noise
= 1
p
=
Pt ACCEERATIN AND
Engine should not make
K = PPw j '7293
DECELERAT TEST
abnormally loud gear noise, 74 9
X + Perm tis test wit the dyn
etc.
eter disoneted Usin stop
) Ater ompletin the reakin oper P: Sht outut [PS] wt, esure te time needed r
ation, retiten the ylinder head : Shat torque [kgm] aeleratin rom idling speed to ma
bots, and he and adjust valve F Quntity o uel osued per mum seed d the time needed or
lerane our [liters/] deeleratio o mxium speed
Fue onsumption PSh to idin seed
Retightening torque
Length dynometer arm m] Accelerating time
15 kgm
: Dynamometer lod [kg] (Wate and oil temperature
Clinder head bolt tightening
uer o revlutions [rp] °
60 C)
sequence
oeiient o dynamometer in Maintenance standard
ase o PS Below 5 sec
b: Quantity o uel onsumed during Decelerating time
easurin period [] (Water and oil temperature
t Fuel onsumption time [Se]
60 C
r: Speii gravity o uel at te time Maintenance standard
EF3-086
o mesurement Below 30 se
12-4 ENGINE TEST PROCEDURES
DIAGRAM FOR OBTANNG WTER VPOR PRESSURE (Pw) FROM DRY BULB TEMPERTURE AND WE
BULB TEMPERATURE
:
c
5
E
E
�
:
"
/
a
1
a
.
"
3 Dry b ul temprate ( ° C)
ES12-7
13. SERVICE DAT
EF1-002
Tis chapter tabuates enine erformance data, various standards for servic-
ing the engine repair limits, wear liits and tghtening or ques for ey
re erence.
MAINTENANCE STANDARD TABLES . . . . . . . . . . . . . . 13- 1
Engine performance 13- 1
Engine proper and reassembly
. . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 13- 2
SERVICE OATA , ;"' �
Cylnder head and valve mechanism . . . . . . . . . . . . . . 13- 5
Lubrition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coong system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 9
Fue sytem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ir intake and exhaust system . . . . . . . . . . . . . . . . . . . . 3- 17
Eleril system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
uiliary equipment . . . . . . . . . . . . . . . . . . . . . . . .
13-21
ABLES O IGHTENING TORQUE . . . . . . . . . . . . . . . . . 3-23
SERVCE DAT 13-
MAINTEACE STANDARD ABLE
ENGINE PEROANCE
Maintenance
Item Nominal value Repair limit Remarks
standard
Idling spee Speed should be
580 • 620
(rpm) stabilized.
- -
Engine oil Iding - - Less thn 10 Oil temperature:
pressure 70 · 80 C
°
kg /cm 2 ) At 3,200 rpm - More than 40 -
Pressure - More than 30 Less than 25
Compression
Difference At 80 220 rpm
pressure
g/m2 etween - Less than 40 - (Engine warm
cylinders
Shaft output 70% of the nitial Value corrected by
PSrpm
-
vale atmospheric pressure
-
Shaft torque - 70% of the initial Value corrected by
kgmrpm value atmospheric pressure
-
When less than 40%
Engine oil consumption of the new car value Pay attention to the
(km/ Q
-
when operated under color of exhaust smoke
-
the same conitions
When less than 60%
Fuel conumption of the initial value Pay attention to the
(km/Q
-
when operated under
-
color of exhaust smoke
the same conditons
Acceleration an Acceleration - Less than 5 -
eceleration
time (sec Deceleration - Less than 30 -
No loa maximum speed (rpm - Below 3450 -
Inlet pen 5 BTDC
- -
valve Close 7 BDC
Valve Valve clearance
- -
timing Open 53 BTDC
03 to 04 mm
xhaust
- -
valve Close 9 ABCD
- -
FD6 15 30' BTDC
Crank angle with engine
Fuel injection tming - -
FD6T 17 BTDC
stopped
13-2 SER VC DATA
ENGINE PROPER AND REASSEMBLY
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
tion (mm (mm)
(mm) (mm)
Flatness of -
Lengthwie Less than 0.10 Repair if main .50
cylinder head
tenance standard (Grinding
mounting -
iewise Less than 0.02 is exceeded. allowance)
suace
� Outoround -
Less than 002 - -
0
J Liner L: Loose ft
Fitting
.
4 tting Upper -
0.01L 0.065 -
T Tigh fit
"
.5 bore allow
Lower 0.02T 0.025L
> ance -
Clearance between bearin -
L Loose fit
0.05T 0.02L - -
cap and enine block T Tight fit
40 to 5.0
Water pressure test
kg/cm2
Insie Inside -
100 10025 Measuring
diameter diameter
positions:
Measure with
Outo From top end)
the liner fitted Less than 0.02 -
<
roun 25, 7020
to the cylinder
: and 180 mm
block Taper
Less than 0.02 -
4
"
5 Flange projection from the - 0.02 0.09 -
>
u top surface
of block Dierence
between - - -
Less than 003
adacet
cyinders
Measuring
position
Outside diameter 100 998 • 99.90 -
245 mm from
the bottom of
piston skirt
C
learance between cylinder
<
0
-
0.10 0.17 -
liner and piston
Inside diameter of piston pin
34 34.00 34.02 - -
bore
Top clearance - 020 0.60 -
Clearance 1st
0.07 0.11 -
0.40
<
between piston
C
ring groove 2nd 3rd 0.04 · 008 -
040
·;
C and piston
0
.
<
ring O ring
002 0.06 0.20
End ap
0.30 050 15
Outside diameter 34 33.99 3400 -
', Clearance between pin and
C
-
0 0.03 0.05
. bore in piston
Clearnce between pin and 003 005 0.10
bore in connecting rod
S VCE DAT A 13-3
Nominal Mantenance
Sec- Repair limt Wea limt
Item dimension standard Remaks
ion mm mm
(mm mm)
Bend -
Less than 005 - -
or the length
Twist of 200 mm
"
V - Less than 0.08 - -
C
Side clearance of connect- When one side s
·. -
010 - 030 -
maintained at
ing rod large end
u
-
C zero
0
Cearance beteen large end -
0.04 -0.10 015
bearing and crank pin
-
STD 7 6 7592 - 75.94 752 7500
Journal 025 us -
75670-75690 - -
outsde 050 us -
75420-75440
diameter
075 us -
7517-75190 - -
Out-of-rond of journal -
Less than 00 0.02 -
Taper on journal -
Less than 00 - -
,
" STD 62 692 - 6194 6.80 6.00
"
Crank pin 025 us -
61675-61695 - -
u
ouside 0.50 s - 61425-6445 -
diameter
075 us -
61175-61195 - -
O-ofrondness of crank pn -
Less than 0.0 0.02 -
Taper of crank pin - Less than 0.01 - -
-
Runout Less than 003 - -
Crankshaft end play - 006 0.14 040 -
Clearance between ournal 015
- 005 - 012 -
and main beain
No 1 5 7. 4 5733 - 5735 - -
Camshaft jornal No 2 57.2 573-5.15 - -
outside diameter o 3 570 5693 - 5695 - -
No 4 568 5673 - 56.75 - -
Camshaft runout -
Less than 0.03 006 -
" Cearance between ornal
. -
002 - 0.0 015 -
and camshaft bshing
"
D6 48.485 4847 -48.51
48.01
Inlet
Cam FD6T 48.80 48 79 -48.83 - 48.32
profle FD6
Exast 48.425 4841 -4.45 47.9
FD6T
End pa
0.5 -5 030 -
13-4 SER VCE DATA
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remarks
ton (mm (mm)
(mm) (mm
C
Gear backlash 0.06 - 0.16 0.30
·;
Clearance etween
" 0.02 - 0.06 0.20
<
Idler gear shaft and bushing
(
End play 0.03 - .12 0.30
Eccentrcity between �
I
9
crankshaft and flywheel 0.20 .
w
Q
<
housing
.
Runout on con�cting
Less than .15 0.18
I surace of clutch disc
Depth of clutch disc
215 19.5
contacting surface A
: i ; ! ·r
.
"
!.:1uv
C f
0 Backlash of PTO gear 0.05 0.25 0.3
.b a
C
U
12 - 18 mm
V-belt tension A WATER PUMP
GENRAOR PULLEY
(Belt eflection when midpont s PULLEY
pressed with a orce of approx.
10 kg)
CRANK PULLEY
TEN·
SION
PULLEY
EF13-001
1 to 18 mm
GRAR WAR
M
l055
F 300
S VC DATA 13-5
CYLNDER HEAD AND VALVE MECHNIS
Nominal Maintenance
Sec- Repair limit Wear limt
Item dimension standard Remarks
tion mm (mm
(mm) (mm
Cylinder head height 90 - - 89.7
Length -
Less than 0.05 0.20 0.30
- Flatness
" -
4 Widh Less than 0.05 0.20 0.30
.
.
4
- When he bols
>
Cylinder head gasket are tighened to
1.3 1.25 · 1.35
u thickness he specied
torque.
Water pressure test - 3.0 kg/cm 2 - -
Inke 0
° °
00' 0 0'
°
- -
Seating ce
.
.
angle Exhaust 45
° ° °
45 00' 45 0' - -
.:
>
Width of contact Inake 2.2 · 2.4 3.5 -
i
>
etween valve
and valve insert Exhaust 2.0 2.2 3.5 -
Inke 0
° ° °
29 0' 0 00' - -
Valve face angle
°
Exhaust 45 ° °
44 0' 45 00' - -
.
Inake 2.0 - - 1.8
Valve head
i
> thickness xhaust 1.5 - -
1.3
Inke 9 8.97 · 8.98 - 8.83
Valve stem out
side diamete Exhaust 9 8.93 8.95 - 8.83
Inake 9 9.0 · 9.02 - -
Valve guide in
side diameter xhaust 9 9.0 · 9.02 - -
-
I,
·: Intake - 0.02 0.05 - 0.15
Clearance etween
:if
t
4
> valve stem xhaust - 0.05 · 0.09 - 0.20
i
>
Projection aove clinder - - -
15
head
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
13-6 SER VCE DA TA
Nominal Maintenance
Sec- Repar limt Wear lmit
Item dimenson standard Remarks
ton mm (mm)
{mm) (m
Free length Outer sprng 5712 - -
o eerence
(Both intake
and exaust) nner sprng 5426 - -
or rerence
25.65 Wen compress
Tenson Outer spring - - 23 kg
2835 kg ed to 435 mm
·;
(Both intake
" and exhaust nner sprng -
1235 -
11 kg
Wen compress
.
1365 kg ed to 405 mm
or bot nner
and outer
Squareness
Less tan 20 -
28 prngs of intake
and eaust
vaves
Rocker saft outsde dameter 20 1998 2000 -
190
Runout of rocker shaft -
Less tan 006 010 -
Valve rocker busng insde
. 20 2002 2004 -
210
diameter
Clearance between vale
u rocker ushng and rocker -
002 006 02 -
shaft
ree lengt 60 - - -
nsde spring Wen compress
enson -
32 kg -
17 kg
ed to 33 5 m
Wen suporte
Runout of push rod -
Less tan 5 -
at ot ends
am follower outside
. 2 1996 1998 -
1985
dameter
� leaance between cam
E follower and bore n -
002 006 -
012
cylinder block
03 or more
Valve clearance sould go, 04 -
sold not go
alve clearance adjustng equence:
" Cynder No. 1 2 3 4 5 6
2 3 4 s 6 7 8 9 10 11 2
5 Valve arangemen
IN EX IN X IN E N EX IN E IN EX
No 1 piston a TD
• • • • • •
on compesson sroke
No 6 pson a TD
• • • • • •
n compesson sroke
SERVC DATA 13-7
LUBRICATION SYSTEM
Nominal Miteace
Sec- Repair limit Wear limit
Item dimension stadard Remarks
tio (mm) (mm)
(mm) (mm)
ide clearace -
0.04 0.0 0.15 -
Tip clearace -
0.04 -0.10 0.20 -
Pump gear backlash -
0.16-0.27 0.50 -
Clearace between drive shaft
outside daeter and gear case -
0.03 • 008 0.20 -
ad oil pump cover bushing
inside diameter
Clearace between Cover -
0.03-0.08 0.20 -
drive shaft outside side
0
diameter and drive
0 gear bushig inside Case -
003 007 0.20 -
diameter side
0
Clearace betwee drive
shaft outside diameter ad -
002-0.06 - -
gear case
Free legth 54.2 - - -
Relief valve
sprig Whn compres
ension -
26.6-29.4kg - -
ed to 46mm
More tha
Relie valve opeig pressure -
10.5-115 - -
kg/cm 2
.
Q 08-
. Opeig pressure - - -
�r . kg/cm 2
3� Short
" Spri free length 66.2 - -
64
E"" valve
= 0
.
: >
1. When compress
Sprig tesio -
1.0 · 20 kg -
3.5kg
ed to 57.7m
4. 3
Opeig pressure - - -
4.7kg/cm 2
Regula
tor Sprig free legth 5.8 - - -
valve
When compress
Sprig tesio -
13.5kg -
7.2kg
Q
ed to 44mm
28-
<
Opeig pressure - - -
0 3.2kg/cm 2
Short
Sprig free length 68.6 -
5 9
valve
Whe compress
Sprig tesio -
9 kg - -
ed to 54mm
Cooler core, leakage test -
0kg/cm 2 - -
13-8 SER VICE DA TA
Nominal Maintenane
Sec- Repair limit Wea limt
Item dimenson standad Remarks
ton (mm (mm
(mm) (mm
18
t Vlve opening pesue 2.0 kg/m 2 - -
.s 2.2 kg/m 2
o .
0 �
u._
Vale pring fee length 15.9 - - -
C:
0 0
-
When ompess
pring tenion 0.74 • 082 kg
ed t 13 mm
Oil prere witc operating pee - 04 06 -
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
1,:·
SERVCE DATA 13-9
COOLING SYSTEM
Nominal Maintenance
Sec- Repai limt Wea lmt
Item dimension tandad Reaks
ton (mm) (mm)
(mm) (mm)
Clearance between body and - 0.3 0.8 -
mpelle
C
Outside diamete of impelle -
:
13.0313.05 -
C
fitting poton of shaft
= Insde damete of mpelle -
12.99 1301 -
Fitting toleance between - -
0.02T0.06T -
T: Tght it
shat and meplle
Less than
-
71.5
76.5 74.578.5
Geate than
81.5
Le than
Valve opening tempeatue 77.0
O 82.0 80 84 -
C) Geate than
87.0
Less than
83
"
.
88.0 86 90 -
Geate than
93
°
-
Moe than Less than
765 C °
-
°
10/90 C 9/90 C
°
- Moe than -
Les than
Valve lt 82.0 C ° °
10/95 C 9/95 C
°
-
Moe than -
Less than
880 C ° °
10/100 C 9/100 C
diato leaage test pessue - 0.5 g/cm2 -
Ung com
ate tan leaage test pessed ai
05 g/c2
pesue
Le than
" ate tan cap 0.6 0 g/cm 2
.
-
0
type 0.8 g/cm 2 Geate than
Valve 0.9 g/cm 2
opening Pesue de
pessue Less than
Radiato cap 0.8 07 g/cm2
- -
type 1.0 g/c 2 Geate than
11 g/cm 2
13- 10 SER VIC DAT
FUEL SYSTEM
Nominal Maitenance Repair Wear
Item dimension standards i imit Remarks
[mm] [mm] [mm] [mm]
Housing tappet hoe inside
24 24.00 · 24.03 - 24.15
diameter
Housing
Pump housing and tappet - 003 - 0.07 0.20
earace
Outside diameter of oi seal
6.8
cotat surface
Cashat
Camshaft pay i axial Adjust with adustin
0 0.0 00
diretion shim
Tappet outside diaeter 24 2395 - 239 23.90
Tappets Tappet adjustin bot head 0
depression
Control seeve and punger 003 00 02
coar pay
Punger Control rak slidin 50 r
Whe static
and resistance or less
deivery Static injectio start
vave 35 245
(am ift)
Difference in injection ° ° ° ° °
60 59 30' 60 30' 59 61
intervl of each ylinder
Tension ever, speed setting
ever and guide evel hole 002 - 0.09
and pin cearance
Tpe
RD Flyweight pin ad bushing 02 0.05 008
governor clearance
Load control ever and 0.0 005 05
bushin earance
Roer inside diameter and
roler pin outside diameter 004 008
learance Total
pay
Tappet roer pi hole ad 03
roer pi outside diameter 02 - 007
Feed ceaace
pump
Roer outside dameter wear 5 4.98 500 46
Housin and pisto cearance 0.03 · 0.06 0.5
Must be no air eaing from the push rod section when the dishare side
Push rod section air tightness is seaed 2 kg/cm 2 compressed air is applied from the intae side and he
fed pump is entered n the oil tank.
SVC DATA 13- 11
Nominal Maintenance Repair Wear
Item dimensin standards limit liit Remarks
[mm] [mm] [mm] [mm]
Time until the oil feed pressure reaches 1.8 kg/cm2
Oil feed pressure at 600 rpm udr he codition gve at the right Sucion pipe
is 30 secds or less. Iside dameter
Feed 300 cc r more of il ed in 15 secnds a 600 rpm 8 mm x length 2 m
Oil feed amount
pump under he condii gien a he righ
25 urns or less until sucin ataned by operat
Priming pump of the primig pump a a speed 5 100 Cam lift 6 mm
strkesminue
Flyweight and flange Adjust with
Timer 0.02-010 -
clearance shims
- -
FD6 - 20 kgcm2 - -
ectio startig
Nzze
pressure
FD6T - 22 kg/cm - -
i!
i:
,
/:
,.\
i:;1!
i!
13- 12 SERVCE DATA
INJECTION QUANTITY ADUSTMENT STANDARD
est conditi
Test condition
�
DKKCNo.101691-9220 DKKCNo11691916 DKKCNo1016919080
DKKC No11919320 DKKC No.101691906 DKKCNo.11691912 DKKCNo.11681917
DKKCNo101691918 DKKCNo.11691-910
DKKNo lOl 601•915
DKKCNo.101691910 DKKCNo11619
m DKKCNo.10169917 DKKCNo116919090 DKKCNo11619
DKKCNo 05780000
Nozl DKKCNo1515376 DKKCNo15015370
(BohType No ON 1212T)
Nzle DKKCNo105780208
DKKCNo 150314310 DKKCNo.150314290
or (BochTpe No. EF8511 /9A
Nzzle
injction
17 20 220
rssure
{kg/cm 2
Fe
ump oi
rssur 16 1.6 1.6
(gcm 2
Injecton
ppe
6 X 2 60 6 X 2 626 6 X 2 626
D ID I '
L
S No 2 i o
Tst oi ( ASTM No. 2D or S 4113
orBoch61V
Tst o
temr 404
ature ° C
Note The ue injecton pum (P/: DKKC o. 10168-9170, 1016819150 1016919120 and 1016919130) have been checked under
te te condtons specfed n te onvece adusment scftons A oter pump have ben checke under the tes ndtons
specified in te sandard adustmen scftons
SER VIC DA TA 13- 13
RAD governor
• DKKC No. 10691-9080, 1069906 101699180 10169-960 069970 and 069900
1) J IS No. 2 light oil (ASTM No 2D or ISO 413
ontro rack Pump speed Injecton quantty Varaton
Rmarks
positon mm) rpm) cc/000 strokes) (%)
97 000 53 566 ±2 Standard
Approx 82 300 7 07 ±5
After fue excessve
Approx 37 0 72 98 settng for start
Bosch o OL 6VII
ontro rack Pump speed Injecton quantty Varaton
Remarks
poston mm rpm cc/000 strokes ()
9.7 0 556 588 ±2 Sndard
Approx 82 300 82 8 ±15
After fue excessve
Approx 137 5 settng for start
• DKK No 609070 and 60950
IS No 2 ght o ASTM No 2D or ISO 413
ontro rack Pump seed Injecton quantty Varaton
Remarks
poston mm rm cc0 strokes (%
03 60 577 623 ±3
.!
i'
'·!
'"
.,
03 00 5 53 ±2 Sndard
;,:
. :·; ('�
:, '- :
.
03 700 29 6 ±
Approx 89 30 68 92 ±5
2 Bosch o OL 6VII
ontro rac Pum seed Injecton quantty Varaton
Remarks
oston mm rm cc/0 strokes (%)
03 60 60 67 ±3
03 00 563 595 ±2 Standard
103 700 47 79 ±
Approx 89 300 78 02 ±5
13- 14 SER VC DA TA
• DKKC No. 101691-9320
1) J IS No. 2 light oi (ASTM N. 2) r SO 4113
Conto ack Pump speed njection quantity Vaiatio
Remarks
position mm) rpm) (cc/1,000 strokes) (%)
9.4 1,000 5.4 55.6 ± Staard
Appox. 7.8 300 8.9 1.5 ±15
126 100 Moe than 70
2 Bosch oi OL61V 1
Conto ack Pump speed ection quantity Vaiatin
Remaks
position (mm) rpm cc/1000 stokes) (%)
9.4 1,000 54.6 57.8 ± Standad
Approx. 78 300 102 13.8 ±15
12.6 100 Moe than 72.8
RLD governor
• KC No 10191900
1) J S No. ight o (ASTM No. 2) or SO 4113
Cot ack Pmp speed necton quantty Varat
Remaks
poston (mm pm cc/1,000 stokes ()
115 100 658 704 ±3
111 100 5 561 ± Stadad
111 00 374 40 ±
9.7 300 10 138 ±15
2 Bsch o O V
Conto ack Pump speed ecto qantt Vaato . ' . .
posto (mm pm cc/1000 stkes %)
Remark
':,;
115 100 685 731 ±3
11.1 1000 551 583 ±2 Stada
111 00 390 436 ±3
7 300 117 152 ±15
RFD governor
• DKC N 101910
1) J S No. light oi S No. 2) or SO 4113
Contro ack Pump speed necto quantty Vaato
Remas
posit mm) (rpm (cc/1000 strokes) ()
9.9 1000 564 59. ±2 Standad
Appo. 8. 300 9.2 12.8 ±15
SERVCE DATA 13- 5
2) Bosch oil OL 61VII
Control rack Pump speed Injction quantty Varaton
poston (mm) rpm (cc/000 stroks Rmarks
(%)
9.9 000 58.7 - 6.9 ±2 Standard
Arox. 82 300 0 - 4.2 ±5
RSV governor
• DK No. 08-50
J IS N 2 lgh oil ASTM No. 2) or ISO 4
Control rack Pmp speed Injcton quantty Varaton
Rmarks
poston (mm (rpm cc/,000 stroks (%)
0.7 350 7 - 74 ±3 Boost prss:
abov 00
0.7 800 - 94 ±2 Sandard
above 300
Approx 2 300 07 - 43 ±15
• DKC No 08-970
J IS No. 2 lht ol (ASTM No. 2 or ISO 4
ontrol rack Pump speed Injcton quanty Varaton
poston mm Rmarks
rpm cc000 stroks (%)
0.4 50 2.4 - 5. ±2 Standard
0.4 900 37 - 8 ±3
Approx 2 300 02 - 3.8 ±5
• DKK No 09-930
J IS No. 2 lht ol ASM No. 2 or ISO 43
Control rack Pump spd Injcton quantty Variaton
Remarks
poston mm (rpm cc/000 stroks (%)
9.5 00 52 59. ±2 Sandard
Approx 82 300 0.23.8 ±5
• KKC No 069-920
J IS No. 2 lht ol SM o. 2 or ISO 4
Control rack Pump sped Injcton quantty Varaton
Rmarks
poston (mm rpm (cc/000 stroks %)
9 750 504 - 53 ±2 Standard
96 900 537 - 583 ±3
Approx 2 300 0238 ±5
13- 16 SER VC DA TA
RAD governor performance cu RFD oernor prormanc cu
L XV
A:
:)2 = • Set the speed control lever at "Full.
0
N OR
R
0 :i- t--�= � . �
00 · Jf --- ----- L
300 --=-- :g1�--= h
i �: SET R
s 0 0 t--'+ i2-
j 160 30t---7
•0
a
C DAMR5 PRING
30 o£. · 2"
a
00 0
0 ! ,. -- -
300 o.s o o
n
0 3 0 3
0 v EF9168
(m) E 96 " DK No 101691913
DKKC No. 101691-9080, 101691900 ONRO RO OON F964
10119180, 1016919160
and 10191917 Set the load control lever at Fll
9 r2 =�·2m
:i!; "u '·J
'i
SPIG SET -- -
I , .
0
t
0
w ROD M
U
w
.
. 82 ROD OON U ,
(mm)
above'
ONRO
F962 CT PTI ) E9169
DKKC No. 0919100
EF9165
DKC 1016919120
I RSV oernor pormac cu
TTI
TT j BOO ROK RL ornor prormanc cu
,.
[
C
1750+,s
a l
" u·
�
gr J
62
± ROD M
a ,d
,.
m
Q
8.9
Q
above
I
aboe
ONRO ROD OON{
7. 2
Q
F916 F9166 below
DKKC No 1016019070 and
101601915
DKKC N o. 101681915
FE ESSIE C
SETIG F EF97
ST 96 �8· 2m Boot ompenator perfomane urve
9
bl
175 t
6 E
w 4
6 J lO±--+-=.
0c z
w 0
U 3 u i,r 4
5 + U 6
= -o r0
be l465
: 480clo t =-+
!0
-
�
0
e
0 =� 125 25
O 2.5±05 7. abov e9,4 EF9-1 3 L
ST PESE (mmHg)
C 9.3PSITI (mm EF967 E958
DKKC N 99 2 0 DKC No 1081910
SERVCE DATA 13- 17
AIR INTAKE AND EXHAUST SYSTEM
Nominal Maintenance
Sec Repair limit Wea limit
Item dimension stnad Remarks
tion mm) (mm)
(mm) m
Play in shaft axial diection -
0.02 - 008 -
010
Play in shaft radial diection - 008 015 - 018
unout f shaft - 0.11 - -
Journal
1016 - -
1013
. Outside diamete pat
of shaft Piston
. 17.34 - -
17.29
ing pat
:
I
nside diamete of bac plate 1270 - - 1273
Beaing
Inside diaete 15.80 - - 1581
pt
f cente
housing Pistn
180 - - 1808
ing pat
Thust bering thicness 436 -
435
One side
Clerane between on
- 01 04 - -
�
.
" .
: buttefl valve
X Ttal of
L " and bd - Less than 05 -
both side
13-18 SER VICE
VICE DA TA
ELECTRICAL SYSTEM
STARTING MOTOR (S25-64B, S25110)
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standad Remarks
tion (mm mm)
(mm) mm
mm
52-64B 19. - -
11.
Bush height
.
52110 18 - - 11
52-64B - 2.4 · 3.0 kg - -
Spring
tension 5-110 -
2.8 · 3. kg -
,
Commtator outside diameter 48 - - 4
0
Eccentricity and tape of
E 0.0 0.4 -
E sliding surace
0
Depth o undercut - 0. · 08 02 -
Rea cover -
13.97 · 1.9 1390
bearing
Center beang -
20.7 - 20.3
20.3 - 2040
Outside
diameter Pinion beaing -
13.97 • 13.9 - 190
c Gear case -
' 13.97
13.97 - 13.9
13.9 190
bearing
� Rear coer - -
0.03 • 007 020
. bearing
.
V
Clearance
Center beaing 0.1 · 017 030
between
each part Pinion bearing -
0.06 - 0.10
0.10 020
and shat
Gear case -
0.03 · 007 020
bearing
Shat bend - - 01
Clearance between pinion and
pinion stopper with plunger -
0.3 · 1 - -
clearance at zero
52- - -
Less than 70
Current 6B
<
a
0 (A) 52
a Less than 110 -
Unde no 110
0
0 oad Geater than
E
52-64B
O ,000
·; PM
.
reater than -
V 52-110
300
Pno pop out oltage V - Less than 18 V -
S ER V
ICE DA TA 13-
13- 19
Nominal Maintenance
Sec Rpair limit Wear limit
Item diension standard Remarks
ion () mm}
(mm (mm)
Cearance between shaft and - -
0.03
0.03 - 0.07
0.07 0.20
0 gear case
- -
. '
. V
<N
Shat outside diameter 1597
1597 1595
1595 15.90
v-
Sat bend - - - 1
GENERATOR
Nomina Maintenance
Sec dimension standard Repair imit Wear imit
tion tem Rearks
m mm (mm mm
Brush LT22559 14.5
4.5 -
7.5
heiht
Others 20 - 14
! Spring LR288-11 B 255 - 345 g - -
,:i
'·
! tension
Others 180 - 360 g -
LT2256 316 - - 306
LT215-0
LT22522C
LT2255 34 - 33
LT22566
Sip ring
LT235-48
outside
diam
� LT21539
" eer
LT22556B
LT25-62S
LT225-63 40 - - 39
LT240-04B
LT24014E
LT415
LR80-11B 50 - 49
Eccentricity and taper o sip -
005 0.3
rin
LR280-11B - 0.03 -
LT24004B
Resist- - -
ance Stator LT2414E 0.11
°
·o LT24015 At 20 C
vale coi
LT235-48 - 017 - -
LT22563
019 - -
13-20 SERVCE DAT
Nominal Mainteace
Sec- sandard Repair limi Wea limi
Item dimensio Remarks
tio mm) mm) (mm) mm
LT22522C
L T22556B
L T22559 - 0.24 - -
L T22562
Sao L T22562
coil
L T225-66 - 029 - -
L T21520 - 048 - -
LT21539
L T21520 - 180 -
L T21539 - 170 -
·o Resis
u
ance LT23548 - 137 - - °
A 20 C
valve
L22522C
L T2255 - 133 -
LR28011B
Roo
coil LT22563
L 24004B - 131 -
L T24014E
LT24015
I:·'
L T22556B t.
L T22562 12.8 - -
L T22562
LT22566 125
REGULAOR (TL2Z-28, TL2Z-17 R2Z-35)
Nomial Maintenance
Sec Repir limit Wea limi
Item dimesio standard Remaks
tio mm mm
mm mm
Adjusmen volage
volage (V) - 28 30 -
� Yoke ap - 09 10
10 - -
Coe gap - 08 1.2
1.2 - -
Pon ap - 04 0.5 - -
Ataction volage V 14 · 8 -
> Yoke gap - 09 10
10 -
�
-
Coe gap - 08 12
12 - -
d
L
Pont gap - 0.4 06
06 - -
SERVICE DAT 13-21
ILIAR
AUXILIA
AUX PME NT
QUPME
RY EQU
COMPRESSOR
COMPRESS OR PULLEY DRIV
DRIVE TYPE
TYPE
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Re marks
marks
tion mm) (mm)
(mm) mm
mm
, Charging Engine 400rpm - Less than 155 - -
Tnk capacity
0 < 30Q
r
. c time speed
�E sec) 2,00rpm - 4 - -
Q8 kg/cm 2
Cylnder nsde diameter 60 - - -
Clearance between pston - 0.15-0.18 - -
and lnder
Compression
Piston ring
- 2 -.4 - 2.
rng
.
.
end gap
Q
0 O rng - .2 -0.4 -
2
.Q
0
Clearane Compression
"
" -
.1-.44 .1
. between ring
-
Q iston ring
and ring Oil ring .2-.054 - .1
u
groove
learance between onnetng
rod small end bushng and -
.5-.035 - 1
piston pin
Sid clearance of onnecting - .2 -.4 -
.4
rod large end
COMPRESSR GEAR DRIVE TYPE
omnal aintenane
Se- Repar lmt Wear lmt
tem dmenson standard Remaks
ton (mm mm
mm mm
mm
. 8 Charging Engine 40rpm
40rpm - ess than 43 - - Tank capacity
, C
tme speed 2rpm 30Q
�E se)
se)
-
9 -
Q8 g/cm 2
Cylnder nside diameter 7 - - -
learane ison top
2nd land)
land)
-
.19-.25 .28 -
between
pston and Pston sirt -
.7 - 13 .18 -
nder
Compression
Pston rng
-
.15-35 1. -
rin
end gap
Ol rng -
.15-.35 1
.
Q Compression
0 dth of 2.5 -
Q
rng
0
ring groove
"
" Ol ring 4 - - -
.
Q
E learance Compression
0 .2 -.6 .1
u between ring
- -
pston rng
and ring Ol rng -
.03-0. .1 -
grove
13-22 SER VCE DAT
Nominal Maintenance
Sec- Repair limit Wear limit
Item dimension standard Remrks
ion (mm) (mm)
mm) (mm)
Clearance between pin and pin T: ight fit
- 0QL • 002T 005L -
bore of piston L Loose fit
Clearance between connecting
rod small end bushing and - 0.02 -004 007 -
pison pin
Crankshaft end play - .10-06 4
0 .10-06 4 1.0 -
Free length 11 35 - - or reerence
"
Suction
I
valve spring When compres-
Q
. ension 045 06 -
sed to mm
mm
Q
"
·= Free lengh 13 - - or rerence
Delivery
valve spring When compres-
ension 04 07 -
sed to 95 mm
VACUUM PUMP
Nominal Maintenance
Repair
Repair limit Wear limit
tem dimension standard Remarks
mm) (mm)
mm) mm)
Length 4.0 - 05
Vae Height 25 - 220
hikness .0 - - -
POWER STEERING OIL PUMP (PULEY DRIVE TYPE)
Nominal Maintenance
Repair limit Wear limit
Item dimension standard Remark
mm) (mm)
(mm) (mm)
Side plate wear - 001 005
Ball bearing play - - 004 -
Clearance between outside diameter - - - 0.1
of haf and body busing
Clearance between outside diameter - - - 00
of relief valve and body
Less than 80
Relef oil CM80 and RM80 - 85 -90 -
More han 90
pressure
kg/cm 2 Less an 85
CK80 - 92.5100 -
More than 00
than 00
POWER STEERIN
STEERIN OIL PUP (GER DRIVE TYPE)
Nominal Maintenance
Repair limit Wear limit
Ie dimension standard Remarks
mm mm
mm) mm)
Ball bearg play - - 0.04 -
Rele il pressure Less than 65
- 675 5
kg/cm 2 Moe han 5
SERVCE DATA 13-23
TABLES OF IGHENING ORQUE
ENGINE PROPER AND EASSEMBLY
Tightenng point Tghenng torque (kgm) Remarks
Pston coolng ol jet connecor bolt 30-4.0
Front end plate mountng bolt 1.0-1.3
Camshaft gear tghtenng nut 19.0-200
Camshaft locatng plate mounng bol 13
Man bearng cap bol 170 -175
Connecng rod cap nut 11-12.0
Idler gear shat mouning bolt 30 40
Idler gear plate mounting bolt 2.0
MS 1.25 15-20
Flyweel housng mounng bol and nu
M 2 x 125 7.0-75
Flwheel mounng bol 15.0-15.5
an mounng bo and nut 1.0-13
Ol pan dran pug 60-70
Tmng gear case mounng bol 1.0-1.3
Engne rear PTO dler shaf mounng bol 00-110
artng moor mounng bolt 7.0
Waer pump mounng bol 10-1.3
Generator bracket mounng bol 40
\�j
i."I
,1
O cooler mounng bo 2
tn
'" O pump mountng bolt 20
i;
Waer manfold mounng bol 1
I'
Noze holder mounng bolt 2.0 -30
)
Nozle ube nut 2.5
Rocker cover mountng bol 08 -10
Ehaus manfold mountng nu 20-25
Crank puley mountng nu 550 -56.0
1s me: 6.0
Cylnder head mounng bol 2nd tme 100
3rd me 150
Rocker shaf bracke mouning bol 35-4.0
FD6 16 -20
Ar nake manfold mounng bol
FD6T 0.9-12
PTO gear mounng nu 14.5-20
PTO dler gear mouning bolt 10-11
13-24 SERVCE DATA
CYINDER HEAD AD VALV MCAISM
Tighening orque
Tghtenng pont Remarks
(kgm)
Engne slnger mounng bolt 4.0
Nozzle sleeve 35 • 40
Adjusng bolt lock nut 3.3
LUBRICTIO SSTM
Tightenng orque
Tghtenng pont Remarks
(kgm)
Ol pump cover mountng bol 1620
Both f full-flow and bypass
Oil fler center bolt 4 .5
flers
Ol fler dran plug 2.327
FUEL SSTM
Se Tghtenng torque
Tghtenng pont Remarks
on (kgm)
FD6 6 -8
Q Nozzle nut
-
0
FD6T 810
Cap nut 45
Delver valve holder 45 5.0
.
Q
0
Bearng cover seng screw 07 09
Tmer round nu 67
0
·; Flyeght round nut 6 7
Q
·2 Inecion pump drve gear mountng bolt 0.8 1.2
AIR TKE ND XUST SSTM
Sec Tghenng torque
Tghenng pon Remarks
tion
Ol nle adapter mountng bol (kgcm) 115 150
Ol oulet adapter mounng bolt (kgcm) 184 19
°
peller lock nut (kgcm) 1 · 3 Tghen (90 )
Back plae and center housng mounng bolt
u 86 104
kgcm)
I Turne housng and center housng mounng
161 184
ol (kgcm)
Compressor housng and back plae mounng
115 150
ol T04 (kgcm)
SERVCE DATA 13-25
AUXIIARY EQUIPMENT
Sec- Tigeing orque
Tighening poin Remarks
tio (kgm)
Bel drive ype 56
Suion valve holder
Gear drive ype 10 • 12
Bel drive ype 56
Deivery vave holder
Gear drive ype 10 · 12
Be drve ype 56
Unloader vave guide
Gear drive ype 1012
.
0 Be drive ype 1.4 · 1.8
C Cylnder ead mouning bo
Ger drve ype 2.5 3.0
E
0
Bearg holder mouning bo .60 0.75
Puey mounng u 7.0 • 8.
Conneor .0 3.5
Conneng od bol gear drve ype 2.3 • 2.
Case over mounng bo bel drive ype 0.600.75
Cyinder mouning bo (gear drive ype) 2.5 3.
Vauum pump mounng bo 0.0.7
Pulley mounig nu bel drive ype) 3.04.
C
E Flow onro valve onneor Inner A 7.5 8.5
C
be drve ype Ouer B 3.5 • 4.5
·o
1
C
·;
ear body mouningbo gear drve ype 3.5
C
C
. Fron brake moung bol bel drve ype 3.5 4.0
C
Rear brake moung bol bel drve ype 2.5 3.0
Reservoir mouning bo be drve ype .54.0
OHER GENL BOLS D NS
Tigening pon Tigening orque kgm)
Remarks
Srew size Pi 4T 7T 6T or u)
M6 1.00 0.41 0.55 0.68 0.91
M 1.25 0.881.3 1.2.1
1.25 1.9 2.6 3.3 • 4.3 Noe
M10
1.50 1.9 2.5 314. Te genng orque speied a lef
1.25 3.5 4.6 5.87.7 mus no be exeeded during
M1 ighening.
1.75 3.3 4.4 5.57.
M14 1.50 5.-7.3 .1 12.0
M16 150 8.311.0 14.0 19.0
Kobelco Engine Parts
email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
ji
14. TOOLS
EF1-002
This chapter dscribs too usd whn rpairing th FD6 & FD6T ngins.
For safty and iincy, us tools covrd in this chaptr whn dissmling
d rsmbling t FD6 & FD6T ngins
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 1
Engine disassembly an reassembly . . . . . . . . . . . . . . . . . . . . . 14- 1
Engine proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ·. . . . . . 14- 2
Cylinder head nd valve mechanism . . . . . . . . . . . . . . . . . . . . . 14- 3 TOOLS '/ . · _ 3 -
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
Air intke and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . 14-10
Auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . 14-13
Engine test procdures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
WRENCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TOOLS 14- 1
SPECIAL TOOLS
ENGIN DISASSMBLY AND RASSEMBLY
Part Number and Part ame Application Shape
99550 96001 Fr disassembling and reassembling engine
Engine stand proper.
99554 97001 For disassembling and reassembling engine
Attachment proper Used fr attahing the engine to
he engine stand
99535 25007 Used to remove and tighten the crank
Socket pulley nut
99690 25000 Used to remove the crank pulley (for
Crank pulley remove taper cone type)
9953 95001 Used to remove the fywheel
Puller blt
9631 25001 Used as a guide when inserting the piston
Piston insert tool into the cylinder liner
ET14-045C
99664 25000 Used to remove, install and retighten the
Socket wrench ylinder head belt
14-2 TOOLS
ENGINE PROPER
Part Number and Part Nae Appication Shp
99561 Z500 Used when perorming the yinder bok
Water eak test too ssembly wter pressre test.
ET14-006
570 Z5000 Used r wter eed nd pressre in the
Hydrauic pup assemby yinder bok nd the cyinder hed
wter pressre test
99600 Z5001 Used to remove nd inst the cyinder
�c-
Cyinder ner too assemby iner.
ET14·014A
99630 zoooo Used to remove nd inst the piston
Piston ring too ring
950 Z002 Used to reove the cshft bshing
Cm bush too ssemby
99590 Z003 Used to insta the camsht bshng
Cam bush too assemby
E42C
TOOLS 14-3
Prt Numbe nd P Nme Application She
99718 Z5002 Use to insert the oil seal an collar on
the front side.
Ol sel collr relce
961 Z5000 Used to insert the oil sel collar on the
Ol seal coll eplcer rer sde
CYLINDER H EAD AND VALVE MEANISM
Prt Nmer nd Prt Nme Applictio Shae
99624 Z500 Used to remove and instll the split collar.
Slit collar tool
e'
ET14·043A
99656 Z5501 Used to remove instll the nozzle
�.,
Nozzle holder sleeve wrench holer sleeve
965 Z5500 Use to remove the nozzle te
�
Nozzle te reover
62 Z5500 Used to correct the inside dimete of
Reme the le gide
e -
d
R 4-50
14-4 TOOLS
Part Number and Part Name Application Shpe
99561 Z5002 Used when performng the cylnder head
Water leak test too assemly water pressure test.
99660 Z500 Used to remove the exhaust and nlet
Valve nsert remover valve insert.
ET14·0208
9965 Z000 Used to ft (cod ttng) the vave nsert
Vave nsert repacer nto the cynder head (for exhaust and
nlet vave nsert.
99670 Z5000 Used to cau after the exhaust vave
Caulking tool ssemy nsert has een ftted to the cynder
head.
ET4-033
9966 Z5000 Use to remove the valve gude from the
ave guide remover cynder head
ET14-03
99666 Z5000 Used for forcng the vave gude nto the
Valve guide repacer cylnder head to the specfed depth.
99674 Z5000 Used to insta the valve stem sea into
Stem seal replacer the valve guide.
E401 A
9965 Z5500 Ued to instll the nozzle tue.
Nozzle tube settng tool
TOOLS 14-5
FUEL SYSTEM
Part Number and Part Name Application Shape
9977 25004 For cleaning nozzle orice.
/
Pin vice
EP14·121
9976 25000 For removal of carbon rom back side o
/.,
Nozzle cleaner· nozzle orice.
. ,
Special tools for injection pum
Par Number and Par Name Applicaion Shape
15796-60 Ued in removing imer
Exracor
i,
'i
;1
15793-100
Plunger pring holder
Tappe puh-up uppor ue
� F14.002
5791-0500 For removal and insallaion o delivery
fi:,
l J: ' valve holder
j
Socke wrench
1,·:i�
E14136
15795000 For ighening leigh mouning nu.
Camha wrench
EP14-140
5796510 Used o remove he governor lyweigh
Eracor
4-
14-6 TOOLS
Pat Numbe and Pat Name Application Shape
157926-5120 Used to remove the goveno lyweigt
Extactor (RFD).
0
P4-139
1579265310 Ued to remove the governor flweght.
Exacto
•;, :·,
>:;li !i;
lij
579120920 For emoval of tmer nt ,;·!
·1ri
-: !,
Specal wrenc lHi
ER40 l'!l
/i
. 1
1 :1
; Id
,!:-
1590120 Ued wth ocket wench
Ltpe handle
ES14•29
157930100 Ued to remove the gvernor cover.
Bo wrenc
5790020 Ued to remove the gvernor cover
Ratchet andle
157916-4320 Used in removing timer.
pecial wrenc
59210120 Ued when emoving and inseting the
Tappet nset tappets.
157936120 Used hen removng and inserting te
appet clamp tappet.
F407
157924120 Used when emoving and nstalling the
Punge net plnge
TOOLS 14- 7
Part Number and art Name Application Shape
15790-030 Used to extract the delivey valve
Delivery valve extactor assembly.
EF4-009
15950120 Used to extract the beaing outer ace
Outer race extactor
EF 14010
1595-810 Used to nstall the bearng oute race
Outer race guide
EF4·01
19410 Use to emove the beaing inne ace
Ine ace etacto
EF14012
1596010 Limit sleeve emoval an installtion use,
Etacto elivey valve gasket insetion use
EF403
1590800 Use as a guie to pevent damaging the
Sal guide oil seal when inserting te seal on the
casaft
1598400 Use to measue the e play of te
Measuing evice camsat
l 8)1
EF4015
159010 For removing govenor spng
tacto
EP445
14-8 TOOLS
Part Number and Part Nae Applicato Shape
157913-620 For remvng torqe ca rod.
Specal wrench
E14.6
1057840190 Fr adjstment f njectio pp.
Cng
EF14-017
1057810050 For adjstment o jeto pmp.
Fxng snd
EF4-018
10782600 Used t measre the cotr rack strke.
Measrng devce
EF14019
10782-6180 Used to easre the contro rack stoe
Measrng devce
F033
1057824010 Fr easreent o plnger stroke
Measrng devce
107826120 Fr easrement o lever strk.
Adstng devce
E1021
TOOLS 14- 9
Pat Numbe and Pat Name Applicton Shape
157976-3100 Fo xing the contol ack.
�
Lock scew
lr=�,1-
EF14-022
105783-000 Fo measuement of time dvancing
Stoboscope perfomnce.
•i·: i
E14023
157840-2720 Fo connectn the coupln to the pump
!:j teste (o 8 cylnde teste)
:·1 Cuckn devce
i '\
'Ii
,! i)
'i
., 1024
i!
157803920 Fo connectn the couplng to the pump
Cucn devce teste ( 12 cylnde teste
"'I
/l;
1ji
i'
1
!/
i
,i
'I
·1 15784020 Fo connectn te couplng to t pump
,
;.1
uckn devce teste (f 12 cylnde teste)
w�
14026
105790020 Injecton pump dssembly and e
Unvel vce sembly stnd
:o
,_ _
14027
14- 10 TOOLS
Timer special too
Part Number and Prt Nme Applictio Shpe
157924-1610 Timer disssembly nd ressembly stnd.
Base
� EF14-02B
157924100 Timer disssembly ad ressembly std
Bushing gide
-,
EF14029
157924-1900 Timer disssembly nd ressembly td.
Thrst bshig
( EF14030
e
1579164320 Used to prevet the timer flyweight
Secial rech holder rom trnng.
EF14-031
1579320200 Used he ssembling the tim er spring.
Timer spring supporter
EF1402
AIR INTAKE AND EXHAUST SYSTEM
Turbocharger
art Number nd rt Nme Applitio Spe
99760 Z500 Used he disssemblig nd ressembling
Trbochrger tool kit the turbochrger.
96764 96000 Used to mesure play i the rdil
Rdil pl measurig tool direction of the shft wheel
EP15057
9965 96000 Adpter monted to the end of the dal
Radil l dpter gauge hen mesrig radil ply
EP15058
TOOLS 14 - 11
Part Number and Part Name Application Shape
99766 96000 Used when measuring xial play of the
End play measuring tool sat wheel
EP15-059
99765 96001 Adapter mounted to the end o te dial
End pla adapter gauge when measurin end play.
99767 96003
Pick
Used wen ftting the piston ring o te
shat to the center ousing
=
= �)
EP5062
99773 96000 Used to remove and install te inpeller
T-handle lock nut
i
EP15-066
i,\I
,
99537 9600 Use to tigten and disassemble te center
Torque renc housing and ack plate
i
/,
Torque 095 kgm
iI[
I
:1
�fr· ;- 1
�ft .,) i'
EP5070
.d� r
99763 Z5500 Used when insertin te piston ring to
0
l-i
t!U.
Piston ring guie te shaft weel (T048 type)
EP15056
99545 96000 Used wen tightening and removing the
Hex wrench oil adapter
99545 Z5500
Hex rench
Used en tigtening an removing the
oil adapter � EP15063
14 - 12 TOOLS
Par Number and rt me Applction Shpe
99546 25500 Used when removing the retining rng t
Retainng rng plier the center housing.
ER14-131
99768 2550 Used when disssembling and ssemblin
0
Holdng fixture the rotting ssembly.
ER14132
99537 25500 Used to tighten nd remove the turbine
housing nd center housing.
/
orque wrench
Torque 1. kgm
EP5069
99537 25501 Used to tighten nd remove the turbine
orque wrench housing nd cente housing.
orque 1. kgm
EP1070
99537 2550 Used to tighten nd remove the compres-
orque wrench sor housing nd bck plte.
Torque 1.3 kgm
EP069
�
10 29001 Used when mounting the rdil ply
Hex socket head bolt mesuring tool
�"'
TOOLS 14- 13
AUXILIARY EQUIPMENT
Air compresor
Part Numbe nd Pt Nam Appictio hap
99744 ZS00l Usd to mov d inst th suctio
�.,
Vv hd to vv hod of th ir comprssor.
9954 96000 Usd to ist th piston of th ai
Piston inst to compsso
ET189B
99744 zssoo Usd to rmov d inst th suctio
�-0,A
';i Vav hod too vav hodr of th air compsso
i ENGIE ES PROCEDURES
,.:
Pt Numb nd Pt Nam ppictio hp
99640 zssoo For msumnt o cyidr comprssion
Compssin gaug prssur.
EP14· 67
99646 ZS00l For masumnt o vav timing and
Timing pat ijction timing
E-053
14- TOOLS
WRENCHES
Part numbe Size [mm] Part name Applicaton Shape
99538 2500 10 s tD L1 L2
99538 25001 1 10 6 15 150 ,o
-�
99538 2500 14 1 1 450 50
99538 2500 17 T-wrench 14 303 00
99538 25004 19 17 5 98 300
-
r
99538 25005 19 6.5 198 00
99538 25006 4 33 150 400
.
EP14-69
4 36 400 400
Toque Used to tghten nuts and ots,
99650 25001
wrench set and to ensure hey ae
99535 25000 10 tightened to specifcatio
9955 25001 1
�
99535 2500 14 I 14) 12) (10)
99535 25003 17 Socket -120 ' r
( It
.
99535 25004 19
' (
99535 25005
EP170
99535 25006 4
9536 25000 8 kgm
Toue . -
wench
Used to tigten cank nuts :,·
'
oue !·
99536 25001 70 kgm and to ensure the ae
rench
C-=� w, t) t ;
tghtened to specficato
; '
S8
KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. North American English
245 E NORTH AVENUE Part Number SME FDS1E00 NA
CAROL STREAM, IL 601 88 U.S.A. Printed in U.S.A. • Bur
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