CMP158 SM687

SF12-20SD/L/G,SF15-20SLC
CMP15-20SD/L/G,CMC15-20SL
SERVICE MANUAL
RATED CAPACITY : 1200~2000kg
Part No.8021718
Manual No. SM-687
Manufactured by #40–1, Ungnam-Dong,

Changwon-City, Kyungnam,
Korea
GENERAL 00
• 00 – 01 REVISION HISTORY
• 00 – 02 FOREWORD
– Foreword
– How to read this manual
• 00 – 03 SAFETY
– General precautions
– Preparations for work
– Cautions during operation
• 00 – 04 STANDARDS
– Standard tightening torque
– Measurement conversions
G E N E R A L
REVISION HISTORY
2003. 05.
00
When new or revised information is published
Mark Indication Action required 01
to update this manual the action to be taken
1
with the pages is indicated in the table. Page to be newly added Add
Pages not marked are not currently revised, Page to be replaced Replace
but are included for page numbering continuity.
( ) Page to be deleted Discard
Revision Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
00–01–10 01–04–10 10–05–90 10–07–18 15–06–10

00–01–20 01–04–20 10–05–10 10–07–19 15–06–20
01–04–30 10–05–11 10–07–20 15–06–30
00–02–10 10–05–12 10–07–21 15–06–40
00–02–20 01–05–10 10–05–13 10–07–22 15–06–50
10–05–14 10–07–23 15–06–60
00–03–10 10–01–10 10–07–24 15–06–70
00–03–20 10–01–20 10–06–10 10–07–25 15–06–80
00–03–30 10–01–30 10–06–20 15–06–90
00–03–40 10–01–40 10–06–30 10–08–10 15–06–10
00–03–50 10–01–50 10–06–40 10–08–20 15–06–11
00–03–60 10–06–50 10–08–30 15–06–12
00–03–70 10–02–10 10–06–60 10–08–40 15–06–13
00–03–80 10–02–20 10–06–70 10–08–50
00–03–90 10–02–30 10–06–80 10–08–60 15–07–10
00–03–10 10–02–40 10–06–90 10–08–70 15–07–20
10–02–50 10–06–10 10–08–80 15–07–30
00–04–10 10–02–60 10–06–11 10–08–90 15–07–40
00–04–20 10–02–70 10–06–12 10–08–10 15–07–50
00–04–30 10–02–80 10–06–13 15–07–60
00–04–40 10–02–90 10–06–14 15–01–10 15–07–70
10–02–10 10–06–15 15–01–20 15–07–80
01–01–10 15–01–30 15–07–90
01–01–20 10–03–10 10–07–10 15–07–10
01–01–30 10–03–20 10–07–20 15–02–10 15–07–11
01–01–40 10–03–30 10–07–30 15–07–12
01–01–50 10–07–40 15–03–10 15–07–13
01–01–60 10–04–10 10–07–50 15–03–20 15–07–14
01–01–70 10–04–20 10–07–60 15–03–30 15–07–15
01–01–80 10–04–30 10–07–70 15–07–16
01–01–90 10–04–40 10–07–80 15–04–10 15–07–17
01–01–10 10–07–90 15–04–30 15–07–18
01–01–11 10–05–10 10–07–10 15–04–50 15–07–19
01–01–12 10–05–20 10–07–11 15–07–20
10–05–30 10–07–12 15–05–10 15–07–21
01–02–10 10–05–40 10–07–13 15–05–20 15–07–22
01–02–20 10–05–50 10–07–14 15–05–30 15–07–23
10–05–60 10–07–15 15–05–40 15–07–24
01–03–10 10–05–70 10–07–16 15–05–50 15–07–25
10–05–80 10–07–17 15–07–26
G E N E R A L
REVISION HISTORY
00 Revision Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page Mark Page
01 number number number number number
2 15–07–27 15–12–12 (20–03–20) 50–02–30 50–05–90

15–07–28 15–12–13 50–02–40
15–07–29 15–12–14 30–01–10 50–02–50 60–01–10
15–07–30 15–12–15 30–01–20 50–02–60 60–01–20
30–01–30 60–01–30
15–08–10 15–13–10 30–01–40 50–03–10 60–01–40
15–08–20 15–13–20 30–01–50 50–03–20 60–01–50
15–08–30 15–13–30 30–01–60 50–03–30 60–01–60
15–08–40 15–13–40 30–01–70 50–03–40 60–01–70
15–08–50 15–13–50 30–01–80 50–03–50 60–01–80
15–08–60 15–13–70 30–01–90 50–03–60 60–01–90
15–08–70 30–01–10 50–03–70 60–01–10
15–08–80 20–01–10 50–03–80 60–01–11
15–08–90 20–01–20 30–02–10 50–03–90 60–01–12
20–01–30 30–02–20 60–01–13
15–09–10 20–01–40 30–02–30 50–04–10 60–01–14
15–09–20 20–01–50 30–02–40 50–04–20
15–09–30 20–01–60 30–02–50 50–04–30 60–02–10
15–09–40 20–01–70 30–02–60 50–04–40 60–02–20
15–09–50 (20–01–8)0 30–02–70 50–04–50 60–02–30
30–02–80 50–04–60 60–02–40
15–10–10 20–02–10 30–02–90 50–04–70 60–02–50
20–02–20 30–02–10 50–04–80 60–02–60
15–11–10 20–02–30 30–02–11 50–04–90 60–02–70
15–11–20 20–02–40 30–02–12 50–04–10 60–02–80
15–11–30 20–02–50 30–02–13 50–04–11 60–02–90
15–11–40 20–02–60 30–02–14 50–04–12 60–02–10
15–11–50 20–02–70 30–02–15 50–04–13 60–02–11
15–11–60 20–02–80 30–02–16 50–04–14 60–02–12
15–11–70 20–02–90 30–02–17 50–04–15 60–02–13
15–11–80 30–02–18 50–04–16 60–02–14
15–11–90 20–03–10 30–02–19 50–04–17 60–02–15
15–11–10 20–03–20 30–02–20 50–04–18 60–02–16
15–11–11 20–03–30 30–02–21 50–04–19
15–11–12 20–03–40 50–04–20 70–01–10
15–11–13 20–03–50 40–01–10 50–04–21 70–01–30
15–11–14 20–03–60 40–01–20 50–04–22 70–01–50
15–11–15 20–03–70 40–01–30 50–04–23
20–03–80 40–01–40 50–04–24
15–12–10 20–03–90 40–01–50 50–04–25
15–12–20 20–03–10 50–04–26
15–12–30 20–03–11 50–01–10
15–12–40 20–03–12 50–01–20 50–05–10
15–12–50 20–03–13 50–01–30 50–05–20
15–12–60 20–03–14 50–01–40 50–05–30
15–12–70 20–03–15 50–01–50 50–05–40
15–12–80 20–03–16 50–01–60 50–05–50
15–12–90 20–03–17 50–05–60
15–12–10 20–03–18 50–02–10 50–05–70
15–12–11 20–03–19 50–02–20 50–05–80
G E N E R A L
FOREWORD
00
FOREWORD
02
1
This shop manual has been prepared as an aid to improve quality of repairs by giving the
serviceman an accurate understanding of the product and by illustrating the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual
and use it to the full effect at every opportunity.
This shop manual mainly contains the technical information necessary for operations performed
in a service workshop.
For ease of understanding, the manual is divided into sections for each main system of the
machine, and the sections are further divided into groups.
! SAFETY
• Improper operation and maintenance of this machine could result in serious injury or death.
• Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
• Always keep the Operation and Maintenance Manual and Parts catalogue near the work
area.
• Obey precautions concerning flammable liquids, hazardous fluids, oils, lubricants and
cleaning solvents.
• To prevent injury to workers, this symbol ! is used to mark safety precautions in this
manual. The precautions accompanying this symbol should always be followed carefully.
• The specifications contained in this shop manual are subject to change at any time and
without any advance notice. Contact your SAMSUNG distributor for the latest information.
HOW TO READ THIS MANUAL
CHAPTER AND SECTION
This manual is issued as a guide to carrying out repair and maintenance. To easily understand
this manual it is divided as follows :
Example) 10 – 01
Section number (01 : Structure and function)
Chapter number (10 : Engine)

G E N E R A L
FOREWORD
00 PAGE
02
2 Page numbering is started from each section. Therefore, revised pages can be easily inserted.
Also, additional pages and revision number can be indicated.
Ex) 15 – 1 c
3rd revision
Additional page from page 15
15th page of the section
For the revision status in this manual, refer to REVISION HISTORY.
SYMBOLS
The following symbols as defined below are used in this manual to convey the intent of the
instructions concerning safety and repair.
Symbol Item Remarks
Special safety precautions are necessary when

Safety
performing the work.
! Special technical precautions or other precautions for

Caution preserving standards are necessary when performing
the work.
Tightening Places that require special attention for the tightening

torque torque during assembly.
Places that require proper tools used in assembling

Tool
and disassembling.
Adhesive Places to be applied with adhesive.
Lubricating Places where oil or lubricant must be added.

G E N E R A L
SAFETY
00
03
! WARNING
SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED
1
This fork lift should not be operated by anyone who is not authorized and properly trained.
Read the Operators Manual carefully, and make yourself familiar with your fork lift.
Inspect and check your fork lift daily before and after use. Do not operatea faulty or damaged fork lift.
Repair work should be done by authorized and trained persons only.
To protect from falling objects, make sure that the Overhead Guard and Load Backrest are correctly mounted and in good condition.
Before starting engine, always set forward/reverse lever in neutral, with hand brake on.
Drive carefully, keeping forks and attachments as low as possible & fully tilted back.
Keep a careful lookout for people, obstructions and the path of travel. Watch clearance, especially overhead and tail swing.
Do not stick hands, feet and other parts of your body outside the Operator’s compartment.
Drive forward when you are climbing a slope with a load. Drive in reverse when you are descending with loads. Do not turn while on a slope.
Slow down before turning. Avoid any sudden start, stop or turning. Lateral tipover can occur if the fork lift is improperly operated.
Do not load fork lift over capacity limit designated on the load chart. Do not lift unstable loads.
This fork lift is not designed for raising or transporting people. Do not use fork lift for those purposes under any circumstances.
Before you get off fork lift, make sure the hand brake is set, lower forks or attachments, put forward/reverse lever in neutral position and
turn off key switch. Do not park on a slope. P/NO.6092-13130
GENERAL PRECAUTIONS
SAFETY PRECAUTIONS
• When carrying out any operation or maintenance, have trained and experienced personnel carry
out the work.
• When carrying out any operation or maintenance, carefully read the Operation and Maintenance
Manual.
Read all the precautions given on the decals which are fixed to the machine.
SAFETY DEVICE
• Make sure that all guards and covers are mounted in their proper position. Repair or replace
if damaged.
• Pay attention to the method of using any safety locking device or safety belt.
SAFETY CLOTHES AND HELMET
• Wear the specified work clothes in the correct manner.

• Use the specified protective gear (helmet, safety glasses, safety shoes, mask, gloves).
Guard against injury from flying pieces of metal
or debris, wear goggles, gloves and helmet.
Always have a trained and experienced welder
carry out any welding work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suitable for welding work.
EX048
G E N E R A L
SAFETY
00 PREPARE FOR EMERGENCIES

03
2 • Know where fire extinguishers are located and
how to use them.
• Keep a first aid kit and an eye wash kit near
the work area.
• Keep emergency numbers for doctors, ambul-
ance service, hospital, and fire department near
your telephone. EX036
HANDLE FLUIDS SAFELY–AVOID FIRES
• Handle fuel with care it is highly flammable.

• Do not refuel the machine while smoking or
when near open flame or sparks.
Always stop the engine before refueling
machine. Fill the fuel tank outdoors.
• Store flammable fluids away from fire hazards. EX028
Do not incinerate or puncture pressurized
containers.
DISPOSE OF FLUIDS PROPERLY
• Improperly disposing of fluids can harm the

environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
• Catch draining fuel, oil, or other fluids in
suitable containers. Do not use food or
beverage containers that may mislead someone
into drinking from them. Wipe up spills at once.
• Do not pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe EX043
relevant environmental protection regulations

when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
G E N E R A L
SAFETY
AVOID HARMFUL ASBESTOS DUST

00
03
• Avoid breathing dust that may be generated 3
when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung
cancer.
EX025
G E N E R A L
SAFETY
00
PREPARATIONS FOR WORK
03
4 a
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause

serious injury.
• Before performing any work on the machine,
attach a “Do Not Operate” tag to the steering
wheel or the right control lever.
• When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting.
USE TOOLS PROPERLY
• Use a tool only for its designed application.

• Keep all tools in good condition and know the
correct way to use them.
• Decide on a place in the repair workshop to
keep tools and removed parts.
• Always keep the work area clean and make
EX033
sure that there is no dirt or oil on the floor.
• Before adding oil or making any repairs, park
the machine on hard, level ground and put
blocks under the wheels or tracks to prevent
the mahcine from moving.
• Before starting work, lower the forks or any
other work equipment to the ground.
CLA
K R
• Turn the engine OFF, remove the start key,

and apply the parking brake.
• Illuminate your work area adequately but safely.

Use a portable safety light for working inside
or under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of
an accidentally broken bulb can ignite spilled
fuel or oil.
EX042
EX042
G E N E R A L
SAFETY
USE HANDHOLDS AND STEPS

00
03
• Do not jump onto or down from the fork lift. 5
• When getting on or off the fork lift, use the
step provided.
• Do not grasp an operating lever or steering
wheel when getting on or off.
• Always keep the step clean and repair it if
damaged.
FX019
FX019
• Never operate with wet or oily hands and feet.
OPERATE FROM THE OPERATOR’S SEAT
• Do not operate the fork lift from any place

other than the designated operator’s position.
• Improper seating may cause serious injury.
FX020
FX020
G E N E R A L
SAFETY
00
CAUTIONS DURING OPERATION
03
6
SERVICE COOLING SYSTEM SAFELY
• Hot coolant can burn you. Let it cool down.

• Turn the radiator cap slowly to release pressure.
Do not remove cap if engine is overheated.
EX039E EX029
AVOID HIGH-PRESSURE FLUIDS
• Escaping fluid under pressure can penetrate the skin causing serious injury.
• Avoid the hazard by releasing pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
• Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
EX062
• Be careful not to break, twist or damage the
high pressure pipes.
A jet spray of high pressure oil may cause
electrical fires.
EX040
HANDLING OF HEAVY OBJECTS
• When raising heavy components, use a hoist or crane.

• Check if the wire rope, chains and hooks are free from damage.
• Always use lifting equipment which has ample capacity. Install the lifting equipment at the
correct places.
• Use a hoist or crane and operate slowly to prevent the component hitting any other part.
• When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
• Before starting work, lower the forks or any
other work equipment to the ground.
• Do not work under the equipment when the
equipment is not sufficiently supported.
G E N E R A L
SAFETY
ELECTRICAL SYSTEM
00
03
• When welding on the machine or working on the 7 a
electrical system, ALWAYS turn the key switch
OFF and remove the lead from the battery
negative ( – ) terminal.
• When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
• When working on the battery, wear goggles or

safety glasses.
• Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin and eat holes
in clothing and cause blindness if splashed into
the eyes. If you spill acid on your clothes or
skin, immediately flush with large quantities of
water.
• If splashed into the eyes, flush with water and
get medical attention immediately.
• Keep sparks, lighted matches, and open flame

away from the top of battery. Battery (hydrogen)
gas can explode.
• Battery posts and cables touched by metal

objects can short circuit and burn you.
Keep tools away from posts, wires and
terminals.
Tighten the battery terminals to ensure good
contact.
• When disassembling and assembling the
battery, make sure that the battery terminals
are correctly connected.
• If water gets to the electrical system, abnormal

operation or failure can result.
Do not use water or steam on sensors,
connectors and instruments in the cab.
EX034
G E N E R A L
SAFETY
00 CAUTIONS DURING OPERATION

03
8 NEVER STAND UNDER FORKS
• Do not allow anyone to stand or walk under

the elevated forks, or load.
Failure to comply can cause serious injury or
death.
FX027
FX027
ROTATING PARTS / ALIGNING HOLES
• Never touch rotating parts such as the fan

blades or fan belt.
• When aligning two holes, never insert your
fingers or hand.
Be careful not to get your fingers pinched in a
hole, or between parts or tools.
EX035
NEVER RIDE ON FORKS
• Never use the forks to lift people.

Failure to comply can cause serious injury or
death.
FX028
FX028
G E N E R A L
SAFETY
PINCHING AND FALLING

00
03
• Do not put your head, hands, arms or feet into 9
the mast.
Entanglement in the mast can cause serious
injury.
• Do not use the mast as a ladder.
Falling from the mast can cause serious injury.
FX028
FX029
FX030
FX030
INFLATING TIRES
• Do not add air pressure immediately to the

tires when the air pressure is low. Inspect the
rim for damage.
If air pressure is added to the tire when the
rim is damaged, the tire can be exploded
causing serious injury or death.
• Check the valve stem, tread, and side wall for
air pressure leaks. EW013
EW013
• The tire must be inflated by trained personnel

only.
• Make sure there is enough hose to permit the
operator to stand away from the safety cage
when air pressure is added to the tire.
• Add air pressure to the tires only in a safety
cage, as illustrated.
• Always wear safety glasses.
G E N E R A L
SAFETY
00 ! IN CASE OF TIP – OVER

03
10
Lateral tip – over can occur if
! the fork lift is improperly operated.

Don’t risk injury or death.
Buckle up belt
Stay in seat
WARNING Slow down before turning!
IN CASE
! OF TIP–OVER
Follow these
instructions : Hold on
DANGER Lean away
steering wheel
Brace feet Don’t jump!
Be extremely careful to prevent the fork lift from tipping over during operation. Decelerate
the fork lift sufficiently when turning a corner or tight curve.
The following precautions should be closely observed to ensure safe operation of the fork
lift as well as to protect other persons against injury.
! Always make sure that your seat belt is securely fastened and the top panel latch is in the
locked position.
! If the fork lift begins to tip. DO NOT ATTEMPT TO JUMP CLEAR. The fork lift will fall
faster than you can jump.
Brace your feet and hold youself inside the operator compartment by holding onto the steering
wheel with both hands.
G E N E R A L
STANDARDS
APPROXIMATE CONVERSIONS
00
04
40
40
Degree °F
Degree °C
1
SI Conv Non – SI Conv SI
20
0
Unit Factor Unit Factor Unit
Torque
32
0
× ×
40
newton meter (N·m) 10.2 = kgf·cm 0.8664 = (lb·in)
newton meter (N·m) × 0.74 = lbf·ft. × 1.36 = N·m
20
newton meter (N·m) × 0.102 = kgf·m × 7.22 = (lbf·ft.)
80
98.6
Pressure (Pa = N/m2)
37
kilopascal (kPa) × 4.0 = in. H2O × 0.249 = kPa
120
kilopascal (kPa) × 0.30 = in. Hg × 3.38 = kPa
60
kilopascal (kPa) × 0.145 = psi × 6.89 = kPa
160
(bar) × 14.5 = psi × 0.069 = (bar)
80
(kgf/cm2) × 14.22 = psi × 0.070 = (kgf/cm2)
200
(newton/mm2) × 145.04 = psi × 0.069 = (bar)
212
100
megapascal (MPa) × 145 = psi × 0.00689 = MPa
240
Power (W = J/s)
120
kilowatt (kW) × 1.36 = PS (cv) × 0.736 = kW
kilowatt (kW) × 1.34 = HP × 0.746 = kW
280
140
kilowatt (kW) × 0.948 = Btu/s × 1.055 = kW
watt (W) × 0.74 = ft·lb/s × 1.36 = kW
320
160
Energy (J = N·m)
kilojoule (kJ) × 0.948 = Btu × 1.055 = kJ
180
360
joule (J) × 0.239 = calorie × 4.19 = J

Velocity and Acceleration
200
400
meter per sec2 (m/s2) × 3.28 = ft/s2 × 0.305 = m/s2

meter per sec (m/s) × 3.28 = ft/s × 0.305 = m/s
220
440
kilometer per hour (km/h) × 0.62 = mph × 1.61 = km/h

Horse Power/Torque
240
BHP × 5252 R.P.M. = TQ (lb·ft) TQ × R.P.M. 5252 = B.H.P.

480
Temperature
260
°C = (°F – 32) v 1.8 °F = (°C × 1.8) + 32

520
Flow Rate
280
l /min (dm3/min) × 0.264 = US gal/min × 3.785 = l /min

560
300
Note : ( ) Non–SI Unit

600
320
G E N E R A L
STANDARDS
00
STANDARD TIGHTENING TORQUE
04
2
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in sections of “Disassembly and Assembly”
METER TABLE
Classification 4T, 5T 10T
Bolt type 10.9
Bolt size Torque kgf·m (lbf·ft) Torque kgf·m (lbf·ft)
M4 0.2 ± 0.02 (1.4 ± 0.1) 0.4 ± 0.04 (2.9 ± 0.3)

M5 0.3 ± 0.03 (2.2 ± 0.2) 0.8 ± 0.08 (5.8 ± 0.6)
M6 0.5 ± 0.05 (3.6 ± 0.4) 1.4 ± 0.14 (10.1 ± 1.0)
M8 1.2 ± 0.12 (8.7 ± 0.9) 3.3 ± 0.3 (23.8 ± 2.2)
M10 2.3 ± 0.23 (16.6 ± 1.7) 6.5 ± 0.7 (47 ± 5)
M12 4.0 ± 0.4 (29 ± 3) 11.3 ± 1.1 (82 ± 8)
<M14> 6.4 ± 0.6 (46 ± 4) 17.9 ± 1.8 (129 ± 13)
M16 9.5 ± 0.9 (69 ± 6) 26.7 ± 2.7 (193 ± 19)
<M18> 13.5 ± 1.4 (97 ± 10) 38.0 ± 3.8 (274 ± 27)
M20 18.6 ± 1.9 (134 ± 14) 52.2 ± 5.2 (377 ± 38)
<M22> 24.7 ± 2.5 (178 ± 18) 69.4 ± 6.9 (500 ± 50)
M24 32.1 ± 3.2 (232 ± 23) 90.2 ± 9.0 (650 ± 65)
M30 62.6 ± 6.3 (452 ± 45) 176.1 ± 17.6 (1270 ± 127)
M36 108.2 ± 10.8 (781 ± 78) 304.3 ± 30.4 (2200 ± 220)
M42 171.8 ± 17.2 (1240 ± 124) 483.2 ± 48.3 (3500 ± 350)
M45 211.3 ± 21.1 (1525 ± 152) 594.3 ± 50.4 (4300 ± 430)
G E N E R A L
STANDARDS
00
MEASUREMENT CONVERSIONS
04
3
LENGTH
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm = 0.1cm, 1µm = 0.001mm
AREA
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 – 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 – 1000000 1 10000 1076400 1195800 –
a 0.01 100 0.0001 1 1076.4 119.58 –
ft2 – 0.092903 – 0.000929 1 0.1111 144.000
yd2 – 0.83613 – 0.008361 9 1 1296.00
in2 6.4516 0.000645 – – 0.006943 0.000771 1
1ha = 100a, 1mile2 = 259ha = 2.59km2

G E N E R A L
STANDARDS
00 VOLUME
04
4 Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
l 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1gal(US)=3785.41 cm3=231 in3=0.83267gal(US)
WEIGHT
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 10 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne(metric) = 1.1023 ton(US) = 0.9842 ton(UK)
PRESSURE
Unit kgf/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kgf/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kgf/cm2 = 735.56 Torr(mmHg) = 0.96784atm

SPECIFICATIONS 01
• 01– 01 GENERAL
– Location of components
– Instrument panel
– Dimension and weight
• 01– 02 LOAD CAPACITY

– Capacity charts
• 01– 03 COOLANT / FUEL / LUBRICATION
• 01– 04 PERIODIC MAINTENANCE
• 01– 05 TIGHTENING TORQUE

S P E C I F I C A T I O N S
GENERAL
LOCATION OF COMPONENTS
DIESEL / GASOLINE TYPE 01

01
1
3 8 7
2
9
1
10
5 11
16
12
15
17
14
13
1. Mast 10. Hood

2. Lift cylinder 11. Counterweight
3. Control lever (Tilt, Lift) 12. Steering tire
4. Load backrest 13. Tilt cylinder
5. Carriage 14. Driving wheel
6. Forks 15. Frame
7. Overhead guard 16. Steering axle
8. Steering wheel 17. Driving axle
9. Driver’s seat
GENERAL
LPG TYPE
01 3 8 7
01
2 2
9
1
4
18
10
5 11
16
12
15
17
14
13
1. Mast 10. Hood

2. Lift cylinder 11. Counterweight
3. Control lever (Tilt, Lift) 12. Steering tire
4. Load backrest 13. Tilt cylinder
5. Carriage 14. Driving wheel
6. Forks 15. Frame
7. Overhead guard 16. Steering axle
8. Steering wheel 17. Driving axle
9. Driver’s seat 18. LPG tank
GENERAL
OPERATOR’S CAB
01
3 1 8 7 9 2 01
3
5
6
10 11 14 12 13
FX131
1. Instrument panel 8. Steering knob

2. Turn signal lever 9. Steering wheel
3. Shift lever (forward–reverse) 10. Inching pedal
4. Parking brake lever 11. Brake pedal
5. Lift control lever 12. Accelerator pedal
6. Tilt control lever 13. Floor plate
7. Horn switch 14. Start key
GENERAL
INSTRUMENT PANEL
01 GASOLINE / DIESEL TYPE
01
4
9 1 4 5 6 7 8 1 10
11 12 13
1. Turn signal pilot lamp 8. Battery discharging warning

4. Engine oil pressure lamp
warning lamp 9. Beacon switch (Option)
5. Air preheating pilot lamp 10. Panel check switch
6. Parking brake pilot lamp 11. Fuel level gauge
7. Transmission oil 12. Hour meter
temperature warning lamp 13. Coolant temperature gauge
GENERAL
LPG TYPE
01
1 4 5 6 7 8 1
01
9 10 5
14 12 13
1. Turn signal pilot lamp 8. Battery discharging warning

4. Engine oil pressure warning lamp
lamp 9. Beacon switch (Option)
5. Air preheating pilot lamp 10. Panel check switch
6. Parking brake pilot lamp 12. Hour meter
7. Transmission oil temperature 13. Coolant temperature gauge
warning lamp 14. LPG warning lamp
GENERAL
DIMENSION AND WEIGHT
01
01
6
GENERAL
Specification
Item Unit Symbol
SF15L SF18L SF20SL SF15G SF18G SF15D SF18D SF20SD
SF12L SF12G CMP20SG
Weight kg(lb) –
CMP15L
2570 2690
(5665) (5930)
CMP18L
2815
(6205)
CMP20SL CMP15G CMP18G
3070 2570 2690 2815 3080
(6745) (5665) (5930) (6205) (6790)
CMP15D
2690
(5930)
CMP18D
2820
(6215)
CMP20SD
3080
(6790)
01
Overall length (including mm
forks) (in)
A
3215 3240 3265 3310 3215 3240 3265 3310 3240 3265 3310
(127) (128) (129) (130) (127) (128) (129) (130) (128) (129) (130)
01
7
mm 1110 (43.7)
Overall width B
(in)
mm 2092 (82.4)
Overall height H
Overall
(in)
mm 115/110
Min. ground clearance J/K 117/114 (4.6/4.5)
(in) (4.5/4.3)
mm 2057 (81)
Overhead guard height C
(in)
mm 1350 (53.1)
Wheelbase D
(in)
Wheel tread mm 930/900 (36.6/35.4)
E/F
(Front/Rear) (in)
1200 1500 1800 2000 1200 1500 1800 2000 1500 1800 2000
Max. load kg(lb) – (2500) (3000) (3500) (4410) (2500) (3000) (3500) (4410) (3000) (3500) (4410)
mm 500 (24)
Load center –
(in)
mm 3000 (118)
Max. lift height G
(in)
mm
Attachment
Free lift height I 100 (3.94)

(in)
Tilt angle 6/10
(Forward/Back) degree M/L
Basic performance
Fork size mm 1070 × 100 × 40 (42.1 × 3.9 × 1.6)

–
(L × W × T) (in)
mm 388 (15.3)
Load center distance (in) N
mm 1015 (40)
Driver’s seat height O
(in)
Max. steering angle degree P/Q 51/75

Chassis
mm 1885 1885 1885

Min. turning radius R 1850 (72.8) 1850 (72.8) 1850 (72.8)
(in) (74.2) (74.2) (74.2)
Steering wheel mm 1450 (57.1)
T
height (in)
Driver’s seat adjustment mm 100 (50/50) (3.9 (1.97/1.97))
V
(Forward/Back) (in)
Front wheel – – 6.50 × 10 – 12PR

Tire
Rear wheel – – 5.00 × 8 – 10PR
GENERAL
PERFORMANCE
Specification
01 Item Unit
SF12L
SF15L SF18L SF20SL
CMP15L CMP18L CMP20SL
SF12G
SF15G SF18G
CMP15G CMP18G
CMP20SG
SF15D SF18D SF20SD
CMP15D CMP18D CMP20SD
km/hr
01 Max. travelling
No load
(mile/hr) 17.4 (10.8) 17.0 (10.5) 17.4 (10.8) 17.0 (10.5) 17.5 (10.8)
8 speed
Full load km/hr 16.5 16.3 16.1 16.0 16.5 16.3 16.1 16.0 17.0
(mile/hr) (10.3) (10.1) (10) (9.8) (10.3) (10.1) (10) (9.8) (10.5)
No load kg 620 602 521 590 620 602 521 590 850
Max. drawbar (lb) (1367) (1327) (1149) (1298) (1367) (1327) (1149) (1298) (1875)
pull kg 1344 1350 1353 1300 1344 1350 1353 1300 1700
Full load
(lb) (2963) (2976) (2983) (2860) (2963) (2976) (2983) (2860) (3750)
Max. gradeability Full load degree

19.6 17.6 15.9 14.5 19.6 17.6 15.9 14.5 23.7 22.0 20.3
Overall
Braking distance m 3.9 4.1 4.6 4.8 3.9 4.1 4.6 4.8 4.1 4.6 4.8
(at max. speed) (ft) (12.8) (13.5) (15.1) (15.7) (12.8) (13.5) (15.1) (15.7) (13.5) (15.1) (15.7)
Fork lifting speed mm/sec 570/530 570/510 570/500 570/530 570/510 570/500 570/530 570/510 570/500
(No load/Full load) (in/sec) (22.4/20.9) (22.4/20) (22.4/19.7) (22.4/20.9) (22.4/20) (22.4/19.7) (22.4/20.9) (22.4/20) (22.4/19.7)
Fork lowering speed mm/sec
510 / 510 (20 / 20)
(No load/Full load) (in/sec)
Lift cylinder drift Full mm/5min
load 25 (0.98)
(Oil temp : 50°C) (in/sec)
Tilt cylinder drift Full mm/5min
load 10 (0.4)
(Oil temp : 50°C) (in/sec)
Type – 4G63 4 TNE 88
Rated output PS/RPM

34.6 / 2300 (25.5 / 2300) 39.2/2400(28.8/2400)
(KW/RPM)
Max. torque kg·m/RPM

12 / 1600 (118 / 1600) 14.0/1400
(N·m/RPM)
No. of cylinder EA 4
Cylinder diameter × Stroke mm (in) 85 × 88 (3.35 × 3.46) 88 × 90

Engine system
Displacement cc 1997 2190
Compression ratio – 8.5 18.0
Weight (Dry) kg (lb) 143 (315) 165
Fuel – LPG Gasoline Diesel
ldling RPM 800 800
Engine speed
Full load RPM 2300 2400
(Range: ±50rpm)
No load RPM 2600 2600

GENERAL
Specification
Item Unit
SF12L SF12G CMP20SG
Cooling method –
CMP15L CMP18L CMP20SL CMP15G CMP18G
Force circulation
01
Opening
temp. °C 82 71 01
Thermostat 9
Full open 95 85
temp. °C
Type – Push type
Fan Diameter mm(in) 431.8 (17) 370
1.1 : 1 1:1
Cooling system
Drive ratio –
Type – V-belt raw edge Raw edge plain, type A

Fan belt
Size in 48 41
Type – Centrifugal
Water pump
l/min
Capacity 85 (22.5)
(USgal/min)
Recommended AF coolant
Engine system
anti-freeze –
Cooling system l
8.5 (2.25)
capacity (USgal)
Pressure kg/cm2
0.85~1.12 (12.1~15.9)
(Radiator cap) (lb/in2)
Fuel pump type – – Cam shaft driving type Diaphragm type
Fuel injection pump – –

Fuel system
Governor – Pneumatic Airflow type
Fuel filter type – – Mechanicel paper element
Fuel tank capacity – 15 kg (33 lb) 37l (8.7 us gal)
Lubricating method – Force lubrication

Lubricating system
Oil pump type – Gear pump
Lubricating system kg/cm2

3.5~4.5 (50~64)
pressure (lb/in2)
Pressure kg/cm2
3.5~4.5 (50~64) 4.0 ± 0.7
Engine (lb/in2)
oil Capacity l
4.8 (1.27) 6.3 (0.5)
(including filter) (USgal)
GENERAL
Specification
Item Unit
SF12L SF12G CMP20SG
01 System voltage V
12
01 Voltage V 12
10
Cold cranking A 430 630
(@-18°C)
Battery
Min. capacity A·H 45
(@25°C)
Electric system
Engine system
Charging V 12
Voltage
Alternator V–A 12 – 50 12 – 40
Voltage V 12
Starter Cranking ratio – 16.5:1 9.77:1
Type – Solenoid shift type
Ignition order
– 1–3–4–2
(order from F.W.)
Type – Power shift type

Transaxle
Model – TA – 12
Model – SSS8 – 11
Torque
converter – 3.00
Torque ratio
Reduction ratio, – 2.833

transmission First stage
Powertrain system
Reduction ratio, Differential 5.429

axle gear
kg/cm2
Clutch working pressure 9.5 ~ 12.0 (135 ~ 170)
(lb/in2)
Torque converter kg/cm2
1.76 ~ 3.16 (25 ~ 45)
charging pressure (lb/in2)
l
Transaxle oil capacity 12 (3.2)
(us gal)
Service brake type – Internal expansion duo servo drum brake type (with auto adjuster)
Braking mm(in) φ17.46×24 (φ0.69×0.94)

Master cylinder
(Diameter × Stroke)
lnching mm(in) φ20×28 (φ0.79×1.10)
GENERAL
Specification
Item Unit
SF12L SF12G CMP20SG
Brake fluid capacity

l
(usgal)
1.0 (0.26)
01
Parking brake type – Drum brake 01
Steering Relief setting kg/cm2 11
92~97 (1310~1380)
system pressure (lb/in2)
Type – Load sensing

Steering unit
Displacement cc/rev. 80
Diameter mm(in) 330 (13)

Steering
wheel Rotating No.
– 4.4
(Lock to lock)
Diameter 75/50 (2.95/1.97)
mm(in)
Steering (Bore/rod)
cylinder
Stroke mm(in) 137 (5.4)
Type – Counterbalance valve built – in type
l /min
Max. flow rate (usgal/min) 75 (20)
Hydraulic system
Main valve
kg/cm2
Max. pressure 235 (3340)
(lb/in2)
Relief setting kg/cm2 193 210 193 210 193 210
pressure (lb/in2) (2750) (2990) (2750) (2990) (2750) (2990)
Type – Gear pump
Rated kg/cm2
235 (3340)
pressure (lb/in2)
Main Pump
Displacement cc/rev 22.8
Rotating rpm 500 ~ 3000

speed
Number EA 2
Lift cylinder
Diameter mm(in) 45 (1.8)
(MFH 3000)
Stroke mm(in 1500 (59)
Number EA 2
Tilt cylinder Diameter mm(in) 75/30 (3/1.2)

(Bore/rod)
Stroke mm(in) 100 (3.9)
l
Hydraulic tank capacity 31 (8)
(usgal)
GENERAL
Specification
Item Unit
SF12L SF12G CMP20SG
01 Type –
BL544
01 Pitch mm(in) 15.875 (0.625)

12
Lift chain Plate 2.43 (0.1)
thickness mm(in)
Attachment
Layers EA 8
Pin diameter mm(in) 5.956 (0.234)
Chain sheave Number EA 2
Mast EA 4
No. of roller
bearing
Carriage EA 6
650 775 900 1130 650 775 900 1130 775 900 1130
Weight of counterweight kg (lb) (1430) (1710) (1985) (2490) (1430) (1710) (1985) (2490) (1710) (1985) (2490)
LOAD CAPACITY
CAPACITY CHARTS
4000
SF12L/SF12G
4000
SF15L/G/D/CMP15L/G/D
01
3750 3750 02
3500 3500
1
3250 3250
3000 3000
2750 2750
Allowable load weight (kg)

2500 2500
2250 2250
2000 2000
MFH 3000
1750 1750
MFH 3000 MFH 3700
1500 1500
MFH 3700
1250 1250
1000 1000
750 750
500 500
MFH 4800
250 250
MFH 4800
0 0
500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
Load center from front face of fork (mm) Load center from front face of fork (mm)
SF18L/G/D/CMP18L/G/D (kg) SF20SL/SD/CMP20SL/SD/SG

4000 4000
3750 3750
3500 3500
3250 3250
3000 3000
2750 2750
2500 2500
MFH 3000 MFH 3000
2250 2250
MFH 3700
2000 2000
MFH 3700
1750 1750
1500 1500
1250 1250
1000 1000
750 750
500 500
MFH 4800 MFH 4800
250 250
0 0
500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
Load center from front face of fork (mm) Load center from front face of fork (mm)
FX199
• The charts above are for standard mast. Optional devices such as the high mast, attachment,
will reduce the allowable load weight.
LOAD CAPACITY
LOAD WEIGHT AND STABILITY
01 The fork lift can be regarded as a seesaw where

the front wheels act as a fulcrum upon which
the counterweight load on the rear wheels is
02 counterbalanced by the load on the forks. Load center
2 Loads that exceed the specified allowable

limits (weight / load center / lift) will cause the
rear wheels to float, reduce steering
performance, and can tip over the fork lift.
FX103
LOAD CENTER AND CAPACITY CHART
The distance between the center of the load and Forward tilt angle Backward tilt angle
the fork carriage is called the load center. The
charts shown here represent the relation
between the load center and the allowable load
30cm(12in)
weight.
When you drive the unit, lift the forks about
30cm above the floor or road and fully tilt the
mast backward. Lifting the load or tilting the
mast forward while driving will change the load FX104
center to tip the fork lift over.
(1) Position the load against the backrest and
support at least 2/3 of load length with both
forks.
(2) Loading by the tip of the forks may damage the mast or forks.
(3) Avoid extreme side unbalance to prevent the load from slipping off.
(4) Operate the tilt control lever carefully when you handle the load.
(5) Abrupt forward tilt operation may cause the fork lift to tip over.
RATED CAPACITY PLATE

CAPACITY kg
LIFTING HEIGHT mm
Rated capacity, lifting height and actual capacity kg
for load center distance are shown on the rated LOAD
capacity plate.
LOAD CENTER DISTANCE

6092-12321
FX320
COOLANT / FUEL / LUBRICATION
Unit : l (gal)
Ambient temperature Filling capacity

Division –22 –4
–30 –20
14
–10
32
0
50
10
68
20
86
30
104 122°F SF12/15/18L/20SL SF12/15/18G SF15/18D/20SD
40 50°C CMP15/18L/20SL CMP15/18G/20SG CMP15/18D/20SD 01
ISO VG22 or VG15 03
Hydraulic oil 31 31 31 1
ISO VG32
ISO VG46
SAE 10W–30
4.8 4.8 –
SAE 5W–30
Engine oil
SAE 10W–50
– – 10
SAE 5W–30
Transmission
CLARK #2776236 12 12 12
oil
Anti freeze
Water 50%, Antifreeze 50% 8.5 8.5 8.5
solution
Propane gas HD–5 15 kg – –
Fuel
ASTM D975 No.1
– FULL FULL
ASTM D975 No.2
ASTM : American Society of Testing and Material

SAE : Society Automotive Engineers
API : American Petroleum Institute
ISO : International Standardization Organization
PERIODIC MAINTENANCE
No.
Period First
month
First
Every
1 month
Every
Every
3 months
Every
Every
6 months
Every
Every
12 months
Every
01
Items 200 hours 200 hours 500 hours 1000 hours 2000 hours
04
Engine system 1
1. Inspection and adjustment (or replacement)
1) Intake/Exhaust valve clearance
2) Belt tension
Cylinder head bolts and
3)
manifold nuts
(4) Fuel strainer (Filter)
5) Idling speed
Electrolyte specific gravity
6)
(Battery)
7) Starting motor and alternator
8)
9)
10)
11)
12)
2. Cleaning
(1) Radiator exterior (Fins)
(2) Fuel strainer (Filter) element
(3) Air cleaner element
4) Fuel tank interior
Cooling system interior
5)
(Radiator)
3. Replacement
(1) Engine oil
(2) Engine oil filter
(3) Coolant
(4) Air cleaner element
∗ If you operate the fork lift in a dusty environment, “)” marked items must be checked more
frequently.
Period First Every Every Every Every

month 1 month 3 months 6 months 12 months
No.
01 Items
Chassis and Attachment

First Every Every Every Every
200 hours 200 hours 500 hours 1000 hours 2000 hours
04 1. Inspection and adjustment (or replacement)

2 1) Brake pedal and inching pedal
clearance
2) Parking brake lever and
operation
3) Lift chain tension
4) Carriage bearing
5) Mast bearing
6) Mast operation
7) Tilt and lift cylinder fitting
8) Tilt and lift cylinder operation
9) Hydraulic pump operation
10) Transmission oil
11) Gear oil (differential and axle end)
2. Lubrication
(1) Lift chain
(2) Free bar bushing
3) Mast mounting bushing and pin
4) Joints
5) Tilt cylinder mounting pin and
bearing
6) Side roller (Carriage)
7) Steering axle bearing and arm
3. Cleaning
1) Torque converter intake filter
2) Hydraulic oil tank interior
4. Replacement
(1) Transmission oil
(2) Transmission oil filter
(3) Hydraulic oil
(4) Hydraulic oil filter
5) Hydraulic oil strainer
6) Brake fluid
7) Wheel bearing grease
8) Gear oil (differential and axle end)
∗ If you operate the fork lift in a dusty environment, “)” marked items must be checked more
frequently.
∗ Change oil and filter after the first 50 hours and again after 100 operating hours when the
transaxle is new or rebuilt.
LUBRICATION
Perform periodic maintenance, replacement and lubricating according to following lubrication chart
to maintain optimum condition. Otherwise service, life will be reduced and breakdowns may occur
frequently. 01
04
3
LUBRICATION CHART CO Anti-freeze
Lubricant G Grease HO Hydraulic oil
Replace EO Engine oil FO Fuel
Check TO Transmission oil BO Brake fluid
Transmission oil filter
Lift chain Mast mounting

EO G
RH, LH(2points) RH, LH(2points)
Brake fluid Tilt cylinder end

BO BO G
(On dash panel) RH, LH(2points)
Transmission oil TO TO
Engine oil EO EO HO HO Hydraulic oil
Fuel(Diesel, Gasoline) FO
Engine oil filter Hydraulic oil filter
Air cleaner
Coolant CO CO
Steer king pin

G
RH, LH(4points) Hydraulic breather
Steer axle link

G
RH, LH(4points)
Wheel bearing
Fuel (LPG) FO
RH, LH(2points)
Every 10 hours or daily

Every 200 hours or monthly
Every 500 hours or every 3 months
Every 1000 hours or every 6 months
Every 2000 hours or yearly
FX203
TIGHTENING TORQUE
TIGHTENING TORQUE
Item Unit
SF12L
SF15L SF18L SF20SL
CMP15L CMP18L CMP20SL
Specification
SF12G
SF15G SF18G
CMP15G CMP18G
CMP20SG
SF15D SF18D SF20SD
01
Bolt, mounting bracket, engine kg·cm
2
18.4 ± 1 (126 ~ 140)
05
(lb·ft) 1
Bolt, transaxle kg·cm2
4.9 ± 0.5 (32 ~ 39)
(lb·ft)
Bolt, steering axle and silent block kg·cm

2
4.2 ± 0.4 (27 ~ 33)
(lb·ft)
Bolt, silent block kg·cm2

6.5 ± 0.7 (40 ~ 50)
(lb·ft)
Bolt, parking brake lever kg·cm2

8.5 ± 0.8 (54 ~ 66)
(lb·ft)
Nut, driving wheel kg·cm2

45 ~ 50 (325 ~ 360)
(lb·ft)
Nut, steering wheel kg·cm2

26.7 ± 2.7 (170 ~ 210)
(lb·ft)
kg·m
Bolt, clamping, rod end, tilt cylinder 3.6 (25)
(lb·ft)
kg·m
Bolt, pin, tilt cylinder 26.7 ± 2.7 (180 ~ 200)
(lb·ft)
kg·m 13.1 ~ 16.1 (95 ~ 116)
Bolt, steering unit
(lb·ft)
kg·m 12.1 ~ 14.7 (85 ~ 105)
Bolt, steering column
(lb·ft)
kg·m 25 ~ 30 (180 ~ 215)
Nut, steering hand wheel
(lb·ft)
kg·m 10.7 ~ 12.9 (75 ~ 90)
Bolt, counterweight
(lb·ft)
kg·m 5.8 ~ 7.2 (40 ~ 50)
Bolt, lift cylinder mast
(lb·ft)
kg·m 29.7 ~ 31 (215 ~ 225)
Rubber
(lb·ft)
Bolt, mast stopper
kg·m 16 ~ 19.7 (115 ~ 140)
Steel
(lb·ft)
ENGINE (FOR LPG & GASOLINE)
(MMC 4G63) 10
• 10 – 01 GENERAL • 10 – 05 ELECTRIC
INFORMATION COMPONENT
– Periodic inspection – Inspection
chart – Distributor
– How to read this – Alternator
chapter – Starter
– Engine model and • 10 – 06 FUEL SYSTEM
numbers – Removal
• 10 – 02 SPECIFICATION – Installation
– General – Carburettor–Gasoline
specifications – Carburettor – LPG
– Service – Air governor
specifications – Other
– Tightening torque components – LP
– Special tools • 10 – 07 COMPONENTS
• 10 – 03 ADJUSTMENT – Rocker arms and
– Valve clearance camshaft
adjustment – Cylinder head and
– Ignition timing valves
adjustment – Front case and oil
– Idling speed pan
adjustment – Piston and
– Air governor connecting rod
(high speed) – Crankshaft and
• 10 – 04 TIMING BELT cylinder block
– Removal • 10 – 08 TROUBLESHOOTING
– Inspection – By symptom
– Installation – By component
E N G I N E
GENERAL INFORMATION
PERIODIC INSPECTION CHART
LUBRICATION
Intervals
Every 200 hours

Lubricant
10
Every 400 hours
Every 600 hours
Every 800 hours

Initial 100 hours
Lubrication 01
after delivery
No.
On delivery
point Type Quantity 1
1 Engine oil pan Engine oil 4 liters (1.06 U.S.gal.)

2 Distributor Engine oil As required
P Change p Inspection
INSPECTION
Intervals
Every 200 hours
Every 400 hours
Every 600 hours
Every 800 hours

Initial 100 hours
after delivery
No. Check point Remarks

On delivery
Cylinder head nuts

1 Manifold nuts
Support bolt
2 Valve clearance
3 Engine operating condition
4 Ignition timing
5 Fan belt tension
6 Distributor
7 Engine compression pressure
8 Spark plugs
9 Starting motor
10 Oil filter element
11 Oil, fuel, water, gas, leakage
12 Cooling water
13 Breather hose, and nipple Checking cracks, clogging
P Change p Inspection
E N G I N E
GENERAL INFORMATION
HOW TO READ THIS CHAPTER
SCOPE OF EXPLANATION
This chapter describes the service procedures for the engine removed from the vehicle.
For procedures concerning removal of the engine from the vehicle and on–vehicle inspection and
10 servicing, refer to the appropriate service manuals separately prepared for the individual models.
01 MAINTENANCE AND SERVICING PROCEDURES

2
• A diagram of the component parts is provided near the front of each section in order to give
the reader a better understanding of the installed condition of component parts.
• The numbers provided within the diagram indicate the sequence for maintenance and servicing
procedures ; the symbol N indicates a non–reusable part ; the tightening torque is provided where
applicable.
a Removal steps
The part designation number corresponds to the number in the illustration to indicate
removal steps.
b Installation steps
Specified in case installation is impossible in reverse order of removal steps. Omitted if
installation is possible in reverse order of removal steps.
c Disassembly steps
The part designation number corresponds to the number in the illustration to indicate
disassembly steps.
d Reassembly steps
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
CLASSIFICATION OF MAJOR MAINTENANCE/SERVICE POINTS
When there are major points relative to maintenance and servicing procedures (such as essential
maintenance and service standard values, information regarding the use of special tools, etc.),
these are arranged together as major maintenance and service points and explained in detail.
SYMBOLS FOR LUBRICATION, SEALANTS AND ADHESIVES
Information concerning the locations for lubrication and for application of sealants and adhesives
is provided, by using symbols, in the diagram of component parts, or on the page following the
component parts page, and explained.
: Grease(multipurpose grease unless there is a brand or type specified)

: Sealant or adhesive
: Brake fluid, automatic transmission fluid or air conditioner compressor oil
: Engine oil or gear oil
E N G I N E
GENERAL INFORMATION
INSPECTION
Only the inspections to be performed by using special tools or measuring instruments are
covered. General service procedures not covered in this manual, such as visual inspections and
cleaning of parts, however, should always be performed during actual service operations.
PRECAUTIONS BEFORE SERVICE

10
REMOVAL AND DISASSEMBLY 01
3
For prevention of wrong installation or reassembly
and for ease of operation, put mating marks to
the parts where no function is adversely affected.
SPECIAL TOOL
Be sure to use special tools when their use is

specified for the operation.
Use of substitute tools will result in malfunction
of the part or damage it.
TIGHTENING TORQUE
Tighten the part properly to specified torque.
SEALANT
Use specified brand of sealant.
Use of sealant other than specified sealant may

cause water or oil leaks.
E N G I N E
GENERAL INFORMATION
REPLACEMENT PART
When oil seal, O – ring, packing and gasket

have been removed, be sure to replace them
with new parts.
However, rocker cover gasket may be reused if

it is not damaged.
10
01
4
RUBBER PARTS
Do not stain timing belt and V – belt with oil or

water.
Therefore, do not clean the pulley and sprocket

with detergent.
OIL AND GREASE
Before reassembly, apply specified oil to the

rotating and sliding parts.
GENUINE PART
When the part is to be replaced, be sure to use

a genuine part.
For selection of appropriate part, refer to the

Parts Catalog.
E N G I N E
GENERAL INFORMATION
ENGINE MODEL AND NUMBERS
• Indicating of engine model and number
Engine model Engine number
4G63 AA0001 to YY9999
The engine model and serial number are

10
stamped on the right side cylinder block surface, 01
at a place behind the alternator. 5
E N G I N E
SPECIFICATION
GENERAL SPECIFICATIONS
Item SF12/15/18G SF12/15/18L/20SL
CMP15/18G/20SG CMP15/18L/20SL
Engine model 4G63 – 32SG 4G63 – 31SL
Water–cooled, 4–cycle
Type
Gasoline – powered LPG – powered
No. of cylinders and arrangement
Combustion chamber type
4, in – line
Semi – spherical
10
Valve mechanism SOHC 02
1 a
Total displacement cc (cu in) 1997 (121.9)
Bore × stroke mm (in) 85.0 × 88.0 (3.3 × 3.5)
Dry weight kg(lb) 143 (315)
Compression ratio 8.5
Compression pressure kgf/cm2 (psi) 11.5 (163.5) at 300rpm
Open 12° BTDC
Intake valve
Close 40° ABDC
Open 54° BBDC
Exhaust valve
Close 6° ATDC
Firing order 1–3–4–2
lgnition timing BTDC/rpm 4°/740
Fuel pump type Mechanical (diaphragm)
Carburettor type Down draft
Governor type Pneumatic
Lubrication system Pressure feed, full–flow filtration
Oil pump type Gear, driven by timing belt
Oil filter type Filter paper, cartridge
Cooling system Water–cooled, forced circulation
Water pump type Centrifugal, driven by V – belt
Thermostat type Wax pellet
Electrical system DC 12, negative ground
Alternator type (12V × 50A) Alternating current, built–in fan and regulator
Starter motor type (12V × 1.2kw) Reduction drive
Distributor type Contact pointless (transistor type)
Spark plug type (NGK or ND) BP4ES or W14EX – U
Quantity of lubricating oil l (gal) 4.0 (1.06)
Quantity of coolant l (gal) 3.1 (0.82)
E N G I N E
SPECIFICATION
SERVICE SPECIFICATIONS
Unit : mm(in)
Item Standard value Limit
Cylinder head Flatness of gasket surface 0.03 (0.001)
Grinding limit
0.2
∗Total resurfacing depth of both
(0.008)
10 cylinder head and cylinder block
Overall height 89.9~90.1(3.539~3.547)
02 Oversize rework dimensions of valve
2 guide hole
0.05 (0.002) 13.05~13.07 (0.514~0.515)
0.25 (0.010) 13.25~13.27 (0.521~0.522)
0.50 (0.020) 13.50~13.57 (0.531~0.534)
Oversize rework dimensions of valve
seat ring hole
0.30 (0.012) 44.30~44.33 (1.744~1.757)
Intake
0.60 (0.024) 44.60~44.63 (1.744~1.757)
0.30 (0.012) 38.30~38.33 (1.508~1.509)
Exhaust
0.60 (0.024) 38.60~38.63 (1.508~1.509)
Camshaft Cam height Intake 41.62 (1.639) 41.12 (1.619)
Exhaust 41.62 (1.639) 41.12 (1.619)
Journal diameter 33.935~33.950 (1.336~1.3366)
Oil clearance 0.05~0.09 (0.002~0.0035)
Valve Overall length Intake 109.76 (4.321)
Exhaust 106.56 (4.195)
Stem diameter Intake 7.960~7.975 (0.313~0.314)
Exhaust 7.930~7.950 (0.312~0.313)
Face angle 45°~45.5°
Thickness of valve head Intake 1.2 (0.047) 0.7 (0.028)
(margin) Exhaust 2.0 (0.079) 1.5 (0.059)
Stem–to–guide clearance Intake 0.025~0.058 (0.001~0.002)
Exhaust 0.050~0.088 (0.002~0.003)
Valve spring Free height 48.0 (1.89) 47.0 (1.85)
Load/installed height 18kg / 40.4
Out–of–squareness 2° or less 4°
Valve guide Overall length Intake 47 (1.85)
Exhaust 52 (2.05)
Inner diameter 8.000~8.018 (0.315~0.316)
Valve seat Valve contact width 0.9~1.3 (0.035~0.051)
Sinkage 0.2 (0.008)
E N G I N E
SPECIFICATION
Unit : mm(in)
Piston Outside diameter 84.97~85.00 (3.345~3.346)
Piston clearance 0.02~0.04 (0.0008~0.0016)
Piston ring End gap No. 1 ring 0.25~0.40 (0.010~0.016) 0.08 (0.03)
No. 2 ring 0.45~0.60 (0.018~0.024) 0.08 (0.03)
Ring–to–ring groove
Oil ring
N0. 1
0.20~0.60 (0.008~0.024)
0.02~0.06 (0.0008~0.0024)
1.0 (0.04)
10
clearance No. 2 0.02~0.06 (0.0008~0.0024)
Piston pin Outside diameter 22.002~22.005 (0.8662~0.8663)
02
3
Press–in load (at room temperature)
750~1750
kg
Connecting Big end center–to–small end center 149.9~150.0
rod length (5.902~5.905)
Bend 0.05 (0.002)
Twist 0.10 (0.004)
Big end thrust clearance 0.10~0.25 (0.004~0.010)
Crankshaft End play 0.05~0.18 (0.002~0.007)
Journal outside diameter 56.985~57.995 (2.244~2.283)
Pin outside diameter 44.985~44.995 (1.7711~1.7715)
Out–of–roundness and taper of 0.005
journal and pin (0.0002)
Concentricity of journal and pin 0.03 (0.0012)
Oil clearance of journal 0.02~0.04 (0.010~0.016)
Oil clearance of pin 0.02~0.05 (0.010~0.020)
Cylinder block Cylinder inner diameter 85.00~85.03 (3.346~3.347)
Flatness of gasket surface 0.05 (0.020)
Grinding limit
0.2
∗Total resurfacing depth of both
(0.008)
Cylinder head and cylinder block
Overall height 283.9~284.1 (11.177~11.185)
Oil pump Drive gear 0.08~0.14 (0.003~0.005)
Side clearance
Driven gear 0.06~0.12 (0.002~0.005)
New belt 7.5~9.0 (0.30~0.35)
Deflection
Used belt 10 (0.40)
Drive belt
New belt 5880
Tension N
Used belt 3920
E N G I N E
SPECIFICATION
Unit : mm(in)
Carburettor Throttle bore diameter 32 (1.26)
Outer venturi diameter 24 (0.94)
Inner venturi diameter 9~12 (0.35~0.47)
Main jet 132.5 (5.22)
10 Main air jet diameter

Pilot jet diameter
0.9 (0.035)
0.55 (0.022)
Pilot air jet diameter 1.6 (0.063)
02 Fast idle opening angle 18.5 (0.728)
4
Alternator Nominal output A 55
Brush length Wear limit
line
Slip ring outer diameter 23 (0.90)
Rotor coil resistance Ω 3~5
Starter motor Nominal output kW 1.2
No – load
Characteristics Voltage V 11.5
Current A 100 or less
Speed rpm 3000
Commutator Outer diameter 32 (1.26) 31 (1.22)
Runout 0.05 (0.002) 0.1 (0.004)
Undercut 0.5 (0.020) 0.2 (0.008)
Pinion gap 0.5~2.0 (0.02~0.08)
Brush length Wear limit
line
Distributor Centrifugal advance crank Start 0 / 400
angle/engine speed ° / rpm End 20 / 2500
Vacuum advance crank Start 0 / 80
angle/vacuum ° / mmHg End 23 / 280
Ignition coil Primary coil resistance Ω 1.18~1.32
Secondary coil resistance kΩ 22.1~29.9
External resistor Ω 1.22~1.49
Spark plug Plug gap 0.7~0.8(0.027~0.031)
Thermostat Valve opening temperature °C 82
Fully open temperature °C 95
Valve lift 8 or more
E N G I N E
SPECIFICATION
TIGHTENING TORQUE
TIGHTENING TORQUE OF EACH PART

Item kgf·m (lbf·ft)
Alternator, ignition coil
Water pump pulley bolt
Alternator pivot nut
0.9 (6.5)
4.2 (30.3) 10
Adjuster lock bolt 2.4 (17.3) 02
Alternator brace bolt 1.4 (10.1) 5
Crankshaft pulley bolt 2.5 (18.1)
Spark plug 2.5 (18.1)
Distributor nut 1.2 (8.7)
Timing belt
Timing belt cover bolt 1.1 (7.9)
Tensioner spring spacer 4.9 (35.4)
Tensioner bolt 4.9 (35.4)
Oil pump sprocket nut 5.5 (39.7)
Crankshaft bolt 12.0 (86.6)
Camshaft sprocket bolt 9.0 (65.0)
Engine support bracket bolt 3.6 (26.0)
Timing belt rear bolt 1.4 (10.1)
Fuel system
Fuel pump 1.1 (7.9)
Carburettor nut 1.2 (8.7)
Intake manifold
Water outlet bolt 1.4 (10.1)
Water temperature gauge unit 1.5 (10.8)
Intake manifold bolt/nut 1.8 (13.0)
Exhaust manifold
Oil level gauge guide bolt 1.4 (10.1)
Heat protector bolt 0.9 (6.5)
Exhaust manifold nut 3.5 (25.3)
Water pump bolt 1.4 (10.1)
Rocker arm and camshaft
Rocker cover bolt 0.6 (4.3)
Bearing cap bolt, M8 2.4 (17.3)
Bearing cap bolt, M6 2.0 (14.4)
E N G I N E
SPECIFICATION
Cylinder head, valve

Cylinder head bolt 2.0 (14.4) + 1/4 turn
+ 1/4 turn
Front case, oil pan
Drain plug 4.0 (28.9)
Oil pan bolt 0.7 (5.1)
Oil screen bolt/nut 1.9 (13.7)
10 Oil Pressure switch
Relief plug
1.0 (7.2)
4.5 (32.5)
02 Oil filter bracket 1.9 (13.7)
6 Plug 2.4 (17.3)
Bolt 3.6 (26.0)
Oil pump cover bolt 1.7 (12.3)
Oil pump ocver screw 1.0 (7.2)
Front case bolt 2.4 (17.3)
Piston, connecting rod
Connecting rod bearing nut 2.0 (14.4) + 1/4 turn
Crankshaft, cylinder block
Flywheel bolt 13.5 (97.5)
Oil seat case bolt 0.5 (3.6)
Rear plate bolt 0.9 (6.5)
0.6 (43.3)
Rear plate cover 1.1 (7.9)
Rear oil seal case bolt 1.1 (7.9)
Bearing cap bolt 2.0 (14.4) + 1/4 turn
Starter motor
Starter motor bolt 2.7 (19.5)
GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
STANDARD BOLTS AND NUTS Unit : kgf·m (lbf·ft)

Torque
Bolt, stud, nut Flange bolt, flange
Nominal (with spring washer) nut
Pitch
diameter Head mark Head mark Head mark Head mark Head mark
4 7 10 4 7
M50 0.80 – 0.5 (3.6) – – 0.6 (4.3)
M60 1.00 – 0.9 (6.5) 1.2 (8.7) – 1.0 (7.2)
M70 1.25 1.2 (8.7) 2.2 (15.9) 3.0 (21.7) 1.3 (9.4) 2.4 (17.3)
M80 1.25 2.5 (18.1) 4.5 (32.5) 6.0 (43.3) 2.6 (18.8) 5.0 (36.1)
M90 1.25 4.2 (30.3) 8.3 (59.9) 10.7 (77.3) 4.7 (33.9) 9.5 (68.6)
M10 1.50 7.3 (52.7) 14.0 (101.1) 14.5 (104.7) – –
E N G I N E
SPECIFICATION
TAPERED THREADS Unit : kgf·m (lbf·ft)

Torque
Size Material of internal threads : Material of internal threads :
Aluminum alloy Cast iron or steel
NPTF 1/6 0.5~0.8 (3.6~5.8) 0.8~1.2 (5.8~8.7)
PT 1/8 0.8~1.2 (5.8~8.7) 1.5~2.2 (10.8~15.9)
PT 1/4 2.0~3.0 (14.4~21.7) 3.5~4.5 (25.3~32.5)
NPTF 1/4
PT 3/8
2.0~3.0 (14.4~21.7)
4.0~5.5 (28.9~39.7)
3.5~4.5 (25.3~32.5)
5.5~7.5 (39.7~54.2)
10
PT 1/2 7.0~10.0 (50.5~72.2) 12.0~16.0 (86.6~115.5) 02
7
TIGHTENING METHOD OF BOLTS / NUTS WITH NYLON OR PLASTIC

COATING, INSERT OR WASHER
A new type of bolt, using nylon or plastic to improve torque retention, is currently used in some
parts of the engine. The tightening method for the bolt is different from the conventional one.
Be sure to observe the method described in the text when tightening the bolt.
Service limits are provided for the bolt. Make sure that the service limits described in the text
are strictly observed.
AREA WHERE THE BOLTS ARE IN USE
• Cylinder head bolts

• Main bearing cap bolts
• Connecting rod cap bolts
TIGHTENING METHOD
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°).
The tightening method varies on different areas.
Observe the tightening method described in the text.
SEALANT
Part to be applied Brand

Water temperature gauge unit Threebond 1104F or equivalent
Semi circular packing Threebond 1212D or equivalent
Rocker cover Threebond 1212D or equivalent
Oil pressure switch Threebond 1211 or equivalent
Oil pan Threebond 1207F or equivalent
Rear oil seal case Threebond 1207F or equivalent
Rear plate bolt Threebond 1104 or equivalent
Oil seal case bolt Threebond 1104 or equivalent
E N G I N E
SPECIFICATION
FORM – IN – PLACE GASKET (FIPG)
The engine has several areas where the form–in–place gasket (FIPG) is in use. To ensure that
the gasket fully serves its necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause
leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking
or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore,
it is absolutely necessary to apply the gasket evenly without a break, while observing the correct
10 bead size.
The FIPG used in the engine hardens as it reacts with the moisture in the atmospheric air, it
02 is normally used in the metallic flange areas.
8
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method.
In some cases, however, the sealant between the joined surfaces may have to be broken by
lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly
hammered in between the joined surfaces.
In this case, however, care must be taken to prevent damage to the joined surfaces. For removal
of the oil pan, the special tool ”Oil Pan Remover” (MD998727) is available. Be sure to use the
special tool to remove the oil pan.
Surface preparation
Thoroughly remove all substances desposited on the gasket application surfaces, using a gasket
scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied
is flat. Make sure that there are no oils, greases and foreign substances deposited on the
application surfaces. Do not forget to remove the old FIPG remaining in the bolt holes.
Form–in place gasket application

Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle
the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away
unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts
in position. When the parts are mounted, make sure that the gasket is applied to the required
area only.
The FIPG application procedure may vary on different areas. Observe the procedure described
in the text when applying the FIPG.
E N G I N E
SPECIFICATION
SPECIAL TOOLS
Tool Number Name Use
MB990767 End yoke holder Holding camshaft sprocket
(Use with MD998719)
MB990938 Handle Installation of crankshaft rear

oil seal (Use with MD998776)
10
02
9
MD998162 Plug wrench Removal and installation of

front case cap plug
MD998285 Crankshaft front Guide for installation of

seal guide crankshaft front oil seal
MD998375 Crankshaft front oil Installation of crankshaft front

seal installer oil seal
MD998440 Leak – down tester Leak– down test of lash adjuster
MD998441 Lash adjuster Air bleeding of lash adjuster

retainer
Air bleed wire
MD998442 Air bleeding of lash adjuster
Lash adjuster
holder
MD998443 Retainer for holding lash

adjuster in rocker arm at time
of removal and installation of
rocker arm and rocker shaft
assembly
E N G I N E
SPECIFICATION
Tool Number Name Use

MD998713 Camshaft oil seal Installation of camshaft oil seal
installer
MD998719 Pulley holding pins Holding camshaft sprocket when
10 loosening or torquing bolt

(Use with MB990767)
02 (Single camshaft engine)
10
MD998727 Oil pan remover Removal of the oil pan
MD998729 Valve stem seal Installation of valve stem seal

installer (8–valve single camshaft engine)
MD998772 Valve spring Compression of valve spring

compressor
MD998776 Crankshaft rear oil Installation of crankshaft rear oil

seal installer seal
MD998778 Crankshaft Removal of crankshaft sprocket

sprocket puller and crankshaft sprocket B
MD998780 Piston pin setting Removal and installation of

tool piston pin
MD998781 Flywheel stopper Holding flywheel and drive plate

E N G I N E
ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
• Being adjusted automatically with a lash adjuster, the valve clearance needs no adjustment.
IGNITION TIMING ADJUSTMENT

10
• Let the engine warm up until the engine
coolant temperature rises to 80 to 90°C.
03
1
• Check that the ignition timing is as indicated
when the engine is running at idling speed.
Standard value :
Approx. 4° BTDC/800 rpm
• If the ignition timing does not conform to the

standard value, adjust by moving the distributor.
IDLING SPEED ADJUSTMENT
GASOLINE ENGINE
• Let the engine warm up until the engine

coolant temperature rises to 80 to 90°C.
• Back off the mixture adjusting screw 3.5 ± 0.5

turns from the fully closed position.
• Adjust the engine speed to the specified low

idling speed with the speed adjusting screw.
• Slowly turn down the mixture adjusting screw

to a point where the engine speed begins to
decrease.
Standard value : 800 ± 20rpm
• After racing the engine two or three times (at approx. 2500rpm), readjust the speed adjusting
screw to the point at which the engine runs at the specified idling speed.
E N G I N E
ADJUSTMENT
LP GAS ENGINE
Idling speed can be adjusted with the idling

screw. Turning the idling screw clockwise
makes air–fuel mixture richer, and vice versa.
Idling speed of the engine mounted on a vehicle
should be set to 800 rpm, which is rather higher
than that of gasoline engines. To set the idling
10 speed, turn in the idling screw clockwise as far
as engine speed increases. When a start of
03 decrease of engine speed is felt, turn back the
idling screw and set the screw to a position
2
where the most stable running of the engine is
attained. Then, adjust engine speed accurately
to 800 rpm with the throttle screw. (The idling
speed adjustment should be performed after the
engine has been warmed completely.)
Idling speed of the engine alone has been set
to 800 rpm.
LP GAS REGULATOR VALVE ADJUSTMENT
With the engine running under full–load(stall)

condition, turn the valve counterclockwise until
the rpm drops. Then, turn the valve clockwise
until engine speed increases to the maximum.
Set the valve to the start position of the maximum
engine speed range. That position will approxi-
mately coincide with the position shown in the
figure.
E N G I N E
SPECIFICATION
AIR GOVERNOR (HIGH SPEED)
HIGH SPEED ADJUSTMENT
• Place all the hydraulic levers in the neutral

position.
• Depress the accelerator pedal all the way. (The
carburettor throttle valve will open fully.)
10
• While holding the adjust screw to prevent it
from turning, rotate the adjusting nut either
03
clockwise or counterclockwise to make the 3
engine run at 2600±50 rpm.
– Clockwise rotation
⇒ Increases the engine speed (increases
the installed load of spring.)
– Counterclockwise rotation
⇒ Decreases the engine speed (decreases the installed load of spring)
ANTI–HUNTING
• Place all the hydraulic levers or power train in

the neutral position.
• Depress the accelerator pedal all the way. (The
carburettor throttle valve will open fully.)
• Slowly rotate the adjusting screw clockwise
until hunting disappears.
– Clockwise rotation
⇒ Increases spring tension (reduces the number
of active turns of spring)
– Counterclockwise rotation
⇒ Reduces spring tension (increases the
number of active turns of spring)
Increasing the spring tension will eliminate hunting, but an excessively high tension will change
the governor characteristics and will produce some effects on the output characteristics of the
engine. It is, therefore, imperative to limit the movement of the adjusting screw to less than
two turns from the standard position.
• Clockwise rotation of the adjusting screw raises the engine maximum speed. Rotate the adjusting
nut counterclockwise to reduce the speed.
• Repeat anti–hunting adjustment two or three times by alternately adjusting the adjusting nut and
the adjusting screw until the best result is obtained.
• The number of active turns of spring should not be less than 11 when the adjustment is finished.
E N G I N E
TIMING BELT
REMOVAL
TIMING BELT REMOVAL
• When the timing belt is to be reused, make an

arrow mark on the back surface of the belt to
indicate the rotating direction with a chalk or
the like so that the belt can be installed in the
same direction.
10
04
1
• Move the timing belt tensioner upward and

temporarily tighten the tensioner lock bolt.
• Remove the timing belt.
CRANKSHAFT BOLT
CRANKSHAFT SPROCKET
CAMSHAFT SPROCKET
E N G I N E
TIMING BELT
INSPECTION
TIMING BELT
Replace belt if any of the following conditions

exist.
10 • Hardening of back rubber.

Back side is glossy without resilience and
leaves no indent when pressed with fingernail.
04
2
• Cracks on rubber back.
• Cracks or peeling of canvas.
• Cracks on tooth bottom.
• Cracks on belt sides.
• Abnormal wear of belt sides.
! The sides are normal if they are sharp as

if cut by a knife.
• Abnormal wear on teeth

– Earlier stage
Canvas worn (canvas fibers napped, rubber lost,
discolored whitish, and unclear canvas texture)
– Latter stage
Canvas lost, rubber exposed (tooth width thinner)
• Missing tooth
INSTALLATION
CAMSHAFT SPROCKET INSTALLATION
: 9.0 kgf·m (65 lbf·ft)

E N G I N E
TIMING BELT
CRANKSHAFT BOLT TIGHTENING
:12.0 kgf·m (86.6 lbf·ft)
TENSIONER INSTALLATION
10
04
:4.9 kgf·m (35.4 lbf·ft) 3
TIMING BELT
• Align the timing mark on the camshaft sprocket

with that on the cylinder head.
• Align the timing mark on the crankshaft

sprocket with that on the front case.
• Align the timing mark on the oil pump sprocket

with its mating mark.
E N G I N E
TIMING BELT
• Install the timing belt on the crankshaft

sprocket, oil pump sprocket and camshaft
sprocket in that order. There should be no
slack on the tension side.
• Apply a reverse direction (counterclockwise)
force to the camshaft sprocket to make the
tension side of the belt “tight”.
In that state, recheck that all the timing marks
10 are in alignment.
• Loosen a turn or two the tensioner bolt and

04 nut that were temporarily tightened to hold the
4 tensioner on the water pump side. This gives
tension to the belt by the action of the tensio-
ner spring.
• Rotate the crankshaft by the amount equival-
ent to two camshaft sprocket teeth in the
forward (clockwise) direction.
Since this step is intended for giving the timing
belt proper tension, do not attempt to rotate the
crankshaft in the reverse (counter-clockwise)
direction or press the belt to check the tension.
• Apply force to the tensioner in the direction

shown by arrow to make the belt engage
completely with each sprocket.
• Tighten the tensioner attaching bolt to the

specified torque.
:4.9 kgf·m (35.4 lbf·ft)
• Tighten the tensioner spacer to the specified torque.
:4.9 kgf·m (35.4 lbf·ft)
! If the nut is tightened first, the tensioner

may also turn together with the nut and
a loose tension of the belt may result.
Always tighten the bolt (at the bottom of
the tensioner) first and then tighten the
nut (at the top of the tensioner.)
• Hold the center of the tension side span of the

timing belt (between the camshaft and oil pump
sprockets) between your thumb and index
finger as shown. Then, make sure that the
clearance between the belt back surface and
cover meets the standard value.
– Standard value : 14mm (0.55 in)
E N G I N E
ELECTRIC COMPONENT
INSPECTION
IGNITION COIL
Perform the following measurements. Replace the ignition coil if the standard values are not
met.
• Measure the resistance values of the primary and secondary coils and of the external resistor
with a tester. If the readings are within the standard limits, it follows that there is no short or
10
open circuit in the ignition coil.
• Standard value
05
– Primary coil resistance value : 10.8 ~ 14.1 Ω 1
– Secondary coil resistance value : 22.1 ~ 29.9 Ω
– External resistor resistance value : 1.22 ~ 1.48 Ω
SPARK PLUG CABLE/HIGH TENSION CABLE
• Check the caps and covering for cracks.

• Measure the resistance values.
• Standard value : 16 kΩ / m
DISTRIBUTOR
INSTALLATION
• Turn the crankshaft so that the No.1 cylinder

is at top dead center.
• Align the distributor housing and gear mating
marks.
• Install the distributor to the engine while

aligning the fine cut (groove or projection) of
the distributor’s installation flange with the
center of the distributer installation stud.
E N G I N E
ELECTRIC COMPONENT
DISASSEMBLY
SIGNAL ROTOR SHAFT/SIGNAL ROTOR
• Remove the signal rotor shaft from the

signal rotor.
10
05 INSPECTION
2
Check the following points. If anything defective is found, repair or replace the appropriate parts.
CAP AND ROTOR
• Make sure that there are no cracks in the cap.

• Check the cap electrodes and rotor electrodes
for damage.
• Wipe away deposits from the cap and rotor.
ASSEMBLY BREAKER PLATE
• Install the breaker plate with its projection (A)

seated in groove (B).
INSTALLATION OF SIGNAL ROTOR
• Install the signal rotor over the rotor shaft,

making sure that the rotor dowel pin is seated
in the groove.
INSTALLATION OF IGNITER
• Adjust the signal rotor–to–ignitor pickup air gap.

– Standard value : 0.8 mm (0.031 in)
E N G I N E
ELECTRIC COMPONENT
ALTERNATOR
DISASSEMBLY
STATOR AND FRONT BRACKET
• With a blade screwdriver inserted between the

front bracket and stator core, pry to separate
10
the stator from the front bracket.
05
! Do not insert the screwdriver too deep as 3
the stator core could be damaged.
ALTERNATOR PULLEY
• With the pulley side facing up, hold the rotor

in a vise and remove the pulley.
! Use care not to damage the rotor.
STATOR ASSEMBLY / REGULATOR AND BRUSH HOLDER
• Remove the solder connecting the stator lead

wire to the main diode of the rectifier when
removing the stator.
• Remove the solder from soldered connections
with the rectifier when removing the rectifier
from the brush holder.
! • When soldering connections or when

removing solder, be careful not to let
heat transfer to the diode for long
periods of time.
Finish soldering and removing solder in
as short a time as possible.
• Be careful not to exert excessive force on the diode leads.
E N G I N E
ELECTRIC COMPONENT
INSPECTION
ROTOR
• Check the rotor coil continuity. Make sure that

there is continuity between the slip rings.
Measure the rotor resistance. If it is excessiv-
10 ely small, it indicates a shorted rotor. If there

is no continuity or if it is shorted, replace the
rotor assembly.
05 • Standard value : 3~5Ω
4
• Check for rotor coil grounding. Make sure that

there is no continuity between the slip ring and
the core. Replace the rotor assembly if there
is continuity.
STATOR
• Check the stator continuity. Make sure that

there is continuity between the coil leads.
Replace the stator assembly if there is no
continuity.
• Check for coil grounding. Make sure that there

is no continuity between the coil and the core.
Replace the stator assembly if there is
continuity.
E N G I N E
ELECTRIC COMPONENT
RECTIFIER
• Inspection of (+) heat sink assembly

Using a circuit tester, check continuity bet-
ween the (+) heat sink and the stator coil lead
connection terminals. If there is continuity in
both directions, the diode is shorted and the
rectifier assembly must be replaced.
10
05
5
• Inspection of (–) heat sink assembly

Check continuity between the (–) heat sink
and the stator coil lead connection terminals.
If there is continuity in both directions, the
diode is shorted and the rectifier assembly
must be replaced.
• Inspection of diode trio

With a circuit tester connected to both ends
of each diode. Check continuity of the three
diodes. If there is continuity in both directions
or no continuity, the diode is damaged and
the rectifier assembly must be replaced.
BRUSH
• The brush must be replaced if worn to the

wear limit line.
E N G I N E
ELECTRIC COMPONENT
• Unsolder the brush lead wires and the brush

will come out.
10
05
6
• When installing a new brush, push the brush
into the holder as illustrated and solder the
leads.
ASSEMBLY
ROTOR
• Before installing the rotor on the rear bracket,

thread a steel wire through the small hole
provided in the rear bracket to hold back the
brush. After rotor installation, remove the steel
wire.
E N G I N E
ELECTRIC COMPONENT
STARTER
REMOVAL AND INSTALLATION
10
05
7
Removal steps
1. Bolt
2. Starter
INSPECTION AND TEST
PINION GAP ADJUSTMENT (PLANETARY GEAR REDUCTION DRIVE TYPE)
• Disconnect the field coil wire from terminal M of the magnetic switch.
• Connect a 12V battery between terminal S and starter motor body (positive terminal to terminal S).
! This test must be performed quickly (in less than 10 seconds) to prevent the coil from
burning out.
• Push the pinion back with a finger and measure the pinion stroke (the travel along which the
pinion is pushed back). This is the pinion gap.
• If the pinion gap is not up to specification,

adjust by adding or removing fiber washers
between the magnetic switch and the front
bracket. Using more washers makes the gap
smaller.
E N G I N E
ELECTRIC COMPONENT
PULL–IN TEST OF MAGNETIC SWITCH
• The pull–in coil is in good condition if the

plunger is pulled in to cause the pinion to move
out when a battery is connected between
terminals S and M of the magnetic switch. If the
pinion does not move out, replace the magnetic
switch.
10 ! • The connector must be disconnected
from terminal M for this test.
05 • The test must be finished within 10
8 seconds.
HOLD–IN TEST OF MAGNETIC SWITCH
• With a battery connected between terminal S

and the body of the magnetic switch, manually
pull the pinion up to the pinion stopper. The
hold–in coil is in good condition if the pinion
remains out when releasing it.
! The test must be completed within 10

seconds.
RETURN TEST OF MAGNETIC SWITCH
• With a battery connected between terminal M

and the body of the magnetic switch, manually
pull the pinion out to the pinion stopper. Both
coils are fully operational if the pinion returns
immediately after releasing it.
! The test must be completed within 10

seconds.
E N G I N E
ELECTRIC COMPONENT
NO–LOAD TEST
• Set up a circuit as shown which connects a

starter motor, battery, ammeter, voltmeter, and
variable resistance.
• The starter motor should be in good condition

if it turns smoothly and steadily when the
switch is turned ON with a maximum variable
resistance value.
10
With the variable resister adjusted so that the 05
voltmeter will indicated 11.5V, if the current and
9
speed are not as specified, locate the cause of
the problem according to the following table
and take necessary measures.
Symptom Possible cause
Current is too large, and starter motor – Contaminated or oil stained metal
rotates at too low speeds. – Friction between armature core and pole
(Motor output torque is insufficient). piece
– Armature coil and / or field coil not properly
grounded
– Armature coil short–circuited
Current is too large, and motor does not – Electromagnetic switch not properly ground-
rotate at all. ed
– Armature coil and / or field coil not properly
grounded
– Seizure of metal
No current is available, and motor does not – Armature coil and / or field coil open–
rotate. circuited
– Brush and / or pigtail open–circuited
– Poor contact of brush and commutator due
to contaminated commutator, high mica,
etc.
Current is too small, and motor rotates at Loose field coil connections (If the shunt coil
low speed. alone is open–circuited or loosely connected,
(Motor output torque is insufficient). the motor will rotate at a high speed.)
Current is too large, and motor rotates at too Field coil short–circuited
high speeds.
(Motor output torque is insufficient.)
E N G I N E
ELECTRIC COMPONENT
DISASSEMBLY
MAGNETIC SWITCH
• Disconnect the field coil wire from terminal M

of the magnetic switch.
10
05
10
SNAP RING
• Using a feeler gauge, measure the end play in

the pinion shaft for the purpose of reassembly.
SNAP RING / STOP RING
• Using an appropriate size socket, push the stop

ring toward the snap ring.
• Remove the snap ring using screwdriver and

then remove the stop ring.
E N G I N E
ELECTRIC COMPONENT
CLEANING OF STARTER MOTOR PARTS
• Do not immerse the parts in cleaning solvent. Immersion of the yoke, field coil assembly or
armature in solvent will cause damage to the insulation.
Wipe clean with a cloth if these parts are dirty. Do not immerse the drive unit in cleaning
solvent. The overrunning clutch has been lubricated at the factory and cleaning with a solvent
will remove the lubricant.
Clean the drive unit using a brush wetted with cleaning solvent and then wipe dry with a cloth.
10
INSPECTION 05
11
COMMUTATOR
• Place the armature on a pair of V–blocks and

check the runout using a dial gauge.
• Standard value : 0.5 mm (0.020 in)
• Limit : 0.1 mm (0.004 in)
• Check the O.D. of the commutator.

• Limit : 31.0 mm (1.22 in)
• Check depth of the undercuts between the

segments.
• Limit : 0.2 mm (0.008 in)
E N G I N E
ELECTRIC COMPONENT
FIELD COIL OPEN–CIRCUIT TEST
• Check for continuity between the field brushes.

There must be continuity.
10
05
12
FIELD COIL GROUND TEST
• Check for continuity between the field coil

brush and yoke.
There must be no continuity.
BRUSH HOLDER
• Check continuity between the brush holder

plate and the brush holder.
The brush holder is okay if there is no
continuity.
OVERRUNNING CLUTCH
• Check that the pinion locks when it is turned

counterclockwise and moves smoothly when it
is turned clockwise.
• Check the pinion for wear or damage.
E N G I N E
ELECTRIC COMPONENT
BRUSH
• Check the brush for roughness of the surface

that contacts the commutator and check the
brush length.
Limit : Wear limit line
• In case the contacting surface has been
corrected or the brush has been replaced,
correct the contacting surface by winding
sandpaper around the commutator.
10
• When removing a worn brush by breaking with 05
pliers, use care to prevent damage to the
13
pigtail.
• Polish the pigtail end with sandpaper for secure
soldering.
• Insert the pigtail into the hole of a new brush
and solder.
• Make sure that there is no excess solder on
the brush surface.
ARMATURE COIL SHORT CIRCUIT TEST
• Set the armature on a growler.

• While applying a thin piece of iron in parallel
with the armature, turn the armature slowly.
The armature is okay if the piece of iron is not
attracted or does not vibrate
! Clean the armature surface thoroughly

before checking
ARMATURE COIL GROUND TEST
• Check insulation between the commutator

segments and the armature coil core.
There should be no continuity.
E N G I N E
ELECTRIC COMPONENT
OPEN CIRCUIT CHECK OF ARMATURE
• Check continuity between segments.

There should be continuity.
10
05
14
ASSEMBLY
INSTALLATION OF STOP RING/SNAP RING
• Using an appropriate tool, pull the stop ring

over the snap ring.
COOLANT TEMPERATURE SENSOR
• When the coolant temperature sensor unit is a

reused one, apply the specified sealant to the
threaded area.
: Threebond 1104 or equivalent
E N G I N E
FUEL SYSTEM
REMOVAL
CARBURETTOR
• Hold the carburettor in a level position while using care not to let fuel spill, remove it from
the intake manifold.
• Turn the carburettor upside down on a pan to drain fuel.
10
FUEL PUMP
06
1
• Placing the piston in No. 1 cylinder at TDC on the compression stroke makes the fuel pump
stoke lift the smallest, allowing easy removal of the pump.
INSTALLATION
FUEL PUMP
• Bring the piston in No. 1 cylinder to TDC on the compression stroke. This provides the smallest
lift of the eccentric cam, allowing easy installation of the fuel pump.
• Apply engine oil to the surface of the push rod and insert it into the hole in the cylinder head.
Make sure that the push rod slides smoothly.
• Install the fuel pump on the cylinder head with the insulator and a new gasket in between,
and tighten the bolts completely.
1. Arm pin 7. Pump cover

2. Rod spring 8. Pump body
3. Rod 9. Push rod
4. Breather hole 10. Camshaft
5. Diaphragm spring 11. Arm
6. Diaphragm
E N G I N E
FUEL SYSTEM
CARBURETTOR–GASOLINE
DISASSEMBLY
The following parts must not be disassembled at the time of disassembly.

• Choke valve and choke shaft
10 • Inner venturi
• Throttle valve and throttle shaft
06
2 RETURN SPRING / CHOKE ROD
• When the spring is removed, avoid prying it with undue force or any other attempt that can
cause damage to it.
• Press the end of the choke rod to force the rod out. Avoid applying a strong force to the
plastic grommet of the rod fit-in hole.
FLOAT CHAMBER COVER
• Since the screws require great force to loosen,

use a phillips screwdriver that exactly fits in the
cross recess in the screw heads.
• To remove the float chamber cover, slowly lift
it, while using care not to damage the float.
Don't tilt the main body, as the pump discharge
weight and the related parts may come out and
could be lost.
PUMP WEIGHT / BALL
• Turn the main body upside down to remove

the weight and ball.
MAIN JET REMOVAL
• To remove the main jet, be sure to use a

screwdriver whose tip exactly fits in the slot of
the jet.
E N G I N E
FUEL SYSTEM
INSPECTION
GENERAL INSPECTION
Check the following and repair or replace parts if faulty.

• Check fuel passages (jets) and air passages(jets or orifices) for clogging. If clogged, wash
throughtly with cleaning solvent or detergent and remove dirt by compressed air. Do not use
wire or other metal pieces.
• Check diaphragms, O – rings and springs for damage and cracks.
10
• Check that needle valve operates lightly. If the valve is hard to operate or is binding. repair 06
or replace. If there is overflow, poor valve to seat contact is suspected. Check thoroughly.
3
• Check the fuel inlet filter (located above the needle valve)for clogging and damage.
• Check the float operation. Check float and lever for deformation and damage and replace if
necessary.
• Check operation of the throttle valve, choke valve and link.
If they do not operate lightly, wash well and apply engine oil sparingly to their shaft.
• Check the float chamber cover and main body for damage and cracks.
FUEL CUT SOLENOID VALVE OPERATION CHECK
• Connect the battery directly to the body and

terminal of the fuel cut solenoid valve to apply
the voltage.
! Use care not to short-circuit the battery.
• Listen for a click which should be heard when

the valve operates normally at the moment the
battery is conncted.
FUEL CUT SOLENOID VALVE RESISTANCE CHECK
Measure the resistance between the body and

the terminal of the fuel cut solenoid valve with
a tester.
• Standard value:Approx. 90Ω at 20°C (68°F)
E N G I N E
FUEL SYSTEM
INSPECTION OF MIXTURE ADJUSTING SCREW (MAS)
• Check tapered end of mixture adjusting screw

(MAS) for damage from overtightening, etc.
10
06
4
THROTTLE BODY CHECK
• Make sure that the throttle shaft moves

smoothly. If any sticky movement is found,
thoroughly clean the shaft, and then coat it with
a small amount of engine oil.
Do not disassemble the shaft unnecessarily.
ASSEMBLY
For reassembly, reverse the order of disassembly while paying much attention to the following:
• Clean every part with clear cleaning oil before reassembly. Check all passages for clogging.
• Replace all the removed packing and gaskets.
• Make sure the throttle and choke linkage operates smoothly. If any sticky movement is found,
clean or replace the linkage, and make sure that the carburettor operates without any problem.
INSTALLATION OF MAIN JETS
• When replacing a main jet, the old jet and the

new jet must be of the same size.
Because the jet is selected after exact flow
measurement by factory. (A size symbol is
stamped on each jet.)
E N G I N E
FUEL SYSTEM
• Main jets have jet size symbols stamped on

their ends for identification.
! Refer to the table in SERVICE SPECIFI-
CATIONS for the size symbols.
10
06
CHECK BALL/WEIGHT INSTALLATION 5
• Install the acceleration check ball and weight.
FLOAT/FLOAT PIN INSTALLATION
• After the float and float pin have been installed, make sure that the float is in a level position.
To ultimately adjust the level of the float, pour fuel in the float chamber after the float has
been installed, and proceed as described below.
Float level adjustment

If the float level is not within the level mark,
adjust the float level by adding or removing
needle valve seat packings.
The float level should normally be within the

level mark. However even if is slightly above or
below the mark, it does not cause any effects
on the carburettor and engine performance.
Strangler spring setting positions

If the strangler spring of the choke valve shaft
is out of position, set it correctly in the positions
shown in the illustration.
E N G I N E
FUEL SYSTEM
INSPECTION AND ADJUSTMENT
FAST IDLE OPENING
• Move the choke lever to place the choke valve

in fully closed position.
10
06 • Measure the clearance (primary throttle valve
to throttle bore)
6
! Refer to the table in SERVICE SPECIFI-
CATIONS for the clearance.
• If the clearance “A” is out of specifications,

adjust to the standard value by the fast idle
adjusting screw.
Screw direction
Clearance Remarks
of rotation
Clockwise
Increases Fast idle speed
increases
Counterclockwise
Decreases Fast idle speed
decreases
CHOKE VALVE OPERATION
With the choke valve lever set to its full position, move the choke valve with a finger to make
sure that the choke valve shaft has not an excessive play and the valve moves smoothly without
sticking
• If the choke valve cannot be moved smoothly, clean the choke valve and the area around it.
• If the play of the choke valve shaft is excessive, replace the flat chamber cover.
PORT
Connect a hand vacuum pump and check each

port for clogging.
If clogged, clean the port and then blow air into
it.
E N G I N E
FUEL SYSTEM
CARBURETTOR – LPG
CONSTRUCTION
The carburettor for LP gas engines is a combination of the upper body (CA100M–3) and
adapter (AA3–67) of the carburettor made by IMPCO. Hereinafter, the carburettor for LP gas
engines is called the “IMPCO” carburettor.
Like gasoline engine carburettors, this IMPCO carburettor is mounted on the throttle body located
10
to the top of the air governor.
The IMPCO carburettor consists of the converter(or vaporizer) and the mixer (or carburettor). The
06
converter is only for the purpose of vaporizing LP gas and has no parts to be adjusted from 7
the outside.
This SERVICE GUIDE relates to maintenance of the carburettor Itself. For other carburettor–related
parts to be prepared by vehicle manufacturers, follow the vehicle manufacturers’ instructions.
1. Cover
2. Air valve
3. Air valve spring
4. Gas metering valve
5. Air passage
6. Diaphragm
7. Idling screw
8. Gas regulating valve
9. Throttle valve
10. Air governor valve
Fuel System
• When an engine cylinder piston is in course of lowering, that piston stroke (hatched portion in
the preceding flgure) develops a negative pressure. The negative pressure is conducted through
passage e in the air valve b to the upper side of diaphragm(6), and atmosphere pushes the
diaphragm upward against the force of spring c.
• The negative pressure on the upper side of diaphragm varies with engine speed and with
opening of throttle valve i. The air valve acts exactly in response to the variations of engine
speed and throttle valve opening so that an adequate quantity of air can flow into the engine.
• Gas metering valve d is fitted to the air valve. It opens with opening of the air valve to adjust
the quantity of air can flow into the engine.
• The idling screw g controls the intake air flow to meter the air–fuel mixture necessary for
supporting engine idling.
• The gas regulator valve h controls the air–fuel mixture when the gas metering valve d has
been brought to its lift end by flowing in of much air. This control is effective only under engine
running condition close to full–load running.
E N G I N E
FUEL SYSTEM
REMOVAL AND DISASSEMBLY
• When removing the carburettor, close the main valve on the LP gas cylinder securely while
the engine is left running.
• After the engine comes to a stop automatically, turn the engine key to OFF position.
• Remove the fuel hose (vapor line) from the carburettor, taking care not to damage the hose.
Remove the adapter mounting nuts from the lower surface of the carburettor and dismount
10 the carburettor.
06
8 a
Removing Carburettor
• Remove the screws fastening the cover and disassemble the carburettor. Take care not to
damage the diaphragm.
Sectional View of Carburettor
1. Gas inlet 7. Air valve diaphragm

2. Vacuum nipple 8. Power fuel mixture
3. Cover adjustment valve
4. Gas metering valve 9. adaptor
5. Air valve spring 10. Carburettor body
6. Air passage
• Do not remove the gas intake (“L” joint) unless it is necessary. It is a plastic part coated with
sealant and, therefore, easily broken by careless handling.
E N G I N E
FUEL SYSTEM
INSPECTION
• Check the diaphragm and packing for damage and deterioration.

• Check and clean the carburettor contact surface of the air valve and the air passage in the
air valve. Thoroughly clean the gas metering valve contact surface, too.
• Clean the gas passage in carburettor body. Check the gas intake and gas regulator valve for
damage. Never disassemble the gas regulator valve.
• Check the spring for damage.
• Check and clean the valves in the throttle body and the air govenor system using the same 10
manner as required for servicing the gasoline engines.
06
9
REASSEMBLY
• Clean all parts. Reinstall them to the positions shown in the assembly drawing.
When fitting the air valve to the carburettor body, be sure to let the “I” mark at the center of
air valve face the gas intake direction. If the air valve is fitted in reverse, hard engine start
and unstable idling may result.
Direction of Installation of Air Valve Assembly
• Fit in the air valve spring to the valve center boss until the spring comes into contact with
the seat.
• Install the cover, taking care not to cause the diaphragm to slip. Tighten the screws.
• When the idling screw has been removed, reinstall it with its spring.
Installing Idling Screw

E N G I N E
FUEL SYSTEM
INSTALLING CARBURETTOR
• Install the carburettor securely, with the gasket fitted in place without fail to assure air–tight
installation of the carburettor. It is desirable to use liquid packing in addition to the gasket.
PERIODIC INSPECTION OF LP GAS UNIT
10 Periodic inspection is indispensable for vehicles to keep them always well maintained and to
assure safe and smooth operation.
For the IMPCO LP gas unit, the general items to be inspected periodically are shown below for
06 your reference. Actual inspection of the LP gas unit, except for the carburettor, should be made
10 in accordance with the vehicle manufacturer’s instructions.
INSPECTION ITEMS
• Check the piping for damage, loose fittings, and noticeable deformation.
• Check the pipe joints and other joining parts for gas leaks by means of soapsuds, checking liquid
or a detector. Never use any fire such as a match, a lighter and a candle for checking a gas leak.
• Check the cover of electric wires and contact points for damage.
• Check the converter and filter for improper installation, loosening and gas leaks.
• Check the gas cylinder stand for loosening and damage.
• Check the valves on the gas cylinder for gas leaks from the fittings.
• Check the vaporizer and other devices for abnormality.
• Check for abnormal leak of exhaust gas from the exhaust pipe.
• Check the rubber hoses for damage and loosening.
• Disassembling and inspecting the carburettor.
• Check the converter for proper function.
• Check the fuel lock–off valve and filter for proper function.
• Clean the air filter element.
INSPECTION TIME
Service interval Applicable inspection item number
Before daily operation 2, 3, 8, 13
Every month 1, 2, 3, 4, 8, 9, 13
Every 3 months 1, 2, 3, 4, 5, 6, 7, 8, 9, 13
Every year 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13
PERIODIC REPLACEMENT PARTS

Replacement interval
Part name Location Every Every Every 2
6 Months Year Years
O – ring JA800
Water hose
Vacuum hose JB Converter–Engine
Converter inner parts JB Converter
Carburettor diaphragm CA100 Carburettor
Filter inner parts VFF30 Fuel lock & filter
LP gas hose LP gas tank–VFF30
Air filter element
E N G I N E
FUEL SYSTEM
AIR GOVERNOR
CONSTRUCTION
10
06
11
Disassembly steps
1. Ventilation hose 9. Plate assembly

2. Gasket 10. Valve assembly
3. Sealing cap 11. Valve shaft assembly
4. Cover plate assembly 12. Piston cover
5. Gasket 13. Gasket
6. Lock nut 14. Stabilizer piston
7. Adjusting nut 15. Piston shaft
8. Adjusting screw 16. Governor body
DISASSEMBLY SERVICE POINTS
! Since the air governor has been adjusted and sealed in the manufacturer’s factory to
conform to the specifications, it should not be disassembled in general cases. Like
any other sealed components, the air governor should not be disassembled anywhere
except the locations where a warranty claim decision is authorized. In addition, the
cam on the throttle valve shaft should never be removed.
E N G I N E
FUEL SYSTEM
INSPECTION
• Check the plate assembly (9) composed of a ribbon spring and coil spring for cracks and any
other damage.
• Check the valve shaft for wear, and also make sure that it rotates smoothly when mounted in
the body.
• Check the piston for damage. Check also the valve fit–in section of the shaft for damage.
10 • Grease packed needle bearings are press–fitted at both ends of the valve shaft hole of the
governor body. Avoid cleaning the body in gasoline or any other solvent.
06
12 REASSEMBLY SERVICE POINTS
! Thoroughly clean all component parts

before installation. Do not apply grease
or oil anywhere in the body except the
needle bearings (grease packed) in the
throttle valve shaft hole.
ADJUSTING SCREW AND NUT SETTING
When assembling the air governor separately

from the engine, temporarily assemble it so that
the throttle valve will be in the fully opened
position. Also make sure that when an air
pressure of 0 to 1.5 kgf/cm2(0~21psi) is slowly
applied to the stabilizer piston from the nipple
side, the throttle valve operates smoothly.
E N G I N E
FUEL SYSTEM
OTHER COMPONENTS – LP
PIPING
From LPG Tank

10
1,2
06
3
13
8
6
4
5
7 32(2)
29
Hydrostatic relief valve 26
36
13
14 21
Vacuum Line
6
25
16 15
33
Liquid gas 31(6)
22
28 To carburettor
Fuel Lock–off 37
valve and filter 35
27
17 as
e dg Liquid gas
10(2)
poriz 25
Va 24
12(2)
11(2)
Water hose
34(2) 23
19(2) 15
18(2)
34(2) 23
19(2)
20
18(2)
Vaporizer
E N G I N E
FUEL SYSTEM
HYDROSTATIC RELIEF VALVE
A hydrostatic relief valve is used in the LPG system to bleed off fuel line pressure in excess
of 2758 kPa(400 psi). It opens and closes automatically when the excess pressure is reduced.
The valve is installed in the three–way adaptor fitting outside the engine compartment and must
always point away from the operator.
Check for leaks and replace valve if it fails to seal properly.
10
VACUUM AND WATER LINES
06
14
• The IMPCO LPG system depends on tight vacuum connections at the fittings.
If hose ends are belled, split or loose, clip off damaged part and reconnect to the fitting.
• Water hoses between engine and vaporizer–

regulator may be either clamp–type or push on
type with reusable fittings. Cut off bad portions
of hose and strip from fittings.
Push hoses solidly back into position. Do not
use cement or clamps on push–on type fittings.
FUEL LOCK–OFF VALVE AND FILTER
OPERATION
The fuel lock–off valve is vacuum operated.

When a slight vacuum is sensed, it opens and
allows liquid fuel from tank to flow through an
internal fuel filter to vaporizer–regulator. Any time
engine stops, whether ignition key is on or off,
fuel is shut off automatically. Also, it filters any
large particles of solid material, 5 microns and
larger, out of fuel before it reaches high pressure
side of vaporizer–regulator.
MAINTENANCE
• The fuel filter element should be checked once

a year and replaced if necessary.
Foreign matter usually will be collected in filter
only when installation is new. Often, a new
tank will have scale or rust particles in it which
will be caught by filter.
E N G I N E
FUEL SYSTEM
• Check hose connections and filter cover (inlet

side) for sign of leakage. Look for stains or
frost caused by evaporation.
Tighten cover screws as required. Disconnect
hoses and reseal threads if necessary.
! Overly tight hose connections may crack
the casting.
10
06
15
VAPORIZER
OPERATION
The vaporizer–regulator is a combined two–stage regulator and vaporizer. It receives liquid fuel
at tank pressure from the fuel lock–off valve and filter and reduces that pressure in two stages
to slightly less than atmospheric.
When the engine is cranking or running, a partial vacuum is created in the fuel line to the
carburettor, which opens the regulator permitting fuel to flow to the carburettor.
In the process of reducing the pressure from approximately 10.6 kg/cm2 (150psi) in the tank to
atmospheric pressure, the liquid propane expands to become a vapor, causing refrigeration.
To compensate for this and to assist in vaporization, water from the engine cooling system
circulates through the vaporizer and raises the temperature of the fuel as it enters the vaporizer
at – 42 ~ 4°C (– 44 ~ 40°F) at full rated fuel flow. The regulator seals off fuel flow when the engine
is stopped.
MAINTENANCE
• Check fuel, water and vapor connections for evidence of leakage, such as stains, frost or gas
odor. Tighten cover screws or reseal hose connections as required.
• Remove fuel vapor hose and check for deterioration. Particularly check vapor outlet fittings for
tightness.
! Overly tight hose connections may crack the casting.
E N G I N E
COMPONENTS
ROCKER ARMS AND CAMSHAFT
REMOVAL
ROCKER ARM AND ROCKER SHAFT
• Before removing rocker arms and shafts

assembly, install the special tool as illustrated
10
to prevent the adjusters from dropping.
07
1
INSPECTION
CAMSHAFT
• Measure the cam height and if the limit is

exceeded, replace.
• Limit : 41.12 mm (1.619 in)
LASH ADJUSTER
! • The lash adjuster is a precision part.

• Keep it free from dust and other foreign
matter.
• Do not disassemble lash adjusters.
• When cleaning lash adjusters, use clean
diesel fuel only.
• Immerse the lash adjuster in clean diesel fuel.

• While lightly pushing down the inner steel ball using the special tool, air bleed wire, move the
plunger up and down four or five times to bleed air.
! Since the spring holding the steel ball is very weak, applying excessive force with the
air bleed wire could deteriorate the function of the lash adjuster.
• Remove the wire and press the plunger. If the plunger is hard to push in, the lash adjuster
is normal. If the plunger can be pushed in all the way readily, bleed the lash adjuster again
and test again. If the plunger is still loose, replace the lash adjuster.
E N G I N E
COMPONENTS
! Upon completion of air bleeding, hold the

lash adjuster upright to prevent inside
diesel fuel from spilling and keep it free
from dust and other foreign matter.
• After air bleeding, set the lash adjuster on the

special tool, leak down tester.
10 ! Remove the bolt from the tester and

adjust the height as shown.
07 • After the plunger has gone down somewhat

2 0.2~0.5mm(0.008~0.020in), measure the time
taken for it to go down 1mm. Replace if the
measured time is out of the specification.
• Standard value : 5~20 seconds/1mm (0.040 in)
[ Diesel fuel at 15~20°C (59~68°F) ]
INSTALLATION
CAMSHAFT
• Apply engine oil to the journals and cams of the camshafts. Install the camshafts on the cylinder
head
ROCKER SHAFT
• Insert the rocker shafts into the front bearing

cap so that the notches on the shafts face up,
and insert the installation bolts without tight-
ening them.
WAVE WASHER
• Install the wave washer in correct direction

as shown.
E N G I N E
COMPONENTS
BEARING CAP
LASH ADJUSTER
10
07
• Immerse the lash adjuster in clean diesel fuel.
3
• Using the special tool (air bleed wire), move the
plunger up and down 4 or 5 times while
pushing down lightly on the check ball in order
to bleed out the air.
• Insert the lash adjuster to the rocker arm, being

careful not to spill the diesel fuel. Then use the
special tool to prevent the adjuster from falling
while installing it.
CAMSHAFT OIL SEAL
SEMI–CIRCULAR PACKING
• Apply sealant to the location shown in the

illustration.
: Threebond 1212D or equivalent.
E N G I N E
COMPONENTS
CYLINDER HEAD AND VALVES
CONSTRUCTION
10
07
4
At the time of installation, apply

engine oil to all sliding surfaces.
1. Cylinder head bolt 11. Exhaust valve

2. Cylinder head assembly 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
4. Retainer lock 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
10. Valve spring 20. Cylinder head
E N G I N E
COMPONENTS
REMOVAL
CYLINDER HEAD BOLT
• Using a 12 mm–12 point socket wrench, loosen

the cylinder head bolts.
10
07
5
RETAINER LOCK REMOVAL
• Store removed valves, springs and other parts,

tagged to indicate their cylinder No. and
location for reassembly.
VALVE STEM SEAL REMOVAL
! Do not reuse removed valve stem seal.
INSPECTION
CYLINDER HEAD
• Check the cylinder head for water leaks, gas

leaks, damage or cracks before cleaning.
• Thoroughly remove oil, water scale, sealant,
carbon deposit, etc. After the oil passages have
been cleaned, blow air to make sure that they
are clear.
E N G I N E
COMPONENTS
• Check the cylinder head gasket surface for flatness by using a straight–edge and feeler gauge.
If the service limit is exceeded, correct to meet the specification.
– Standard value : 0.03 mm (0.001in) or less
– Limit : 0.2 mm (0.008in)
– Grinding limit : 0.2 mm (0.008in)
– Cylinder head height (when new) : 89.9~90.1mm (3.539~3.547in)
! Grinding the cylinder head is permitted as long as the total thickness of the metal
10 removed from the

0.2 mm (0.008in).
cylinder head and the cylinder block does not exceed
07 VALVE
6
• Check the valve face for correct contact. If
incorrect, reface.
Valve seat contact should be maintained
uniform at the center of valve face.
• If the margin exceeds the service limit, replace
the valve.
• Standard value
A Intake : 1.2 mm (0.047 in)
B Exhaust : 2.0 mm (0.079 in)
• Limit
A Intake : 0.7 mm (0.028 in)
B Exhaust : 1.5 mm (0.059 in)
VALVE SPRING
• Measure the free height of spring and, if it is

smaller than the limit, replace.
• Limit : 48.8 mm (1.921 in)
• Measure the squareness of the spring and, if
the limit is exceeded, replace.
VALVE GUIDE
• Measure the clearance between the valve

guide and valve stem. If the limit is exceeded,
replace the valve guide or valve, or both
E N G I N E
COMPONENTS
VALVE SEAT RECONDITIONING PROCEDURE
• Before correcting the valve seat, check for

clearance between the valve guide and valve 0.9~1.3 mm (0.035~0.050in)
m
3m
and, if necessary, replace the valve guide. .9~1.
60° 0
• Correct to obtain the specified seat width and 60°
angle.
• After correction, valve and valve seat should be
lapped with a lapping compound.
25° 43.5°
10
43.5°~44° ~44°
25°
07
7
VALVE SEAT REPLACEMENT PROCEDURE
• Cut the valve seat to be replaced from the

inside to thin the wall thickness. Then, remove 0.5~1.0 mm(0.020~0.040in)
the valve seat.
Cut away
0.5~1.0 mm
(0.020~0.040in)
• Rebore the valve seat hole in the cylinder head

to a selected oversize valve seat diameter.
• Before fitting the valve seat, cool the valve seat
in liquid nitrogen, to prevent the cylinder head
Height of
bore from galling. valve
seat
Oversize I.D
• Using a valve seat cutter, correct the valve

seat to the specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”
E N G I N E
COMPONENTS
VALVE GUIDE REPLACEMENT PROCEDURE
• Using a press, remove the valve guide toward the cylinder block side.
• Rebore the valve guide hole to the new oversize valve guide outside diameter.
! Do not install a valve guide of the same size again.

• Valve guide hole diameter :
0.05 O.S. 13.05~13.07 mm (0.514~0.515 in) Press Press
10 0.25 O.S. 13.25~13.27 mm (0.521~0.522 in) Removal Installation
11.5mm
0.05 O.S. 13.50~13.52 mm (0.531~0.534 in)
Push
07 Push rod rod
• Press in the valve guide to the position shown
8
in the illustration.
• Standard value : 11.5 mm (0.453 in) Valve Valve
guide guide
! • Press–fit the valve guide, working from
the cylinder head top surface.
• Note that the intake and exhaust side valve guides are different in length.
• After installing valve guides, insert new valve in them to check for sliding condition.
INSTALLATION
VALVE STEM SEAL
• Install the valve spring seat.

• Using special tool, install the new valve stem seal to the valve guide.
! CAUTION
• Do not reuse removed valve stem seal.
• The special tool must be used to install the
valve stem seal. Improper installation could MD998729
result in oil leaking past the valve guide.
E N G I N E
COMPONENTS
VALVE SPRING
• Direct the valve spring end with identification

color toward the rocker arm. Spring
Identification retainer
color
Stem seal
10
Spring seat
07
9
RETAINER LOCK
MD998772
CYLINDER HEAD BOLT
• When installing the cylinder head bolts, check

that the shank length of each bolt meets the
limit. If the limit is exceeded, replace the bolt.
Standard value : 120.4 mm (4.74 in)
• Apply engine oil to the bolt threads and
washers. Shank length
• According to the tightening sequence, tighten

the bolts to 8.0 kgf·m (58 lbf·ft), using a
12 mm~12point socket wrench.
• Loosen the bolts completely.
• Torque the bolts to 2.0 kgf·m (14.4 lbf·ft)
• Tighten the bolts 1/4 turns (90°) more.
• Tighten the bolts 1/4 turns (90°) additionally.
E N G I N E
COMPONENTS
FRONT CASE AND OIL PAN
REMOVAL
OIL PAN
10 • Remove the all oil pan bolts.

0.7 kgf·m (5.1 lbf·ft) MD99872
07 • Drive in the special tool between the cylinder
10 block and oil pan.
• Slide the tool by striking the edge of the
special tool to separate the oil pan from the
cylinder block.
PLUG REMOVAL
• If the plug is too tight, hit the plug head with

a hammer two to three times, and the plug will
be easily loosened. Plug
MD998162
INSPECTION
OIL PUMP
• Assemble the oil pump drive gear and driven

gear to the front case.
• Check the side clearance using a feeler gauge.
• Standard value
– Drive gear : 0.08~0.14mm (0.003~0.006 in)
– Driven gear : 0.06~0.12mm (0.002~0.005 in)
E N G I N E
COMPONENTS
INSTALLATION
OIL PUMP OIL SEAL
Socket
Oil seal wrench
Front case 10
07
11
CRANKSHAFT FRONT OIL SEAL
MD998375
Oil seal
Front case
OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR
• Apply engine oil amply to the gears and line

up the alignment marks.
Alignment
mark
FRONT CASE
• Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to
the outer circumference of the special tool to install the front case.
When an oil seal is provided on the front case, the special tool must always be used.
• Install the front case assembly through a new front case gasket and temporarily tighten the
flange bolts (other than those for tightening the filter bracket).
E N G I N E
COMPONENTS
• Mount the oil filter bracket with the oil filter bracket gasket in between, and partially tighten
the 4 bolts, each with a washer.
• Tighten the bolts to the specified torque.
1.9 kgf·m (13.7 lbf·ft)
PLUG INSTALLATION
10 2.4 kgf·m (17.3 lbf·ft)

Plug
07
12
MD998162
OIL PRESSURE SWITCH INSTALLATION
1.0 kgf·m (7.2 lbf·ft)

Sealant
Threebond 1211 or equivalent
! • Keep the end of threaded portion clear

of sealant.
• Avoid overtightening.
E N G I N E
COMPONENTS
OIL PAN INSTALLATION
• Clean both mating surface of the oil pan and cylinder block.
• Apply a 4mm(3/16”) wide bead of FIPG to the entire circumference of the oil pan flange. The
oil pan should be installed within 15 minutes after the application of FIPG.
Threebond 1207F or equivalent
10
07
13
Bolt hole Groove portion

portion
• Note the difference in bolt lengths at the

➞Crank pulley side
location shown.
0.7 kgf·m (5.1 lbf·ft)
M6×8
E N G I N E
COMPONENTS
PISTON AND CONNECTING ROD
REMOVAL
CONNECTING ROD CAP
10 • Mark the cylinder number on the side of the

connecting rod big end for correct reassembly.
Cylinder number
07
14
PISTON PIN
Guide A : 17.9mm
Push rod
• The special tool, piston pin setting tool
(MD998780), consists of the parts shown in the
illustration.
Guide A : 18.9mm
• Insert the special tool, push rod, into the piston
from the side on which the front mark is
stamped in the piston head, and attach the Guide C
guide C to the push rod end. Guide A : 20.9mm
• Place the piston and connecting rod assembly
on the special tool, piston pin setting base, with
Base
the front mark facing upward.
Guide A : 21.9mm
• Using a press, remove the piston pin.

Push rod
! Keep the disassembled pistons, piston
pins and connecting rods in order
according to the cylinder number. Front mark
Front
mark
Guide C
Base
E N G I N E
COMPONENTS
INSPECTION
PISTON RING
• Check for the clearance between the piston

ring and ring groove. If the limit is exceeded,
replace the ring or both piston and ring.
10
07
15
• Install the piston ring into the cylinder bore,

Force is down with a piston, its crown being
Press down ring
in contact with the ring, to correctly position it
with piston
at right angles to the cylinder wall. Then,
measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston
ring.
– Standard value
No. 1 : 0.25~0.40 mm (0.010~0.016 in)
No. 2 : 0.45~0.60 mm (0.018~0.024 in) Piston ring end gap
Oil : 0.20~0.60 mm (0.008~0.024 in)
– Limit
No. 1, No. 2 : 0.8 mm (0.030 in)
Oil : 1.0 mm (0.040 in)
E N G I N E
COMPONENTS
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD)
• Remove oil from the crankshaft pin and the

connecting rod bearing.
• Cut the plastic gauge to the same length as
the width of the bearing and place it on the
crankshaft pin in parallel with its axis.
• Install the connecting rod cap carefully and
10 tighten the bolts to the specified torque.
• Remove the bolt and carefully remove the
07 connecting rod cap.
• Measure the width of the plastic gauge at its
16
widest part by using the scale printed on the
plastic gauge package.
– Standard value : 0.02~0.05 mm (0.0008~0.002 in)
– Limit : 0.1 mm (0.004 in)
INSTALLATION
PISTON PIN
• Measure the following dimensions of the piston,

piston pin and connecting rod.
A : Piston pin insertion hole length
B : Distance between piston bosses
D C
C : Piston pin length
D : Connecting rod
• Obtain dimension L (to be used later) from the Connecting Rod
above measurements by using by following Piston pin
Piston
formula.
(A – C) – (B – D)
L =
2
• Insert the special tool, push rod, into the piston
pin and attach the guide A to the push rod B A
end.
• Assemble the connecting rod in the piston with
their front marks facing the same direction.
• Apply engine oil to the entire periphery of the
piston pin.
• Insert the piston pin, push rod and guide A assembly having assembled in step (3) from the
guide A side into the piston pin hole on the front marked side.
E N G I N E
COMPONENTS
• Screw the guide B into the guide A until the

3mm(0.120in)+L2
gap between both guides amounts to the value
L obtained in step (2) plug 3 mm (0.120 in).
Guide B
Guide A
10
07
• Place the piston into the piston setting base 17
with the front marks directed upward.
• Press–fit the piston pin using a press. Push rod
If the press–fitting force required is less than the
standard value, replace the piston and piston Piston pin
pin set or/and the connecting rod.
Front Front mark
– Standard value : 750~1750 kg (1653~3858 lb)
mark
Guide A
Base
Guide B
OIL RING
• Fit the oil ring spacer into the piston ring

groove. First, install the upper side rail, and
then install the lower side rail.
! The side rails and spacer may be installed

in either direction.
The new spacers and side rails are
painted in the following colors to identify
their sizes.
Size Identification color

STD. No color
0.25 mm O.S. White
0.50 mm O.S. White
0.75 mm O.S. Blue
1.00 mm O.S. Yellow
E N G I N E
COMPONENTS
• To install the side rail, first fit one end of the

rail into the piston groove. Then press the Side rail gap
remaining portion into position by finger. See
illustration.
! CAUTION
The side rail could be broken if it is
expanded with a piston ring expander in the
10 same way as with a compression ring.
07 • Make sure that the side rails move smoothly

18 in either direction.
Piston ring
expander
PISTON RING NO. 2 / PISTON RING NO. 1
• Using a piston ring expander, fit No. 2 and then

No. 1 piston ring into position.
! • Note the difference in shape between No. 1

and No. 2 piston rings.
• Install piston rings No. 1 and No. 2 with
their side having marks facing up. (on the
crown side)
PISTON AND CONNECTING ROD
• Liberally coat engine oil on the circumference

of the piston, piston ring, and oil ring.
• Arrange the piston ring and oil ring gaps (side
rail and spacer) as shown in the illustration. Upper side rail No.1
• Insert the piston and connecting rod assembly
from above the cylinder in such a way that the
front mark (arrow) on the top of the piston will
Piston pin
be directed toward the camshaft sprocket.
Lower side
rail
E N G I N E
COMPONENTS
• Insert the piston and connecting rod assembly

with the piston rings held firmly with a ring
band. Forcing it by pounding should be avoided
because damage to the piston rings or crank
pin could result.
10
07
19
CONNECTING ROD BEARING
When the bearings are replaced, select and

install them according to the identification colors No.1
on the crankshaft and identification marks
No.4
stamped on the connecting rod bearing.
Crankshaft Connecting rod bearing

Pin
Pin O.D. Identification Thickness
identification
(mm) mark (mm)
color No.2
44.995 ~ 1.487 ~ No.3
Yellow 1
45.000 1.491
44.985 ~ 1.491 ~
None 2
44.995 1.495
44.980 ~ 1.495 ~
White 3
44.985 1.499
Connecting rod inside diameter :

48.000 ~ 48.015 mm
Identification
mark
CONNECTING ROD CAP
• Verifying the mark made during disassembly,

install the bearing cap to the connecting rod.
If the connecting rod is new with no index
mark, make sure that the bearing locking
notches come on the same side as shown. Cylinder No.
Notches
E N G I N E
COMPONENTS
• Mark sure that connecting rod big end side

clearance meets the specification.
– Standard value : 0.10 ~ 0.25 mm
(0.004 ~ 0.010 in)
– Limit : 0.4 mm (0.016 in)
10
07
20
CONNECTING ROD CAP NUT
• Since the connecting rod bolts and nuts are torqued according to the tightening method, for
fasteners with nylon / plastic coating or insert they should be examined BEFORE reuse. If the
bolt threads are “necked down”, the bolts should be replaced.
Necking can be checked by running a nut with fingers to the full length of the bolt’s thread.
If the nut does not run down smoothly, the bolt should be replaced.
• Before installing the nuts, the threads should be oiled with engine oil.
• Install both nuts on the bolts finger tight, then alternately torque each nut to assemble the cap
properly.
• Tighten the nuts to 2.0 kgf·m (14.4 lbf·ft) and plus 1/4 (90°) turn.
E N G I N E
COMPONENTS
CRANKSHAFT AND CYLINDER BLOCK
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD)
Use of the plastic gauge can facilitate the oil

clearance measurement work. Plastic gauge 10
To use the plastic gauge proceed as follows :
• Remove oil from the crankshaft journal and
07
crankshaft bearing. 21
• Install the crankshaft.
• Cut the plastic gauge to the same length as
the width of the bearing and place it on the
journal in parallel with its axis.
• Install the crankshaft bearing cap carefully and
tighten the bolts to specified torque.
• Remove the bolt, and carefully remove the
crankshaft bearing cap.
• Measure the width of the plastic gauge at its
widest part by using a scale printed on the
plastic gauge package.
– Standard value : 0.02 ~ 0.04 mm
(0.0008 ~ 0.0016 in)
– Limit : 0.1 mm (0.004 in)
CYLINDER BLOCK
• Visually check for scratches, rust, and corro-

sion. C D E
A F
Use also a flaw detecting agent for the check.
If defects are evident, correct, or replace. B G
• Using a straight–edge and feeler gauge, check
the block top surface for warpage. Make sure
that the surface is free from gasket chips and
other foreign matter.
– Standard value : 0.05 mm (0.002 in)
– Limit : 0.1 mm (0.004 in)
E N G I N E
COMPONENTS
• Check the cylinder walls for scratches and

seizure, if defects are evident, correct (bored
to oversize) or replace.
• Using a cylinder gauge, measure the cylinder
bore and cylindricity. If worn badly, rebore all
cylinders to an oversize and replace piston
12mm
rings. Measure at the points shown in the
illustration.
10 • Standard value
– Cylinder I.D. : 85.00~85.03 mm
07 (3.345~3.3476 in)
– Cylindricity : 0.01 mm (0.0004 in)
22
CYLINDER BORING
• Oversize pistons to be used should be deter-

mined on the basis of the largest bore cylinder.
• Oversize pistons are available in four
sizes (0.25 mm, 0.50 mm, 0.75 mm and 1.00 mm
–0.010, 0.020, 0.030, 0.040 in)
Rebore the cylinder to a diameter that matches
the selected piston outside diameter with the
specified clearance. Thrust
Piston O.D
The reference piston outside diameter measur- direction
ing point is shown in the illustration.
• Based on the measured piston O.D. calculate
the boring finish dimension.
Boring finish dimension=Piston O.D.×0.02~0.04mm(0.0008~0.0016in) (clearance between piston
O.D. and cylinder)–0.02 mm(0.0008in) (honing margin)
• Bore all cylinders to the calculated boring finish dimension.
! CAUTION
To prevent distortion that may result No.3
from temperature rise during boring, bore No.2
cylinders, working from No. 2 to No. 4 to
No. 1 to No. 3
No.4
• Hone to the final finish dimension (piston
O.D.+ clearance between piston O.D. and
cylinder).
• Check the clearance between the piston and No.1
cylinder.
– Standard value
Clearance between piston and cylinder :
0.02~0.04 mm(0.0008~0.0016 in)
No.5
E N G I N E
COMPONENTS
INSTALLATION
CRANKSHAFT BEARING
• When the bearings are replaced, select and

install them according to the identification
colors on the crankshaft and the identification Cylinder bore
marks stamped on the cylinder block. size mark
10
07
23
Cylinder block
bearing support I.D mark
Unit : mm (in)
Cylinder block
Crankshaft journal Crankshaft bearing
bearing support section
Ident. color O.D. Ident.mark I.D. Ident.mark Thickness
Yellow 56.994~57.000 61.000~61.006 1.988~1.991
0 1
(2.2439~2.2441) (2.4016~2.4018) (0.0783~0.784)
61.006~61.012 1.991~1.994
1 2
(2.4018~2.4020) (0.784~0.785)
61.012~61.018 1.994~1.997
2 3
(2.4020~2.4022) (0.785~0.786)
None 56.988~56.994 61.000~61.006 1.991~1.994
0 2
(2.2436~2.2439) (2.4016~2.4018) (0.784~0.785)
61.006~61.012 1.994~1.997
1 3
(2.4018~2.4020) (0.785~0.786)
61.012~61.018 1.997~2.000
2 4
(2.4020~2.4022) (0.786~0.787)
White 56.982~56.988 61.000~61.006 1.994~1.797
0 3
(2.2434~2.2436) (2.4016~2.4018) (0.785~0.786)
61.006~61.012 1.997~2.000
1 4
(2.4018~2.4020) (0.786~0.787)
61.012~61.018 2.000~2.003
2 5
(2.4020~2.4022) (0.787~0.789)
E N G I N E
COMPONENTS
• Install the bearings having an oil groove to the

cylinder block. Grooved
• Install the bearings having no oil groove to the Grooveless
bearing caps.
Identification
Upper bearing
mark
Lower bearing (for No. 1,2,4,5)
(for No. 1,2,4,5) Grooveless
10 No.3 bearing
Identification
mark
07
24
BEARING CAP/BEARING CAP BOLT
• Install the bearing caps so that their arrows are

positioned on the timing belt side.
• When installing the bearing cap bolts, check
that the shank length of each bolt meets the
limit. If the limit is exceeded, replace the bolt.
– Limit : Max. 71.1 mm (2.79 in)
• Torque the bearing cap bolts to 2.5 kgf·m (18 lbf·ft) and, from that position, retighten them
1/4 (90°) turns more.
• After installing the bearing caps, make sure

that the end play is correct. If the end play
exceeds the limit, replace the crankshaft bear-
ings.
– Standard value : 0.05~0.25 mm
(0.002~0.010 in)
– Limit : 0.4 mm (0.016in)
REAR OIL SEAL
MB990938
MD998776
E N G I N E
COMPONENTS
SEALANT APPLICATION TO REAR OIL SEAL CASE
Threebond 1207F or equivalent

Sealant
10
07
25
REAR PLATE
Install the rear plate with the bolts coated with sealant.
• Sealant : Threebond 1104 or equivalent
OIL SEAL
Using a proper jig, install the oil seal in such a way that the oil seal end surface will be flush
with the oil seal case end surface.
OIL SEAL CASE INSTALLATION
Install the oil seal case with the bolts coated with sealant.
Threebond 1104 or equivalent
E N G I N E
TROUBLESHOOTING
BY SYMPTOM
Abnormal Ignition Loose connection in – Check connections
combustion system ignition system wiring. and retighten.
Defective spark plug. – Replace spark plug.

Incorrect ignition timing. – Adjust ignition timing.
Carburetion
related
components
Defective carburettor. – Repair or replace
carburettor.
10
Contaminated or clogged – Clean fuel filter element 08
fuel filter element and pipe. and pipe.
Entry of air from carburettor – Retighten set bolts or
or intake manifold. replace heat insulator
and/or intake manifold
gasket.
Valves and related Defective valves and related – Adjust or repair valves
components components. and related components.
Cylinder head Carbon deposited in – Disassemble and clean.

combustion chamber.
Clogged cylinder head – Clean or replace
water tube. water tube.
Cylinder gasket blowby. – Replace gasket.
Insufficient Ignition system Incorrect ignition timing. – Adjust ignition timing.

output out of adjustment Defective spark plug. – Replace spark plug.
Insufficient fuel Defective carburettor. – Repair or replace

carburettor.
Damaged cylinder head – Replace gasket.
gasket, etc.
Clogged fuel pipe. – Clean pipe.
Clogged fuel filter. – Clean or replace.
Air in fuel system. – Check connections
and retighten.
Damaged fuel pipe. – Replace pipe.
Fuel pump not functioning – Repair or replace.
properly.
Damaged diaphragm. – Replace.
Defective valve. – Replace.
Insufficient
intake air in Clogged air cleaner – Clean or replace
carburettor element. element.
Carburettor choke always – Repair or replace
in operation. carburettor.
Air governor malfunction. – Repair or replace
air governor.
E N G I N E
TROUBLESHOOTING
Insufficient Overheating Insufficient coolant. – Add coolant and

output check for leaky points.
Leaks from radiator. – Repair or replace
radiator.
Loosened or damaged – Retighten clamp or replace
radiator hose connection. hose.
Leaks from water pump. – Replace.
10 Coolant leaks from

cylinder head gasket.
– Retighten cylinder head
bolts or replace gasket.
Cracks in cylinder head – Replace.
08 or block.
Loose fan belt tension. – Adjust or replace.

Worn or damaged fan belt. – Replace.
Oil on fan belt. – Clean.
Thermostat not functioning – Replace.
properly.
Water pump not – Replace.
functioning properly.
Clogged radiator. – Clean radiator and coolant
passages.
Incorrect ignition timing. – Adjust ignition timing.
Improper engine oil. – Refer to lubrication table
and replace oil with a
recommended one.
Too lean mixture. – Repair or replace
carburettor.
Incorrect valve clearance – Make measurements on or
adjustment. replace
auto–lash adjuster.
Insufficient
compression Engine out of order. – Refer to page 10–08–4
pressure and make repairs.
Overcooling Defective thermostat. – Replace thermostat.

(Coolant Extremely low atmospheric – Place cover or anything
temperature temperature. proper on the front of
does not rise.) radiator.
Poor Engine Engine out of order. – Refer to page 10–08–4

acceleration and make repairs.
Caburettor Carburettor out of order. – Replace or repair

carburettor.
Ignition system Defective distributor. – Repair or replace

distributor.
Defective spark plug. – Replace spark plug.
E N G I N E
TROUBLESHOOTING
Excessive Engine Engine out of order. – Adjust or repair valves.

fuel
consumption Carburettor Defective carburettor. – Repair or replace
carburettor.
Clogged air bleeder. – Clean or replace.
Damaged gaskets. – Replace.
Improper idling speed. – Adjust idling speed.
Ignition system Incorrect ignition timing – Adjust ignition timing. 10

Excessive Excessive 08
engine oil engine oil Engine out of order. – Refer to page 10–08–5
consumption consumption and make repairs.
Oil leaks Engine out of order. – Refer to page 10–08–5

and make repairs.
E N G I N E
TROUBLESHOOTING
BY COMPONENT
ENGINE
Valves and Poor idling Incorrect valve clearance. – Make measurements on or

related replace auto–lash adjuster.
components
10 Valve not in close contact – Reface seat surface.
with valve seat.
Excessive clearance – Replace valve and valve
08 between valve stem and guide.
valve guide.
Abnormal Incorrect valve clearance. – Make measurements on or

combustion replace auto–lash adjuster.
Valve binding. – Disassemble, correct or
replace.
Deteriorated valve spring. – Replace spring.
Insufficient Incorrect valve clearance.– Make measurements on or

output replace auto–lash adjuster.
Pressure leaks from valve – Reface.
seat.
Valve stem seizure. – Repair or replace.
Excessive fuel Deteriorated or broken – Replace spring.
consumption valve spring.
Engine Poor Valve damaged by heat. – Reface or replace valve.

startability Intake manifold gasket not – Retighten set bolts or
tight enough. replace gasket.
Cylinder head gasket – Replace gasket.
blowby.
Poor Valve damaged by heat – Adjust or replace.

acceleration or not properly serviced.
Insufficient compression – Disassemble and repair
pressure. engine.
Cylinder head gasket – Replace gasket.
blowby.
Excessive fuel
Pressure leaks from – Retighten cylinder head
consumption
cylinder head gasket. bolts and replace gasket.
Insufficient Piston ring binding or worn. – Replace ring.
output Piston ring or ring worn. – Disassemble and repair
engine.
E N G I N E
TROUBLESHOOTING
Engine Excessive oil • Oil leaks.

consumption Loose oil drain plug. – Retighten plug.
Loose oil pan set bolts. – Retighten set bolts.
Damaged oil pan gasket. – Replace gasket.
Loose timing gear cover – Retighten set bolts or
or damaged gasket. replace gasket.
Defective crankshaft front
oil seal.
Defective crankshaft rear
– Replace oil seal.
– Replace oil seal.

10
oil seal. 08
Damaged cylinder head – Replace gasket.
gasket.
Loose oil filter set bolt. – Retighten set bolts or
replace oil filter gasket.
• Oil working its way up.

Piston ring gaps in – Adjust ring gap positions.
improper positions.
Piston rings or ring grooves – Replace piston or rings.
worn or rings
seized in grooves.
Carbon deposit oil return – Replace rings.
hole of oil ring.
Worn piston and cylinder. – Rebore and hone cylinder
and install oversize piston.
Excessive quantity of oil – Oil quantity : 4.8l
in oil pan.
• Oil working its way down.

Worn valve stem and – Replace valve and guide.
valve guide.
Defective valve stem oil – Replace oil seal.
seal.
Excessive Excessive oil clearance. – Replace bearing.

engine noise due to worn crankshaft
bearing.
• Fusion in crankshaft – Replace bearing and check
bearing. lubrication system.
Worn connecting rod –Replace bearing.
bearing.
• Bent connecting rod. – Repair bent connecting rod
or replace.
• Fusion in connecting rod – Replace bearing and check
bearing. lubrication system.
E N G I N E
TROUBLESHOOTING
Engine Excessive • Excessive clearance due – Rebore and hone cylinder

engine noise to worn cylinder. and install oversize piston.
Worn piston or piston pin. – Replace piston and piston
pin.
• Piston seizure. – Replace piston.
Broken piston ring. – Replace piston ring.
10 Excessive camshaft end

play.
Worn crankshaft thrust
– Replace camshaft thrust
plate.
– Replace bearing.
08 bearing.
• Worn timing gears. – Replace.
Excessive valve clearance. – Make measurements on or
replace auto–lash adjuster.
E N G I N E
TROUBLESHOOTING
CARBURETTOR
Carburettor Poor engine Needle valve and valve – Clean or replace.
startability seat not seating properly.
Incorrect float level. – Adjust.
Worn float lip. – Replace.
Worn float level pin and – Replace level pin and its
related components. related parts.
Malfunction choke valve. – Repair.
10
Poor idle Idle rpm set out of – Adjust idling speed.
adjustment.
08
Damaged idle adjust screw. – Replace adjust screw.
Clogged idle passage or – Clean.
idle port.
Clogged bypass screw. – Clean jet.
Worn throttle shaft. – Replace shaft.
Loose vacuum pipe union. – Retigthen union.
Idling circuit not air tight. – Clean.
Incorrect float level. – Replace.
Abnormal
Too lean mixture. – Clean or replace.
combustion
Inner dirty carburettor. – Clean carburettor.
Defective float level. – Adjust float.
Poor
Defective accelerating – Disassemble or replace.
acceleration
pump plunger.
Clogged pump jet. – Clean or replace.
Defective accelerating – Replace linkage.
linkage.
Malfunction power piston. – Replace power piston.
Malfunction power valve. – Replace.
Clogged power jet. – Clean or replace.
Float lever too low. – Adjust float.
Throttle valve not opening – Adjust valve.
completely.
Insufficient
Clogged main jet. – Clean.
output
Incorrect float level. – Adjust float.
Malfunction power piston. – Replace power piston.
Malfunction power valve. – Replace power valve.
Worn throttle shaft. – Replace shaft.
Throttle valve not opening – Adjust valve.
completely.
Choke valve stuck close. – Repair or replace
Excessive
fuel Float lever too high. – Adjust float.
consumption Defective power valve. – Replace valve.
Choke valve not opening – Check linkage, replace.
completely.
Improper idling speed. – Adjust idling speed.
E N G I N E
TROUBLESHOOTING
ELECTRICAL COMPONENTS
Distributor Poor engine Cracked distributor cap – Clean or replace.
starting and burnt or contaminated
cord insertion hole.
Poor engine
acceleration Centrifugal and vacuum – Repair or replace.
advance device
Insufficient malfunction.
10 engine output
Excessive fuel
consumption
08
Spark plug Poor engine Improper spark plug gap. – Adjust or replace.
starting Carbon deposit in spark – Clean or replace.
plug.
Abnormal
Improper heat range of – Replace spark plug with
combustion in
engine spark plug. proper one.
Loose or defective plug – Repair or replace.
Poor engine cord.
acceleration
Insufficient
engine output
Ignition coil Poor engine Defective ignition coil. – Replace ignition coil.
starting
Poor engine
acceleration
Starter Starter does Improperly connected – Repair.

not rotate. terminals.
Switch contacts in loose – Replace switch.
contact.
Magnet switch contact – Grind or replace contact
plate burnt or in loose plate.
contact.
Magnet switch holding coil – Replace.
open–circuited.
Brush in loose contact – Reface.
with commutator as a
result of wear.
Commutator burnt with – Exchange or replace
consequent poor commutators.
conduction of electricity.
High mica of commutator. – Perform under–cutting.
Field coil not properly – Replace.
grounded or short–circuited.
E N G I N E
TROUBLESHOOTING
Starter Starter does Field coil not properly – Repair.

not rotate. soldered.
Armature not properly – Replace.
grounded.
Armature short–circuited. – Rewind or replace.
Brush spring broken or – Replace spring.
with inadequate tension.
Brush holder not properly
insulated.
– Clean brush or replace
holder.
10
Worn bearing bushing. – Replace bushing. 08
Starter rotates
Wires of armature coil – Rewind or replace.
but slowly and
irregularly. about to be short–circuited
or grounded.
Field coil not properly – Repair connections.
connected or about to be
short circuited.
Commutator heat–damaged – Replace armature.
with consequent poor
conduction.
Brush movement due to – Repair or replace.
damaged or worn
commutator.
Commutator vibrating, – Repair or replace.
causing brush to move.
Lifted mica between – Perform under–cutting.
commutator segments
causing brush to move.
One or two commutator – Repair or replace.
segments lifted causing
brush to move.
Commutator in loose – Repair or replace.
contact due to worn brush.
Chipped brush. – Repair or replace.
Pinion does not
engage with Worn starter clutch pinion – Replace.
ring gear. end.
Clutch rotates always – Replace.
freely.
Deteriorated clutch drive – Replace.
spring.
Does not rotate in – Replace.
overrunning direction.
Poor sliding of splined – Rub surfaces smooth,
section. clean and repair.
Worn bushing. – Replace.
E N G I N E
TROUBLESHOOTING
Starter Pinion does not Improper projection – Adjust with stud bolt.
engage with position of magnet switch
ring gear. pinon.
Worn bearing bushing. – Replace.
Motor Magnet switch coil layer – Replace.
10 continues to
rotate and does
not stop.
shorted–circuited.
Magnet switch contact
plate seizure.
– Replace.
08 Starter switch does not – Replace switch.

return properly.
Battery Run–down • Alternator

battery Drive belt slipping. – Adjust belt.
Stator coil grounded or – Replace or repair.
open–circuited.
Rotor coil open–circuited. – Replace.
Brush and slip ring not – Replace brush if worn.
properly connected. (Clean holder.) Polish
(Brush does not properly slip ring.
come down.)
Diode short–or – Replace rectifier assembly.
open–circuited.
• Battery
Short or improper – Add electrolyte and adjust
electrolyte. specific gravity.
Defective plates. – Replace.
(internal short circuit)
Terminals in loose contact. – Clean and then retighten.
• Wiring
Open circuit or loose – Repair.
contact between key
switch and alternator
terminals L and R.
Burnt fuse of – Replace fuse and repair
above–mentioned circuits contacting section of
or holder in loose contact. holder.
Open circuit or loose – Repair.
contact between battery
and alternator terminal B.
Burnt fuse of – Replace fuse and repair
above–mentioned circuits or contacting section of holder.
holder in loose contact.
Overcharged Defective IC regulator – Replace.

battery
ENGINE (FOR DIESEL)
(YANMAR 4TNE 88) 15
• 15 – 01 SPECIFICATIONS AND PERFORMANCE
• 15 – 02 CROSS SECTIONAL VIEWS
• 15 – 03 COOLING WATER, LUBRICATING OIL AND FUEL OIL
• 15 – 04 TROUBLESHOOTING
• 15 – 05 SPECIAL SERVICE TOOLS AND MEASURING

INSTRUMENTS
• 15 – 06 MEASUREMENT, INSPECTION AND ADJUSTMENT
• 15 – 07 MEASURING PROCEDURE, SERVICE DATE AND

CORRECTIVE ACTION
• 15 – 08 DISASSEMBLY AND REASSEMBLY
• 15 – 09 SERVICE DATE
• 15 – 10 TIGHTENING TORQUE
• 15 – 11 FUEL INJECTION PUMP FOR DIRECT INJECTION

SYSTEM
• 15 – 12 GOVERNOR
• 15 – 13 SERVICE INFORMATION FOR CARB ULG

REGULATION
E N G I N E
SPECIFICATIONS AND PERFORMANCE
DESCRIPTIVE BREAKDOWN OF MODEL NAME
TNE (A) (T) –
Shi ping identifier

Turbocharger
Model subdivision
Cylinder bore (mm)
Model code
Number of cylinder
APPLICATION CATEGORY
15
Application code Usage Eng. Rev. Type Revolution speed(rpm)
01
1
CL 1500 / 1800
Generator drive Constant
CH 3000 / 3600
VM 2000 ~ 3000
General use Variable
VH 3000 ~ 3600
* For cngine application category described in Chapter 1, Specifications and Performance

E N G I N E
4TNE88
*Output conditions : intake back pedssure ≤ 250 mmAq, exhaust back pressure ≤ 550 mmAq,
other conditions complying with JIS D 1005–1986. After minimum 30 hour’s
run–in.
Model
4TNE88
Item Unit
Application – CL VM
Type – Verical, 4-cycle water–cooled diesel engine
Combustion – Direct injection system
15 No. of Cylinders
– Bore × Stroke
mm 4–88×90
Displacement l 2.190
01
Firing order – 1–3–4–2
2
Revolution speed rpm 1500 1800 2000 2200 2400 2600 2800 3000
Contknuous 16.4 19.6
kW(HP) – – – – – –
rating (22.0) (26.3)
Output*
18.0 21.6 24.1 26.5 28.8 31.3 33.7 36.0
Max. rating kW(HP)
(24.1) (29.0) (32.3) (35.5) (38.6) (42.0) (45.2) (48.3)
Max. revolution
1575+500 1870+500 2180+500 2400+500 2590+500 2810+500 2995+500 3210+500
speed at no load
rpm
Min. revolution
SPECIFICATIONS
≤1200 ≤800
speed at no load
Direction of rotation – Counterclockwise(viewed from flywheel)
Power take off – Flywheel
Conpression ratio – 18.0
Fuel injection timing
deg 10 ± 1 12 ± 1 14 ± 1 16 ± 1
(FID, b.T.D.C.)
Conpression MPa
3.43 ± 0.1 (35 ± 1), at 250 rpm
pressure (kgf/cm2)
Fuel injection MPa
19.6 +1.00 (200 +1.00 ) 19.6+1.00 (200 +1.00)
pressure (kgf/cm2)
Recommend diesel has oil – ISO 8217 DMA, BS 2869 A1 or A2(Cetane No. 45 min.)
Lubrication system – Forced lubrication with trochoid pump
Lubrication oil capacity
l 5.8 / 2.3 7.9 / 2.5
Max / Effective
Recommend lubricating oil – API grade CC class or higher
Cooling system – Liquid cooling / Radiator
Cooling water capacity l 2.7(for engine only)
Cooling fan
mm Pusher type, 6 × φ370
No. of blade × dia.
E N G I N E
Model
4TNE88
Item Unit
Application – CL VM
Revolation speed rpn 1500 1800 2000 2200 2400 2600 2800 3000
Crank V-pulley dia./
SPECIFICATIONS
mm φ120 / φ90 φ110 / φ110

Fan V-pulley dia.
Governor – Mechanical centrifugal governor(All speed type)
Starting system – Electrical
∗1 Dimensions
mm 683 × 498.5 × 618 632 × 498.5 × 618/658 × 498.5 × 618
L×W×H
∗1 Dry weight kg 184 160 / 170 15

Transient speed
% ≤10 ≤8 ≤12
01
differdnce 3
Governing
performan Steady state ≤5 ≤4 ≤9 ≤8 ≤7
PERFORMANCE
%
ce(full speed band
speed sec
ranger)
Recovery time ≤5 ≤6
Fluctuation of
rpm ≤15 ≤25
revolution
0.29 ± 0.05 0.34 ± 0.05
Rated operation MPa
L.O.Press (3.0 ± 0.5) (3.5 ± 0.5)
(kgf/cm2)
ldling ≥0.06(≥0.6)
*1. Designation of engine dimension and dry weight in numerals.

CL / CH application: engine with flywheel housing
VM / VH application: engine with back plate/with flywheel housing
E N G I N E
CROSS SECTIONAL VIEWS
CROSS SECTIONAL VIEWS
DIRECT INJECTION SYSTEM
15
02
1
E N G I N E
COOLING WATER, LUBRICATING OIL AND FUEL OIL
COOLING WATER
PROPER USE OF COOLING WATER
Impurities in cooling water are deposited in the engine and radiator in the form of scale and
cause rusting. For this reason, heat conduction of the cooling system and cooling water flow
are impaired, and cause cooling functions to reduce and the engine to overheat. Therefore, drain
the cooling water at intervals of 400 hours or one year. Never use hard water as the cooling
water.
In order to prevent the cooling water from freezing in cold weather, be sure to use an antifreeze
agent. For further information on and proper usage and type of rust-preventive agents,
15
antifreezes, and cleaning agents, contact your nearest dealer. 03
1
COOLING WATER SYSTEM DIAGRAM
Indirect injection system and direct injection

system
LUBRICATING OIL
PROPER USE OF LUBRICATING OIL
Use of proper lubricating oil bring about the following effects.

• The friction part of the engine is protected from friction and wear.
• The engine parts is protected from rusting and corrosion.
• The high temperature part of the engine is effectively cooled.
• The engine is protected from leakage of combustion gas.
• The engine parts are protected from sludge deposits.
For the above reasons, use lubricating oil API Service Classification Class CC or better.
E N G I N E
reference : lubricating oil to be used at ambient temperature.
Select the viscosity of lubricating oil depending on ambient temperature at which the engine is
used, according to SAE Service Grade shown below.
SAE 5W–20
SAE 20W–40
SAE 10W–30
SAE 10W
SAE 20W
15 SAE 20W–20
SAE 20W–30
03
SAE 20W–40
2
-30 -20 -10 0 10 20 30 40(°C)
Ambient temperature at which the engine is used, °C

: Recommend SAE Service Grade
LUBRICATION SYSTEM DIAGRAM
Direct injection system

E N G I N E
FUEL OIL
PROPER USE OF DIESEL GAS OIL
Use a diesel gas oil equivalent to or better than ISO 8217 DMA, BS 2869 Part1 class A1 or
Part2 class A2. (Cetane Number : 45min.)
Give your customers instructions on proper use of fuel oil, or the customers may suffer from
troubles stated below.
• Deposits on the exhaust value

Deposits on the exhaust value cause unburnt oil mixture in exhaust gas and erosion of the
exhaust valve seat, to occur in addition to poor compression, imperfect combustion, excessive
fuel consumption, etc. 15
• Deposits in the piston ring groove 03
Deposits in the piston ring groove cause blow-by gas, poor lubrication, imperfect combustion,
3
excessive fuel consumption, contamination of lubricating oil, premature wear, etc. of the cylinder
liner and piston ring.
• Clogging or corrosion of nozzle hole in fuel injection valve

Imperfect combustion causes the fuel injection mechanism to wear and corrode and the nozzle
to be clogged.
FUEL SYSTEM DIAGRAM
• Direct injection system

E N G I N E
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLE CAUSES AND REMEDIES
The following table summarizes the symptoms and causes of general trouble. If any symptom of trouble is found, a corrective action shall be taken before the said symptom develops into a serious accident.
Carefully read Chapter 6, Measurement, Inspection and Adjustment, and Chapter 7, Measuring Procedures, Service Data and Countermeasures. Familiarize yourself with Chapter 6 and Chapter 7, which practice
is Extremely important for extending the service life of the engine.
High knocking sound during combustion

Fails to start Insufficient Poor ex- Hunting Lubricating oil Coolant Air
engine output haust color intake
Engine starts Exhaust color During
Excessive fuel consumption

but stops soon. work
Uneven combustion sound
Poor return to low speed

symptom of trouble
Exhaust temperature rise

Low coolant temperature
Abnormal engine noise
Excessive consumption
Exhaust smoke
Large engine vibration

15
Engine will not start
Corrective action
Much blow–by gas

Low L.O. pressure
Mixture with water
Diluted by fuel oil
Cause
Pressure drop
Pressure rise
During idling
During work
04
Overheat
Regular
1
White
White
Black
Black
More
Less
Nil
Improper clearance of intake/exhaust valve Adjust the valve clearance. (Refer to chapter 6, 6-2.)
Compression leakage from valve seat Rap valve seat. (Refer to chapter 7, 7-1-2)
Seized of intake/exhaust valve Correct or replace.
Blowout from cylinder head gasket Replace the gasket.(Refer to Chapter 8, 8-2-(10))
Seized or broken piston ring Replace the piston ring. (Refer to Chapter 7, 7-4-3, 4, (5))
Worn piston ring, piston or cylinder Make honing and use oversize parts.(Refer to Chapter 7, 7-2-3, & 7-4-(8))
Seized crank pin metal or bearing Repair or replace.
Engine system
Improper arrangement of piston ring joints Correct the ring joint positions. (Refer to chapter 7, 7-4-(5))
Reverse assembly of piston rings Properly reassemble.(Refer to chapter 7, 7-4-(5))
Worn crank pin and journal metal Measure and replace. (Refer to chapter 7, 7-5-3 and 7-7-(5))
Loosened connecting rod bolt Tighten bolt to the specified torque.(Refer to chapter 10, 10-1)
Foreign matter trapped in combustion Disassemble and repair the combusion chamber.
chamber Elimunate foreign matter.
Excessive gear backlash Adjust meshing of gears.(Refer to chapter 7, 7-8-(2))
Worn valve guide of intake/exhaust valves Measure and replace.(Refer to chapter 7, 7-1-(3))
Poor governor Repair and adjust(Refer to Chapter 13.).
Improper open/close timing of Adjust valve clearance(refer to chapter 6, 6-2) and check
intake/exhaust valves intake/exhaust valve timing.(Refer to chapter 9 9-1)
Dirty blower Clean the blower
charger
Turbo
Waste gate malfunction Disassemble and inspect the waste gate.

Worn journal bearing Disassemble and inspect the journal bearing
Cooling water system
Cooling effect of radiator, excessive Malfunction of thermostat(Kept closed).(Refer to chapter 6, 6-9)

Cooling effect of radiator, insufficient Manufuction of the thermostat(kept opened)(Refer to chpter 6, 6-9)
Slipping fan belt.(Refer to chpter 6, 6-3)
Check water leakage from cooling water sysem. (Refer to chapter 6,
Insufficient cooling water level 6-7.) and clean cooling water system.(Refer to chapter 3, 3-1.)
Cranked water jacket Repair and replace
Slackened fan belt tension Adjust fan belt tension.(Refer to chapter 6, 6-3.)
Poor thermostat Check or replace.(Refer to chapter 6, 6-9.)
E N G I N E
TROUBLESHOOTING
High knocking sound during combustion

Fails to start Insufficient Poor ex- Air
Hunting Lubricating oil Coolant
engine output haust color intake
Engine starts Exhaust color During
but stops soon. work
Excessive fuel consumption

Sympton of trouble
Uneven combustion sound
Poor return to low speed

Exhaust smoke
Exhaust temperature rise

Low coolant temperature
Trouble with the engine
Excessive consumption
Large engine vibration
Engine will not start
Low L.O. pressure

Mixture with water
Diluted by fuel oil
Much flow-by gas

Cause
Pressure drop
Pressure rise
During idling
During work
Overheat
Regular
White
White
Black
Black
More
Less
Nil
15
Lubricating oil system
Improper properties of lubricating oil Use proper lubricating oil. (Refer to Chapter 3, 3-2)
Leakage from lubricating oil piping system Repair
Check and repair. (Refer to Chapter 7, 7-9)
Insufficient delivery capacity of trochoid pump
04
Clogged lubricating oil filter Cleaning or replace. 3
Poor pressure control valve Clean, Adjust or replace.
Insufficient lubricating oil capacity Proper lube oil supply
Excessively early timimg of fuel injection
Check and adjust. (Refer to Chapter 6, 6-5)
pump
Excessively late timimg of fuel injection
Check and adjust. (Refer to Chapter 6, 6-5)
pump
Improper properities of diesel gas oil Use proper diesel gas oil.(Refer to Chapter 3, 3-3)
Water entering fuel system Inspect and repair(Refer to Chapter 6, 6-7)
Fuel system
Clogged fuel filter Cleaning or replace

Air entering fuel system Perform air bleed.
Clogged or cracked fuel pipe Cleaning or replace.
Fuel insufficiently supplied to fuel injection Inspect the fuel tank calce cock fuel filter fuel pupung and
pump fuel feed pump.
Uneven injection volume of fuel injection pump Inspect and adjust.(Refer to Chapter 11 and 12)
Excessive fuel injection volume Inspect and adjust.(Refer to Chapter 11 and 12)
Poor spray pattern from fuel injection nozzle Inspect and adjust.(Refer to Chapter 6 and 6-4-(2))
Electric Wiring. Air/ exhaust
gas system
Clogged air filter Cleaning

Engine used at high temperature or at high altitude Use more High-output engine
Clogged exhaust pipe Cleaning
Malfunction starting motor Repair or replace.
Repair or replace.
system
Malfunction alternator
Open-circuit of wires Repair
Under voltage of battery Recharge of battery.(Refer to Chapter 6, 6-8)
E N G I N E
TROUBLESHOOTING
TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION

PRESSURE
*: For the compression pressure measuring procedure, refer to chapter 6, 6-1. Measurement of
compression pressure.
Reduction in compression pressure of the cylinder is one of major causes of an increase in

blow by gas (which causes contamination and incresed consumption of lubricating oil, and other
trouble) ad well as the engine starting failure.
The compression pressure is influenced by the following factors:
1. Degree of clearance between the piston and cylinder.
2. Degree of clearance around intake / exhaust valve seats.
3. Gas leak through the nozzle gasket or cylinder head gasket.
In addition, the compression pressure decreases as the engine parts are worn and lose durability
15
through use of the engine for a long period. 04
Scratches on the cylinder or piston caused by dust or foreign matter through the soiled air 5
cleaner element, and wear or breakage of piston rings also decrease the compression pressure.
For this reason, diagnose the engine status by measuring the compression pressure.
Causes and countermeasures to be taken when the compression pressure is less than
the limit value.
* For the compression pressure limit value, refer to Chapter 6, 6-1. Measurement of compression
pressure.
No. Item Cause Countermeasures
1 • Filter element of • Clogged filter element. • Clean the filter element.
air cleaner • Broken filter element. • Replace the filter element with a
• Defective filter element new one.
seal
2 • valve clearance • Excessive valve • Adjust the valve clearance
clearance or no clearance (Refer to Chapter 6, 6-2.)
3 • valve timing • Improper valve timing • Adjust the valve clearance
• Improper valve clearance (Refer to Chapter 6, 6-2.)
• Inspect and adjust of the value
rocker arm. (Refer to Chapter 7,
7-3, 7-6 and 7-8.)
4 • Cylinder head gasiket • Gas leak through the • Replace the gasket.
• Nozzle gasiket gasiket • Re-tighten the cylinder head and
nozzle to the specified torque.
5 (Refer to Chapter 10, 10-1.)
• Intake / exhaust valve • Gas leak caused by worn • Rap valve seats.
• valve seat valve seats or trapped (Refer to Chapter 7, 7-1. 2.)
foreign matter • Replace the intake / exhaust valves.
• Seizure of valves
6 • piston • Gas leak caused by • Perform honing and use oversize parts.
• piston ring scratches and wear of (Refer to Chapter 7, 7-2. 3. and 7-4. 8.)
piston, piston ring and
• Cylinder cylinder
E N G I N E
SPECIAL SERVICE TOOLS AND MEASURANG INSTRUMENTS
SPECIAL SERVICE TOOLS AND MEASURING

INSTRUMENTS
Although main engine parts can be disassembled and reassembled only with standard service
tools, it is recommended to provide the following special service tools and measuring instruments
for more efficient and accurate work, correct measurement, diagnosis, and troubleshooting.
SPECKAL SERVICE TOOLS
No. Tool name Applicable model and dimension Illustration
1 Valve guide
extraction
(mm)
15
tool
Dimension
05
l1 l2 d1 d2
Model 1
4TNE88 20 75 7.5 11
• Locally manufactured
2 Valve guide
insertion tool
(mm)
Dimension l1 l2 d1 d2
Model
4TNE88 15 65 14 20
3 Connecting
rod bushing
(mm)
replacer
Dimension l1 l2 d1 d2
Model
4TNE88 20 100 26 -0.3
-0.6
29 -0.3
-0.6
4 Valve spring
compressor Model Yanmar Code No.
(Replacement All model 129100-92630
of valve spring)
E N G I N E
No. Tool name Applicable model and dimension Illustration

5
Filter wrench Sold on market
(Removal and
installation of
L.O. filter)
6
Camshaft
15 bushing tool
(Extraction of Dimension l1 l2 d1
(mm)
d2
camshaft Model
05 bushing) 4TNE88 18 70 45 -0.3
-0.6 48 -0.3
-0.6
2
Flex-Hone
7
(for honing
cylinder liner) Model Yanmar Code No.
* : For the usage 4TNE88 129100-92430
procedure of
the Flex-Hone,
refer to Page
15–07
8 Piston
insertion
tool (insertion Model Yanmar Code No.
of piston) All model 129100-92630
Note : The above piston insertion tool is applicable
to postons 60~125mm in diameter.
Piston ring Sold on market

9
replacer
E N G I N E
MEASURING INSTRUMENTS
No. Instruments name Purpose of use Illustration
1 Dial gauge Measures bent shafts, distorted flat surface,

gaps, etc.
2 Test indicator Measures the limited small portions and deep

pertions unmeasurable with dial gauge.
15
05
3
3 Magnetic Used together with the dial gauge:holds the dial

stand gauge at different angles.
4 Micrometer Measures the outside diameter of the crankshaft,

piston, and piston pin, etc.
5 Cylinder Measures the inside diameter of the cylinder

gauge liner, cinnecting rod metal, etc.
6 Vernier Measures the outside diameter depth, thickness,

callipers width, etc. of various items.
7 Depth Measures the sinkage of the valve.

Micrometer
E N G I N E
8 Square Meadures inclination of valve spring, squareness

of engine parts, etc.
9 V-block Measures bent shaft.
15
05
4 10 Torque Used for tightening bolts and nuts to the
wrench specified torques.
11 Thickness Measures gaps between the rings and mating

gauge ring grooves and around shaft couplings during
installation.
12 Cap tester Checks the fresh water system for leakage.
13 Battery Checks the antifreeze for concentration and the

coolant tester battery electrolyte for specific gravity, and
charging state.
14 Nozzle tester Checks the fuel injection valve for spray

patterns and injection pressure.
E N G I N E

15 Digital Measures Tempera of each part.
thermometer
16 Contact Measures RPM of the rotary shaft by bringing

type the gage head into contact with the mortise.
15
05
5
Photouelec Applies a reflecting tape on the circumference
tric type of the rotating parts to measure RPM.
Tachometer
High Measures engine RPM’s using pulse system,

pressure irrelevantly to the center of the rotary shaft and
fuel pipe the circumference of the rotary object.
clamping
type
17 Circuit tester Measures the resistance, voltage, and continuity

of electric circuits.
18 Compression Measures compression pressure.

gauge kit
Yanmar Code No.
TOL-97190080
E N G I N E
MEASUREMENT, INSPECTION AND ADJUSTMENT
MEASURING THE COMPRESSION PRESSURE
MEASURING PROCEDURE
• Warm up the engine. Remove the fuel injection pipe and fuel injection valve from the cylinder
to be measured.
• Crank the engine before attaching the compression gauge adapter.
∗ : 1. Crank the engine when the regulator handle has been turned to “STOP” position (no
injection state).
2. For the compression gauge and compression gauge adapter, refer to Chapter 5, 5-2. 15
• Attach the compression gauge adapter and 06
compression gauge to the cylinder to be 1
measured.
∗ : Never fail to attach the gasket to the tip of
the adapter.
• Crank the engine by the starting motor until the
reading of the compression gauge is stabillized,
by taking steps shown in (2), ∗1.
Measuring the compression pressure
[Reference:List of Engine Compression Pressures]
compression pressure at 250 rpm Dispersion of compression

Model (kgf/cm2) pressure among cylinders
Standard Limit (kgf/cm2)
4TNE88 35 ± 1 27 2~3
Reference: Variation of Compression

Pressures with Engine Speed
• Direct injection system
ACTION TO BE TAKEN WHEN THE MEASURED COMPRESSION PRESSURE IS

BELOW THE LIMIT VALUE.
Trouble occurs in a part of the engine. For troubleshooting, refer to Page 15-04 trouble diagnosis
through measurement of compression pressure.
E N G I N E
ADJUSTING THE VALVE HEAD CLEARANCE
• Inspect and adjust a valve head clearance while the engine is in cold state.
• Raise the piston in the cylinder to be measured to the top dead center (TDC) of compression.
• Losen the lock nut and adjusting screw.
Make sure that the valve cap is free from
inclination or trapped dirt.
15
06
2
• Insert a thickness gauge in between the rocker

arm and valve cap. Tighten the adjusting screw
until the clearance listed below is attained.
(mm)
All models
Intake / exhaust valve
0.15~0.25
head clearance
Adjusting the valve head clearance
*: 1. If the valve cap is worn or otherwise

damaged on the head, replace it with a
new one.
2. Make sure that the valve cap is nested on
the head of intake / exhaust valves.
E N G I N E
CHECKING THE V-BELT TENSION
Push the center of the V-belt between the alternator and cooling water pump with a finger. If
the deflection is 10-15 mm, the V-belt tension is acceptable. If not, adjust the V-belt tension
using the adjust at the alternator.
15
06
3
Adjusting of the V-belt tension
MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS

OF THE FUEL INJECTION VALVE
Measuring the injection pressure
* : Thoroughly remove carbon deposits from the

injection nozzle before making measurement.
• Connect the fuel injection valve to the high
pressure pipe of the nozzle tester.
• While pumping the lever of the nezzle tester
sliwly, read the pressure gauge on the nozzle
tester the moment the nozzle starts fuel
injection.
* : For injection pressure of dach engine, refer to
Chapter 1, “Specifications and Performance”
• if the measured injection pressure is lower than
Measuring the injection pressure with a
the specified value, replace the pressure
nozzle tester
adjusting shim with a thicker one.
E N G I N E
Type of pressure
adjusting shim injection pressure adjustment
thickness(mm)
Indirect 0.1, 0.2, 2.3, Increase the pressure adjusting shim the thickness
injection 0.4, 0.5 by 0.1 mm and the injection pressure is increased
system by 7-10 kgf/cm2.
Direct 0.13, 0.15, Increase the pressure adjusting shim the thickness
injection 0.18, 0.4, by 0.1 mm and the injection pressure is increased
system 0.5, 0.8 by about 19 kgf/cm2.
15 [Reference: Structure of fuel injection valve]
06 Indirect injection system Direct injection system
CHECKING THE SPRAY PATTERNS
While pumping the lever of the nozzle tester 4-6times per second at the specified injection
presster(Refer to Chapter 1, specigications and performance), check the sptay patterns. If the
following trouble is found, clean or replace the nozzle.
• Make syre that the pattern is neither stream nor sliver.

• Ensure that fuel is sprayed conically around the nozzle center line and that a fuel injection
spreading angle is 5-10° in the indirect injection system or approx. 150° in the direct injection
system
E N G I N E
[Normal spray pattern] [Abnormal spray pattern]
Indirect injection system Indirect injection system

15
06
5
Direct injection system Direct injection system
• Place a sheet of white paper 30 cm below the nozzle. The injection spray should form a
perfect circle.
• No oil should drip from the nozzle after injection.
• Oil should not ooze from the injection hole whem the pressure is raised to a little less tham
the specified 20 kgf/cm2.
• Test the injection with a nozzle tester;retighten and test again if there is excessive oil leak
from the overflow coupling. Replace the mozzle as a set if the leaking oil is still excessive.
E N G I N E
NOZZLE VALVE SLIDING TEST
Thoroughly wash the nozzle valve using clean diesel oil. Hold the nozzle body vertically, and
lift the nozzle valve approx. 1/3 of its length with one hand.
Check to see if the nozzle falls smoothly by itself gravity when released. If so, the nozzle valve
is good. In case of a new nozzle, remove the seal peel, and immerse it in clean diesel oil or
the like to clean the inner and outer surfaces and to thoroughly remove rust-preventive oil before
using the nozzle. Note that a new nozzle is coated with the seal peel to shut off outer air.
15
06
6
Nozzle valve sliding check by gravity Nozzle valve sliding check by gravity
for indirect injection system for indirect injection system
NOZZLE BODY IDENTIFICATION NUMBER
Y DN – O S D YD1
Design code
No code: pintle type
D: throttle type
Size: size P
: size S
Injection angle
Type: pintle type
YANMAR Indirect injection system
Y DLL A – 150 P 244JO
Design code
Size: size P
: size S
Injection angle
Nozzle insertion angle
Code A: angle
No code: No angle
Type: DLL(semi-long type)
YANMAR Direct injection system
E N G I N E
CHECKING AND ADJUSTING THE FUEL INJECTION TIMING
DIRECT INJECTION SYSTEM
• Using the crankshaft pulley, turn the engine in the specified direction. Check the injection timing
at the delivery valve of the fuel injection pump for cylinder No. 1.(Cylinders are numbered se-
quentially from cylinder No. 1 from the flywheel side).
15
06
7
• When the crankshaft is turned in the specified direction, the oil level rises at the tip of the
delivery valve spring holder. At that time, stop the ctankshaft.
• Identify the timing mark stamped on the flywheel through the access hole of the flywheel
housing.
*: For fuel injection timing for each engine model, refer to Page 15–01, and performance.
E N G I N E
• If the measured injection timing differs from the

specified timing, adjust the injection timing by
turning down the fuel injection pump toward the
engine or to the opposite side after loosening
the lock nut of the fuel injection pump.
– If injection timing is late, turn down the fuel

injection pump away from the engine.
– If the injection timing too early, turn the
injection pump down toward the engine.
15 ADJUSTING THE NO-LOAD MAXIMUM(OR MINIMUM) REVOLUTIONS
06 • First warm up the engine. Then, gradually

8 increase the engine speed up to the no-load
max. revolutions (Refer to Chapter 1,
Specifications and Performance).
• If the present no-load max. revolution differ
from the specified one, adjust the no-load max.
revolution using the no-load max. revolution
adjusting bolt.
• Set the engine to the idling revolution, (Refer
to page 15–01 Specifications and Performance)
by turing the no-load min. revolution adjusting
bolt.
* : The illustration shows the partial

perspective view of the governor for the
direct injection system.
E N G I N E
CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR

WATER LEAKAGE
CHECKING THE COOLING WATER SYSTEM FOR WATER LEAKAGE
∗ : the cooling water system can be checked

effectively while the engine is warm.
• Supply cooling water up to the normal water

level in the radiator. Attach the cap tester body
to the radiator.
• Start the cooling water pump, and set it to a
pressure of 0.9 ± 0.15kgf/cm2. Any lower
reading of the pressure gauge on the cap
15
tester indicates water leak from the cooling 06
water system. Then, detect the portion where
9
cooling water leaks from the cooling water
system.
Checking the cooling water system for

water leakage
CHECKING THE RADIATOR CAP
Attach the radiator cap to a cap tester. Set the

tester to a pressure of 0.9 ± 0.15kgf/cm2. Check
to see if the cap is opened at the set pressure.
if not, replace the cap, because it is defective.
Checking the radiator cap
CHECKING THE BATTERY
STRUCTURE OF THE BATTERY

E N G I N E
CHECKING THE BATTERY
• Electrolyte level
Check the electrolyte level in each cell. If the level is low, add deionzed water to bting the
level to the UPPER level as illustrated below.
15
06
10
• Battery charge
Using a battery tester or hydrometer, check the
state of the battery. if the battery is discharged,
recharge it.
Measurement with a battery tester

To check the battery with a battery tester,
securely hold the (+) terminal of the battery with
the red clip of the battery tester and the (–)
terminal with the black clip. Judge battery charge
level from the indicator pesition:
Green zone : normal
Measuring the battery charge with battery
Yellow zone : somewhat discharged
tester
Rel zone : abnomal or much discharged
E N G I N E
Measurement with a hydrometer

When using a hydrometer, correct the measured
specific gravity according to the temperature.
The specific gravity of the electrolyte of the
battery is the standard when measured at 20°C.
Correct the specific gravity according to the
following equation, as it changes by 0.0007 per
1°C.
S20 = St + 0.0007 (t–20)
Measured
electrolyte Measuring the remaining battery charge
temperature
Measured specific gravity
with hydrometer
15
Specific gravity converted to 20°C 06
11
Hydrometer and remaining battery charge
Specific gravity Discharged level Remaining level

Hydrometer
(at 2°C) (%) (%)
1.260 0 100
1.210 25 75
1.160 50 50
1.110 75 25
1.060 100 0
How to read a hydrometer
• Terminal
Repair or cleam the terminals if corroded or soiled.
• Fittings
Repair or replace the fittings if corroded.
Re-tighten them if loosened.
• Appearance of the battery
Replace the battery if cracked or deformed.
Clean it using fresh water if contaminated.
E N G I N E
CHECKING THE SENSORS
CHECKING THE THERMOSTAT AND THERMOSWITCH
• Thermostat
Put a thermostat into water in a container.
While measuring water temperature, heat the water. Make sure that the thermostat functions
at a temperature of 69.5-72.5°C. (80.5~83.5°C are used as option parts)
15
06
12
• Thermoswitch
Put a Thermoswitch into an antifreeze or oil in
a container. While measuring liquid
temperature, heat the liquid. If the tester shows
continuity at a temperature of 107-113°C, the
thermoswitch is acceptable.
• PRESSURE SWITCH
Remove the connector from the pressure

switch.
While runing the engine, bring the tester probes
into contact with the switch terminal and
cylinder block. If the tester shows continuity,
the pressure switch is defective.
Continuity test
E N G I N E
CHECKING THE OIL COOLER
The oil cooler is of the core type and cooled by fresh water. It is installed as a standard
component on turbocharged engines in the TNE series.
• Replace the packing at the joint and O-rings at the time of reassembly after disassembly.
• When the oil cooler is disassembled and cleaned for periodic inspection, remove the scale by
using descaling agent “Unicon 146”.
• Cooling tube leak check
Close either the inlet or outlet of the cooling tube. Apply an air pressure (5.0 kg/cm2) from the
other end and check if air is leaking by immersing the tube in water. If leaking, repair or
replace the cooling tube.
15
06
13
CHECKING THE PISTON COOLING NOZZLE
• The piston cooling nozzle function

A nozzle made of a steel pipe is installed below the main gallery in the cylinder body. The
lubricating oil from the main gallery is constricted at the nozzle hole(φ1.77mm) at the tip end
of the steel pipe to be jet-sprayed. This jet spray comes into contact with the rear face of the
piston for cooling it.
Jet flow rate 1.3l/min

Jetting pressure 3.5kg/kg/cm2
• Checking the piston cooling nozzle

– Check the nozzle hole at the tip end for clogging with dirt or foreign matter, and clean it.
– Check the brazed portion of the steel pipe for loosening or freeing by vibration. Replace with
a new part if defective.
E N G I N E
MEASURING PROCEDURE, SERVICE DATE AND CORRECTIVE ACTION
MEASURING PROCEDURE, SERVICE DATA AND

CORRECTIVE ACTION
In maintaining various parts, make measurerment according to the following measurerment

procedure. If any trouble is found and if any part deviates from the standard size, replace it
with a new one. However, if any part within the limit is expected to deviate from the standarl
prestmably because of the record of its use, be sure to replace such a part beforehand.
CYLINDER HEAD
15
DISTORTION AND INSPECTION OF THE COMBUSTION SURFACE 07
1
• Remove intake / exhaust valves and fuel injection valve from the engine. Cleam the surface of
the cylinder head.
• Place a straight-edge along each of the four sides and each diagonal of the cylinder head.
Measure the cleatance between the straight-edge and combustion surface with a thickness
gauge.
(mm)
Cylinder head
combustion Standard Wear limit
surface distortion
All models 0.05 or less 0.15
Measuring the combustion surface

distortion
• Visually check to see if the combustion surface is free from discoloration, cracks, and crazing.
In addition, use the color check kit for cracks and crazing
E N G I N E
INTAKE / EXHAUST VALVE SEATS
• Valve sinking
Over long periods of use and repeatde lappings, combustion effciency may drop.
Meawure the sinking depth and replace the valve and valve seat if thd valve sinking depth
exceeds the standard value.
(mm)
3/4TNE88
Standard Wear limit
15
Intake
Valve 0.306 ~ 0.506 1.0
valve
sinking
Exhaust
07 depth
valve
0.3 ~ 0.5 1.0
Measuring the valve sinkage
Width and angle of the valve seat

Remove carbon deposits from the seat surface. Measure width and angle of the seat using
vernier calipers and an angle gauge.
(mm)
4TNE88
Standard Wear limit
Valve Intake 1.07 ~ 1.24 1.74

seat
width Exhaust 1.24 ~ 1.45 1.94
Valve Intake 120° –

seat
width Exhaust 90° –
Measuring the valve seat width
E N G I N E
[Valve Seat Correction Procedure]
• When the seat surface is worn or roughened

slightly, lap the seat surface with a valve
compound mixed with oil to a smooth state.
• When the seat surface is worn or roughened
heavily, correct seat surface or seat cutter, and
finish it according to step(1).
Valve seat correction angle

15
07
3
[Procedure for Using The Seat Grinder and Seat Cutter]
• Correct the roughened seat surface with a seat

grinder or seat cutter.
Seat grinder Angle(θ)
Intake valve 30°
Exhaust valve 45°
(1) When the seat with is enlarged from the

initial value, correct it by grinding the seat
surface with a 70° seat grinder or seat cutter.
Then, grind the seat to the standard width
with a 15° grinder.
(2) : When using a seat cutter, evenly apply
pressure taking care of avoiding uneven
cutting.
(3) Knead valve compound with oil and finish the valve seat by lapping.
* : if any valve requires correction, be sure to measure the oil clearance between the valve stem
outside dia. and valve guide inside dia. if the oil clearance exceeds the limit, replace the
valve or valve guide before correcting the valve seat surface. (For oil clearance between the
valve and valve guide, refer to page 15–03.)
(4) Finally, lap the valve using only oil.
*1. After the valve seat is corrected, thoroughly clean the valve and cylinder head using diesel
oil or the like. Thoroughly remove the valve compound or grindstone powder.
2. For slightly poor contact, take steps (3) and (4).
E N G I N E
[Extraction of Valve seat]
2/3TNE68 : All
Without
3TNE74 : VM
valve seat
Direct injection system : CL and VM
Without 3TNE74 (IDI) : CL and VH
valve seat Direct injection system : CL and VH
Turbocharged engine : All
• Grind the citcumference of the intake / exhaust

valve head being or having been used to the
15 dimension smaller than the valve seat outer

diameter.
• Grind the citcumference of the stem end of the
07 valve to the same dimension as the fitting
4 diameter of the cotter.
• Weld the intake / exhaust valve head with the
valve seat at three positions.
• Hit the stem end of the intake / exhaust valve
to extract the valve seat.
[Insertion of Valve seat]

• Put the Valve seat in a container which
contains liquefied nitrogen, or ether or alcohol
with dry ice to cool it sufficiently.
• heat the cylinder head around the portion for
valve seat insertion to 80~100°C with a dryer.
• With the new intake / exhaust valve, securely
insert the sufficiently cooles valver seat into the
cylinder head by tapping the head of the
intake / exhaust valve.
• Stand the cylinder head until the entire cylinder
head is cooled to normal temperature.
Insertion of valve seat
E N G I N E
INTAKE / EXHAUST VALVE
• Wear and bend of the valve stem

Replace a valve stem if bent or worn badly.In this
case, replace the valve guide at the same time.
• valve stem and valve guide
Oil clearance is a difference between the valve
guide inside diameter measured with a three-
point micrometer (capable of measuring inside
diameter between 4mm and 8mm) or a cylinder
gauge (capable of measuring 6mm or greater
inside diameter) and the stem outside diameter
measured is near the limit, replace both the
intake / exhaust valve and valve guide with new
ones.
Measuring the valve stem outside diameter
15
(mm) 07
4TNE88 5
Standard Wear limit
Stem O.D 7.955 ~ 7.975 7.9
Intake
Guide I.D 8.010 ~ 0.070 8.1
Valve
Oil clearance 0.035 ~ 7.970 0.2
Stem O.D 7.955 ~ 6.96 7.9
Exhaust
Guide I.D 8.015 ~ 8.030 8.1
Valve
Oil clearance 0.045 ~ 0.075 0.2
• Thickness of valve head

Measure the thickness of valve head with a
micrometer
When the measured value is near the wear
limit, replace the valve with a new one.
(mm)
4TNE88
Standard Wear limit
Thick- Intake
ness of valve 1.244 ~ 1.444
valve 0.50
Exhaust 1.35 ~ 1.55
head valve
E N G I N E
[Replacing the Valve Guied]
• Extrant the valve guide from the cylinder head (mm)

using the valve guide extraction tool.
4TNE88
* For the valve guide extraction tool, refer to
page 15–05 Standard Wear limit
Valve guide
• In a container containing liquefied nitrogen, 5 –
projection
ether or alcohol together with dryice, put the
valve guide to cool it. Then hit the sufficiently
cooled valve guide to fit into the cylinder head
using the valve guide insertion tool.
15 * For the valve guide insertion tool, refer to

page 15–05
07 • After inserting the valve guide, finish the inside

6 of the valve guide.
• Chedk the projection of the valve guide.
Valve guide projection

E N G I N E
VALVE STEM SEAL
[Time of Replacement]
• When oil loss is found excessive
• When the valve stem seal is removed
• When intake / exhaust valves are removed
[Precautions on Installation]
Make sure that the entire surface of valve stem is smooth, and sufficiently apply lubricating oil
to the valve stem before reassembling intake / exhaust valves.
15
07
7
Hatched portion indicates where to apply

lubricating oil
E N G I N E
CHECKING THE VALVE SPRING
• Visually check to see if the valve spring is free from flaws and corrosion.
• Measure the free length (length of the spring) and inclination(squareness of the side of the coil)
(mm)
4TNE88
Standard Wear limit
Free length 42 –
Valve
Inclination – 1.1
spring
Tension(kg)
15 (when compressed
to by 1mm)
*Tension at variable pitch.

*2.36 / 3.101 –
07 Measuring the free length

8
Measuring the valve spring inclination Measuring the inclination of valve spring
CHECKING VALVE SPRING HOLDER AND COTTER
Check contact of thd inner surface of the valve spring holder with the circumference of the cotter
as well as contact of the inner circumference of the cotte with the notch on the head of tne
valve stem. If such contact is uneven or if tne cotter sinks, replace the cotter with a new one.
E N G I N E
CYLINDER BLOCK
CHECKING THE CYLINDER BLOCK
• Visually check to see if the cylinder block is

free from water leak, oil leak and cracks. If any
cylinder block is suspected to be cracked,
check it by color check.
• Replace the cylinder block if badly damaged
and incorrectable.
• Thoroughly clean each oil hole. Make sure that
it is not clogged.
15
Measuring the cylinder bore 07
9
MEASURING THE BORE AND DISTORTION OF THE CYLINDER
Measuring the bore of each cylinder with a

cylinder gauge. Measure the cylinder at point a,
approx. 20 mm below the crest of the liner, and
at points b and c at equal pitch (a–b = b–c)
Obtain distortion (roundness and cylindricity of
each cylinder) from the measured values as
follows :
– Roundness:
Difference between max. and min. bore values
on the same cross section of each liner.
– Cylindricity:
Difference between max. and min. bore values
in the same direction of each liner.
Honing (honing and boring) is requires when
the measured value exceeds the limit.
* For oversized piston and piston ring, refer to
this page 15–07.
(mm)
4TNE88
Standard Wear limit
Cylinder bore 88.000 ~ 88.030 88.20
Cylinder bore measuring positions
Cylinder roundness 0.00 ~ 0.01 0.03
Cylindricity 0.00 ~ 0.01 0.03
E N G I N E
HONING
• Ptactice of honing
Honing or boring the cylinder if unevenly worn,
flawed, or otherwise damaged. Slight uneven
worn, flaws, etc. may well be only honing with
a Flex-Hone. However, significant uneven wear
should be first bored and then honed. It is
important to take into carefyl consideration as
to whether the cylinder can attain perfect
roundness after honing, boring, or both,
considering maximum wear. In addition,
15 carefully study as to whether prepared

oversized pistons and piston rings are
applicable. (For the oversized piston and piston
07 ring, refer to this page 7–4, 8.)
10
• Procedure for using the Flex–Hone
It is common practice to use thd Flex–Hone for honing. The procedure for using it appears in
the following table. Any material must allow for approx. 1/1000mm when honed with the Flex-
Hone.
Necessary items
Flex-Hone, power drill, and honing fiuid
Flex-Hone Applicable bore

Model
Yanmar code No. (mm)
3/4TNE88 129400-92430 83~95
handing procedure
Apply the honing fluid to the Flex-Hone.

Insert the Flex-Hone into the cylinder while
turning it, move it up and down for about 30
sec for a cross hatch angle of 30 – 40°. Extract
the Flex-Hone while turning it.
* Use the Flex-Hone at a speed of 300 -
1200rpm. Use of the Flex-Hone at a higher
speed may be hazardous.
* Never insert into or extract from the cylinder
the Flex-Hone, while the power drill left
stopped.
E N G I N E
OVERHAUL OF CYLINDER (REFERENCE)
15
07
11
VALVE ROCKER ARM
MEASURING PROCEDURE THE OUTSIDE DIAMETER OF ROCKER ARM SHAFT

AND INSIDE DIAMETER OF ROCKER ARM
oil clearance is the difference between the rocker arm inside diameter measured with a cylinder
gauge and the rocker arm shaft outside diameter measured with a micrometer. When the oil
clearance is near the limit, replace the rocker arm shaft and rocker arm with new ones.
(mm)
3/4TNE88
Standard Wear limit
rocker arm shaft outside diameter 15.966 ~ 15.984 15.95

Intake/exhaust
rocker arm bushing inside diameter 16.000 ~ 16.020 16.09
rocker arm
Oil clearance 0.016 ~ 0.054 0.14
E N G I N E
Measuring the rocker arm shaft outside Measuring the rocker arm shaft inside
diameter diameter
15 CHECKING PUSH ROD BEND, MEASURING TAPPET OUTSIED DIAMETER AND

07 CHECKING CONTACT SURFACE
12
Put the push rod on the stool, and measure the gap between the push rod and stool to make
sure the push rod is in close contact with the stool. Also, measure the outside diameter of the
tappet with a micrometer.
(mm)
4TNE88
Wear
Standard
limit
Push rod bending 0.03 or less –
Tappetstem outside 11.975
11.93
diameter ~ 11.990
Tappet guide hole 12.000
Tappet 12.05
inside diameter ~ 12.018
0.010
Oil clearance 0.12
~ 0.043
Measuring the push rod bend
E N G I N E
OTHER CHECKS
• Valve rocker arm shaft spring

Check to see if the rocker arm shaft spring is
free from corrosion and wear. If not, replace it
with a new one.
• Wear of intake / exhaust valve rocker arm and
valve cap
Check the intake / exhaust valve rocker arm for
their contact surfaces with valve cap. If any of
them is abnormally worn or partially flaked,
replace it.
• Check the portion where the valve clearance
adjusting screw is in contact with the push rod.
if the portion is worn and flaked, replace the
15
pushrod of adjusting screw. 07
13
Measuring the tappet outside diameter Checking the tappet contact surface
E N G I N E
PISTON AND PISTON RING
CHECKING THE PISTON
• Remove carbon deposits from the head and

combustion surface of the piston so as not to
impair the piston, Check to see if there is any
crack or damage.
• Check the circumference and ring groove of the
piston, and replace if worn or damaged.
15
07
MEASURING THE PISTON OUTSIDE
14
DIAMETER
To measure the piston outside diameter,

measure the long diameter of the oval hole in
vertical direction to the pin hole and at a position
22-25mm from the lower end of the piston.
Measuring the piston outside diameter
4TNE88
Standard Wear limitt
Piston outside diameter 87.945 ~ 87.975 87.90

Minimum clearance between piston and
0.040 ~ 0.070 _
cylinder
SHAPES OF PISTON RINGS
Model 4TNE88
Application CH, VH, w/turbocharged
Top ring
E N G I N E
MEASURING THE RING GROOVE WIDTH, RING WIDTH, AND END XLEARANCE
To measure the piston ring groove width, first

measure the width of the piston ring. Then,
insert the piston ring into the ring groove that
gas been carefully cleaned. Insert a thickness
gauge in between the piston ring and groove to
measure the gap between them. Obtain the ring
groove width by adding ring width to the
measured side clearance.
To measure the end clearance, push the piston

15
ring into the sleeve using the piston haed, insert 07
a thickness gauge in end clearance to measure. 15
If the sleeve is wotn, measure the end clearance
after pushing the piston ring to the portion of
the sleeve which is less worn (approx. 30mm
from the lower end of the sleeve).
Measuring the side clearance
Measuring the end clearance of piston

ring
E N G I N E
4TNE88
Standard Wear limit

Ring groove 2.060 ~ 2.075 –
width
Ring width 1.970 ~ 1.990 –
Top ring
Min. side 1.970 ~ 1.990 –
clearance
End clearance 0.200 ~ 0.400 1.5
Ring groove 2.025 ~ 2.040 –
width
15 2nd ring
Ring width
Min. side
1.970 ~ 1.990
0.035 ~ 0.070
–
–
clearance
07 End clearance 0.200 ~ 0.400 1.5
16
Ring groove 4.015 ~ 4.030 –
width
Ring width 3.970 ~ 3.990 –
Oil ring
Min. side 0.025 ~ 0.060 –
clearance
End clearance 0.200 ~ 0.400 1.5
REASSEMBLY OF PISTON RING
• Using the piston ring replacer, insert the piston

ring into the ring groove, with the
manufacturer’s mark near the joint of the piston
ring facing up to the combustion chamber side.
After fitting the piston ring, make sure that the
piston ring moves freely.
• Stagger the piston ring joints at 120° intervals,

making sure that they are not aligned along the
piston. Apply lube oil to the circumference of
the piston.
E N G I N E
MEASURING THE OUTSIRD DIAMETER OF THE PISTON PIN AND THE PIN HOLE
DIAMETER
Measure outside diameter of the piston pin and

pin hole diameter. Replace the piston pin if the
wear limit is exceeded.
Apply lubricating oil to the piston pin before
inserting it into the piston.
(mm)
4TNE88
Standard Wear limit
Piston
Piston pin
outsied diameter
25.987 ~ 26.000 25.90 15
and Piston pin
piston hole dia.
26.000 ~ 26.009 26.02 07
pin Oil clearance 0.000 ~ 0.022 0.12 17
Measuring point of the piston pin O.D.
Measuring the piston pin outside diameter Insertion of piston pin
[REFERENCE] TOP CLEARANCE
(mm)
4TNE88
Standard Wear limit
Top clearance 0.660 ~ 0.780 –
LIST OF THE OVERSIZED PISTON AND PISTON RING
(0.250S : Oversized by 0.25mm)

Size Piston assy code
Model Piston ring assy code
classification (including Piston ring assy)
4TNE88 CL 0.250S 129001 – 22900 129001 – 22950

VM
E N G I N E
CONNECTING ROD
VISUAL INSPECTION
Inspect the portion near the boundary of the chamfered portion and I-beam section of the big
and small ends of the connecting rod as well as the portion near the oil hole of the bushing
at the small end for cracks, deformation, and discoloration.
MEASURING THE TWIST AND PARALLELISM
Measuring the twist and parallelism by use of the connecting rod aligner.
15 (mm)
All models
07
Standard Wear limit
18
Twist and parallelism 0.03 or less per 100mm 0.08
Measuring the twist and parallelism Measuring the twist with connecting rod
aligner
MEASURING THE CRANKPIN AND BUSHING CLEARANCE
To Measure the oil clearance of the crankpin

and bushing, Measure the inside diameter of the
crankpin metal and outside diameter of the
crankpin, and obtain the difference between
them.
If the Measured oil clearance cxceeds or near
the wear limit, replace the crankpin metal. If the
crankpin is excessively or unevenly worn, grind
the crankpin, and use an oversized crankpin
metal.
* To measure the inside diameter of the crankpin
metal, reassemble the crankpin metal to the Measuring the inside diameter of the
crankpin metal
connecting rod and tighten the rod bolt to the
specified torque, making sure each metal is fitted
on the correct position.
E N G I N E
(kgf·m)
4TNE88
Specified torque
Rod bolt tightening
torque
4.5 ~ 5.5
(Apply lube oil
to the rod bolt)
(mm)
4TNE88
Standard Wear limit
Crankpin side
Crankpin bushing inside dia.
Crankpin metal thickness
51.000 ~ 51.010
1.492 ~ 1.500
–
– 15
Crankpin outside diameter 47.952 ~ 47.962 47.91
Oil clearance 0.038 ~ 0.074 0.16
07
19
MEASURING THE OIL CLEARANCE

BETWEEN THE PISTON PIN BUSHING
AND PISTON PIN
To measured of oil clearance between the piston

pin bushing and piston pin, measure the inside
diameter of the piston pin bushing and outside
diameter of the piston pin, and obtain the
difference between them.
Measuring the inside diameter of the

piston pin bushing
(mm)
4TNE88
Standard Wear limit
piston pin bushing inside diameter 26.025 ~ 26.038 26.10
piston pin
piston pin bushing outside diameter 25.987 ~ 26.000 25.90
side
Oil clearance 0.025 ~ 0.051 0.2
E N G I N E
CHECKING THE CRANKPIN METAL FOR

CONTACT
Apply a blue ink or a minium to the crankpin

metal upper surface. Attach the crankpin metal
to the connecting rod, and tighten the rod bolt
to the crankshaft to the specified torque (Refter
to page 15–07–20) to check the metal for
contact. If the surface occupies 75% or more of
the total surface, the crankpin metal is
acceptable in terms of contact.
15 ASSEMBLING THE PISTON AND CONNECTING ROD

07 Assemble the piston with the connecting rod, with the mark at the big end of the connecting
20
rod facing the fuel injection pump. Reassemble the piston so that the recess of the combustion
chamber is on the side of the fuel injection pump as seem from the top.
Direct injection system piston Indirect injection system piston
SIDE GAP OF THE CONNECTING ROD
After attaching the connecting rod to the

crankshaft, tighten the rod bolt to the specified
torque(see this page 15–03). Measure the side
gap by inserting a thickness gauge into the side
gap. If thd standard is exceeded, replace the
arankpin metal or connecting rod.
(mm)
All models
Side gap 0.2 ~ 0.4
Measuring the connection rod side gap
E N G I N E
OVERSIZED CRANKPIN METAL
(0.25mm, Oversized)
Crankpin metal
Metal thickness
Part code No.
(mm)
4TNE88 129150–23350 1.265
CAMSHAFT
CAMSHAFT SIDE GAP

15
Before extracting the camshaft, bring a dial
07
21
gauge into contact with the camshaft gear and
measure the side gap around the camshaft. If
the measured value exceeds the limit, replace
the thrust metal with a new one.
(mm)
All models
Side gap 0.05 ~ 0.25
CHECKING THE CAMSHAFT FOR APPEARANCE
Check the camshaft for the contact surface of the tappet to the cam, seizure and wear of the
bearing, and damage of the cam gear.
E N G I N E
MEASURING THE BEND OF THE CAMSHAFT
Support the camshaft with V blocks. Using a dial

gauge, measure the runout of the journal at the
center of the camshaft, while rotating the
camshaft.
Take 50% of the measure runout as bend.
(mm)
All models
Standard Wear limit
15 camshaft bend 0.02 or less 0.05

Measuring the camshaft bend
07
22
MEASURING THE INTAKE / EXHAUST CAM HEIGHT
Measuring the cam height
4TNE88
Standard Wear limit
Intake cam 38.635 ~ 38.765 38.40
Cam height
Exhaust cam 38.635 ~ 38.765 38.40
E N G I N E
MEASURING THE OUTSIDE DIAMETER

OF THE CAMSHAFT BEARING
Measuring the outside diameter of the camshaft

with a micrometer. Calculate the oil clearance
from measured camshaft outside diameter and
the camshaft bushing inside diameter measured
with a cylinder gauge after inserting the
camshaft bushing into the cylinder block.
15
(mm)
07
4TNE88 23
Standard Wear limit
Camshaft journal outside diameter 44.925 ~ 44.950 44.85
Gear side
Oil clearance 0.040 ~ 0.130 –
Intermediate
Flywheel side
EXTRACTING THE CAMSHAFT BUSHING
Extract the bushing with camshaft bushing tool(refer to 15–05)

E N G I N E
CRANKSHAFT
SIDE GAP AROUND THE CRANKSHAFT
Before extracting the crankshaft and when

reassembling it, bring a dial gauge into contact
to the end of the crankshaft. Force the
crankshaft to measure the thrust gap.
Alternatively, insert a thickness gauge ditectly
into a thrust gap between the thrust metal in the
standard part and crankshaft to measure the
side gap.
15 If the limit is exceeded, replace the thrust metal
with a new one.
07
(mm)
24
All models
Thrust gap 0.090 ~ 0.271
COLOR CHECK OF CRANKSHAFT
Clean the crankshaft and check it using a color

check kit or a magnaflux inspector. Replace the
crankshaft if the cracked or badly damaged. If
the crankshaft is slightly damaged, correct it by
re-grinding.
Color check inspection
CHECK THE METAL
check the metal for flaking, melting, seizure, and the state of the contact face. Replace the
metal if found defective.
E N G I N E
BEND OF THE CRANKSHAFT
Support the crankshaft with V-blocks at both

ends of the journals;measure the runout at the
center journal with a dial gauge while rotating
the crankshaft to check the extent of crankshaft
bend.
(mm)
All models
Standard
Bend 0.02 or less
15
07
25
Measuring the crankshaft bend
MEASUREMENT OF CRANKPIN AND JOURNAL
Measure the outside diameter, roundness, taper angle of the crankpin and journal. If uneven
wear or roundness exceeds the wear limit but Measured outside diameter is within the limit, use
the crankpin and journal after correcting them by regrinding. Replace them with new ones, if
any of the limit is exceeded.
An oversized crankpin metal by 0.25mm is available.(See this page 15–07.)
Measuring position of the crankpin and crankjournal

E N G I N E
(mm)
4TNE88
Standard Wear limit
Crankpin outsied diameter 47.952 ~ 47.962 47.91

Crankpin
Camshaft journal outside
53.952 ~ 53.962 53.91
diameter
Bearing metal thickness 1.995 ~ 2.010 –
Crank journal
Crank journal and bushing
0.038 ~ 0.068 0.15
oil clearance
15 PRECAUTIONS IN MOUNTING THE METAL CAP
07 • The lower metal(cap side) has no oil groove.

26 • The upper metal(cylinedr block side) gas an oil groove.
• Check the cylinedr block alignment No.
• Place the relief mark “FW” of the cap on the flywheel side.
• Place the main bearing metal on the flywheel side.
UNDERSIZED MAIN METAL BY 0.25MM AND THE OVERSIZED THRUST METAL BY

0.25MM
Main metal Thrust metal

Metal thickness(mm) Metal thickness(mm)
Part code Part code
Standard Standard
3/4TNE88 129150 – 02870 2.125 129150 – 02940 2.125
E N G I N E
GEARS
CHECKING GEARS
Inspect the gears and replace if the teeth are damaged, worn or chipped.
MEASURING THE BACKLASH
Apply a dial gauge onto the pitch circle of the gear and measure the backlash.
(mm)
Crankshaft gear,
4TNE88
15
Backlash
Camshaft gear, Idle gear and 0.07 ~ 0.15 07
Fuel injection pump drive gear 27
L.O pump gear 0.11 ~ 0.19
CHECKING AND MEASURING THE IDLING GEAR SHAFT AND IDLING GEAR
• Measure thd bushing inside diameter and the idle gear shaft outside diameter, and replace the
bushing or idling gear shaft if the oil clearance exceeds the wear limit.
(mm)
4TNE88
Standard Wear limit
Shaft outside 45.950 ~ 45.975 45.93
Idle gear Bushing inside dia. 46.000 ~ 46.025 46.08
Oil clearance 0.025 ~ 0.075 0.15
• Make sure that the oil hole of the idle gear shaft and bushing is a through hole.
Indirect injection system Direct injection system

E N G I N E
• Geat train
After installing each gear, make sure that alignings (A),(B) and (C) of the idle gear are aligned
with those of the fuel injection pump gear, cam gear and crank gear.
15
07
28
(View the gear case)

E N G I N E
TROCHOID PUMP
CLEARANCE BETWEEN OUTER ROTOR

AND PUMP BODY
Insert a thickness gauge between the outer rotor

and pump body to measure the clearance.
(mm)
All models
Standard Wear limit
Clearance between outer
rotor and pump body
0.10 ~ 0.16 0.25 15
Measuring the clearance between 07
outer-rotor and pump body 29
CLEARANCE BETWEEN OUTER ROTOR

AND INNER ROTOR
Insert a thickness gauge between the top of the

inner rotor tooth and the top of the outer rotor
tooth to measure the clearance.
(mm)
All models
Standard Wear limit
– 0.15
rotor and inner rotor
Measuring the clearance between
outer rotor and inner rotor
E N G I N E
SIDE CLEARANCE BETWEEN PUMP BODY AND INNER ROTOR, OUTER ROTOR
• Place a straight-edge against the end of the

pump and insert a thickness gauge between
straight-edge and the rotors to measure the
side clearance.
(mm)
4TNE88
Standard Wear limit
pump body and
inner-, outer-rotor 0.03 ~ 0.09 0.15
15 side clearance
Measuring the clearance between
pump body and inner–, outer–rotor
the
07
30
CLEARANCE BETWEEN ROTOR AHSFT AND SIDE COVER HOLE
Measure the rotor shaft outside diameter and the side cover hole diameter, and calculate the
difference between the hole diameter and the outside diameter.
(mm)
All models
Standard Wear limit
– 0.15
rotor and inner rotor
OTHERS
• Check for looseness of drive gear / rotor shaft fitting, and replace the entire assembly if loose
or wobbly.
• Push the oil pressure regulating valve piston from the oil. hole side, and replace the entire
assembly if the piston does not return due to spring breakage, etc.
• Make sure that the rotor shaft rotates smoothly and easily when the drive gear is rotated.
E N G I N E
DISASSEMBLY AND REASSEMBLY
Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each
application. Therefore, description in this Chapter is started with the steps to be taken just after
the peripheral parts have been removed.
Perform the procedure, with reference to the attached drawings, “Engine component Exploded
View.”
DISASSEMBLY
∗ For the number following the part name, refer to attached drawing 1 and 2, “Exploded Views
of Engine Components”
15
08
Step Removal Parts Remarks
1
1. Thoroughly remove sand, dust, dirt
and soil from the surface of the
1 engine.
2. Drain cooling water and lubricating
oil from the engine.
1. Remove turbocharger(74) and

exhaust manifold(1).
2
2. Remove intake manifold(2) and
surge tank(75).
1. Close the fuel cock valve of the 1. If nozzle seat(7) is left on the cylinder head,
fuel tank. remove the cylinder head before extracting
2. Remove high-pressure fuel pipe(3). nozzle seat(7).
3. Remove fuel return pipe(4). 2. To prevent dust from entering fuel injection
4. Loosen the tightening nut on fuel nozzle(6), fuel injection pump(8) and high-
3 injection nozzle retainer(5) and pressure fuel pipe(3), seal their respective
extract the retainer and fuel threads with a tape or the like.
injection nozzle(6). 3. Whenever extracting fuel injection nozzle(6),
∗ Fuel injection nozzle for lndirect replace nozzle protector(9) with a new one.
injection system is screwed type.
4 1. Remove bonnet assembly(10).
1. Remove valve rocker arm shaft 1. Attach a tag to push rod(12) for each cylinder
assembly(11). No. to put the push rod in order.
2. Remove push rod(12). 2. Remove valve cap(13) from the intake/exhaust
valve head.
5 3. Note that tappet(59) of the indirect injection
system can be removed at the same time
when push rod(12) is extracted.
4. Attach a tag to tappet(59) for each cylinder No.
to put the tappet in order.
E N G I N E
1. Remove fan mounting bolt(14), 1. Never turn down alternator(18) vigorously

and then remove fan(15). toward the cylinder block. Otherwise, your
2. Loosen adjusting bolt(16) for the finger may be nipped and alternator(18)
V-belt adjuster, and then remove broken.
6
V-belt(17).
3. Remove alternator(18).
4. Remove the spacer for cooling
fan(19) and V-pulley(20).
1. Remove lubricating oil filter
15 7
assembly(21).
2. Extract dipstick(22) from the oil
dipstick hole.
08
2 1. Disconnect fuel return pipes(23) to
8 (26).
2. Remove fuel filter(27).
1. Disconnect cooling water pipe(28)

from the cooling water pump.
9
2. Remove thermostat assembly(29).
3. Remove cooling water pump(30).
1. Remove cylinder head tightening 1. Lay a cardboard or the like on the floor and
bolt(31). place cylinder head assembly(32) on it so as
2. Remove cylinder head assembly not to damage the combustion surface.
(32). 2. Order of loosening the cylinder head tightening
3. Remove cylinder head gasket(33). bolts.
10
E N G I N E
3. To remove the intake/exhaust valves from

cylinder head assembly(32), take the following
steps.
(1) Using a valve spring compressor (see
page 15–05), compress valve spring(34)
and remove valve cotter(35).
15
08
(2) Remove valve retainer(36) and valve
3
spring(34).
(3) Remove intake valve(37) and exhaust
valve(38).
1. Remove crankshaft V-pulley 1. Extract crankshaft V-pulley(40) by hitting the

clamping bolt(39). bolt of the puller using a plastic hammer or
11
2. Using a puller, extract crankshaft the like.
V-pulley(40).
1. Remove oil pan mounting bolt(42) 1. Never fail to remove stiffner bolt(44) at the
under gear case(41). center of the gear case.
12 2. Remove gear case mounting bolt 2. When removing the gear case, carefully protect
(43). oil seal(45) from damage.
3. Remove gear case(41).
1. Remove the nut from fuel injection 1. Before removing fuel injection pump(8), make
pump drive gear(46). Extract fuel sure of the position of the arrow of the pump
injection pump drive gear(46) using body for adjusting fuel injection timing as well
13
a puller. as the positio of the scribed line of the gear
case flange.(Applies only to direct injection
system.)
14 1. Remove lubricating oil pump(47).
1. Remove starting motor(55) from

15
flywheel housing(54).
1. Remove flywheel mounting bolt (56). 1. Carefully protect the ring gear from damage.
16
2. Remove flywheel(57).
1. Remove flywheel housing(54). 1. Carefully protect the oil seal from damage.
2. Remove oil seal case(58) with a
17 screwdriver or the like by utilizing
grooves on both sides of oil seal
case(58).
E N G I N E
1. Remove oil pan(60) and spacer 1. Put the cylinder block with the attaching
(61) surface of the cylinder head facing down.
2. Carefully protect the combustion surface of the
cylinder block from damage.
18
3. For indirect injection system, be careful to the
possibility of the tappet to drop off when the
cylinder block is turned upside down, because
the tappet is cylindrical in shape.
1. Remove idle gear shaft(48), and 1. Turn the cylinder block aside and carefully
15 19
then remove idle gear(49). prevent tappet(59) from jamming on the cam.
2. Remove mounting bolt(52) of thrust 2. Preheat camshaft gear(50) and camshaft
bearing(51) through the hole of the assembly(53) to 180°C~200°C which are shrink
08 camshaft gear(50). Remove fitted, before removing them.
4 camshaft assembly(53).
20 1. Remove gear case flange(62).
21 1. Remove lubricating oil strainer(63).
1. Remove crankpin side cap(64) of 1. Before extracting piston(66), remove carbon

the connecting rod. deposits from the upper wall of the cylinder
• While turning crankshaft(65), using fine sandpaper, while taking care not to
place piston(66) in the bottom damage the inner surface of the cylinder.
22 dead center (BDC). 2. Make sure that cap No. of connecting rod(67)
agrees with cylinder No.
3. Take care not to let crankpin metal(68) fall
when removing connecting rod crankpin side
cap(64).
1. Remove main bearing cap bolt(69). 1. Before extracting crenkshaft(65), measure the
While shaking main bearing cap side gap around it.
(70), remove main bearing cap(70)
together with lower main bearing
metal(71).
2. Extract crankshaft(65), taking care
not to damage it.
3. Remove upper main bearing metal
23
(72).
E N G I N E
Apply a dial gauge to the end of crankshaft(65).

Force the crankshaft on both sides in the axial
direction to measure the thrust gap. Alternatively,
insert a thickness gauge directly between the
base thrust metal and the thrust surface of the
crankshaft to measure the gap.
If the limit size is exceeded, replace the thrust
metal with a new one.
(mm)
All models
Thrust gap 0.090~0.271
2. Notice on the removal of thrust metal(73).

15
(1) When removing thrust metal(73), ascertain 08
the position and direction where thrust 5
metal is installed in relation to the cap.
(2) Make sure that the thrust metal groove is
outward in relation to the cap.
1. Remove piston(66) and connecting 1. To selectively remove a desired piston and

rod(67) assembly. connecting rod assembly without extracting
crankshaft(65), take the steps itemized below:
(1) Remove carbon deposits from the upper
wall of the cylinder using fine sandpaper,
taking care not to damage the inner
surface of the cylinder.
24
(2) While turning the crankshaft, with the
crankpin side cap(64) removed, raise the
piston up to the top dead center (TDC).
(3) Extract the piston/connecting rod assembly
while tapping the connecting rod(67) at the
large end with the handle of a plastic
hammer or the like.
25 1. Remove tappet(59).
E N G I N E
PRECAUTIONS BEFORE AND DURING REASSEMBLY
To reassemble engine components, reverse the procedure of diassembly. However, follow the
precautions below particularly before and during reassembly.
CLEANING THE COMPONENT
Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure
that they are free from chips, dust, sand, and other foreign matter.
PARTS TO BE REPLACED DURING REASSEMBLY

15 Be sure to replace the following parts with new ones during assembly.
08 (1) Valve stem seal
(2) Head gasket packing
6
(3) Nozzle protector of the fuel injection valve
(4) Various copper packings, O-rings and gasket packings.
MEASURING THE SIDE GAP AROUND CRANKSHAFT
Apply a dial gauge to the end of the crankshaft.

Force the crankshaft on both sides in the axial
direction to measure the thrust gap.
Alternatively, insert a thinkness gauge directly
between the base thrust metal and the thrust
surface of the crankshaft to measure the gap. If
the limit size is exceeded, replace the thrust
metal with a new one.
(mm)
All models
Threst gap 0.090~0.271 Measurement of side gap around
crankshaft
E N G I N E
GEAR TRAIN
After having installed each gaer, make sure that marks A, B and C of the idle gaer align with
marks of the fuel injection pump drive gear, camshaft gear and crankshaft gear as shown below.
15
08
7
Viewed from gear case
WHERE TO USE LIQUID PACKINGS
1. Between the cylinder block and gear case flange

2. Between the gear case flange and gaer case cover
3. Between the cylinder block and oil seal case (indirect injection system only)
4. Oil pan installation surface
∗ Use Three Bond No. 005(Yanmar part code : 97777-001212( as the liquid packing.
∗ Apply the liquid packing so as not to form any break on the midway. Otherwise, oil leakage,
etc., may result.
COATING THE LUBRICATING OIL ON INTAKE/EXHAUST VALVE STEM
Apply lubricating oil down to the lower surface

(hatched portion in the figure) of the valve guide
before reassembling the valve stem.
REASSEMBLY OF THE PISTON RING
1. Insert the piston ring into the ring groove,

where the side with the manufacturer’s mark
on the matching ends facing up (to the
combustion chamber side), using a piston ring
replacer. After fitting the piston ring, make
sure it moves easily and smoothly.
E N G I N E
2. Assemble the piston rings to the cylinder,

staggering the piston rings joints at 120°
intervals, making sure that they are not
aligned along the piston. Apply lube oil to the
circumference of the piston.
15
08
8
COATING THE LUBRICATING OIL TO PUSHROD ADJUSTING SCREW CONTACT
Apply lubricating oil to the hatched portion of the

push rod as shown in the figure, before
reassembly.
E N G I N E
ASSEMBLY DIRECTION OF PISTON AND CONNECTING ROD
Piston Connecting rod
4TNE88
15
ORDER OF TIGHTENING CYLINDER HEADS AND TIGHTENING TORQUE 08
9
Tighten cylinder heads in numerical order shown below to the specified torque.
(kgf·m)
4TNE88
Tightening torque 8.7~9.3
AFTER HAVING REASSEMBLED THE CYLINDER HEADS, CARRY OUT

CONFIRMATION RUNNING TO SEE IF THEY ARE FREE FROM LEAKAGE OF
WATER AND OIL.
E N G I N E
SERVICE DATE
SERVICE DATA
CYLINDER HEAD
Model 4TNE88
Item Standard Wear limit
Cylinder head combustion surface distortion 0.05 or less 0.15
Intake 120° –
Valve seat angle
Exhaust 90° – 15
Intake 1.07~1.24 1.74
Valve seat width 09
Exhaust 1.24~1.45 1.94 1
Valve stem outside dia. 7.955~8.025 7.9
Intake valve Valve guide inside dia. 8.010~7.975 8.1
Oil clearance 0.035~0.070 0.2
Valve stem outside dia. 7.955~8.030 7.9
Exhaust valve Valve guide inside dia. 8.015~7.970 8.1
Valve guide projection 15 –
Intake valve 0.306~0.506

Valve sinking depth 1.0
Exhaust valve 0.3~0.5
Intake valve 1.244~1.444

Thickness of valve head 0.5
Exhaust valve 1.35~1.55
Open b.TDC 10°~20° –

Intake valve timing
Close a. BDC 40°~50° –
Open b. BDC 51°~61° –

Exhaust valve timing
Close a. TDC 13°~23° –
Free length 42 –
Inclination – 1.1
Valve spring
Tension(kg) 2.36(Variable pitch)/
–
(when compressed to 1mm length) 3.101
Intake & exhaust valve clearance 0.15~0.25 –

E N G I N E
SERVICE DATE
CYLINDER BLOCK
(Unit : mm)
Model 4 TNE88
Cylinder bore 88.000~88.030
L mark 88.020~88.030
88.20
Cylinder bore M mark 88.010~88.020
S mark 88.000~88.010
Cylinder roundness 0.00~0.01 0.03
Cylindricity 0.00~0.01 0.03
15
09 VALVE ROCKER ARM
(Unit : mm)
2
Model
4TNE88

Rocker arm shaft outside dia. 15.966~15.984 15.95
Intake & Exhaust
Rocker arm bushing inside dia. 16.000~16.020 16.09
rocker arm
Pushrod bending 0.03 or less –
Tappet stem outside dia. 11.975~11.990 11.93
Tappet Tappet guide hole inside dia. 12.000~12.018 12.05
PISTON
(Unit : mm)
Model 4TNE88
Piston outside dia. 87.945~87.975
L mark 87.965~87.975
ML mark 87.960~87.965 87.90
Piston outside dia.
MS mark 87.955~87.960
S mark 87.945~87.955
Min. clearance between piston and cylinder 0.040~0.070 –
Top clearance 0.660~0.780 –
Piston pin outside dia. 25.987~26.000 25.90
Piston and piston pin Piston pin hole dia. 26.000~26.009 26.02
E N G I N E
SERVICE DATE
PISTON RING
(Unit : mm)
Model 4TNE88
Ring groove width 2.060~2.075 –
Ring width 1.970~1.990 –
Top ring
Min. side clearance 0.070~0.105 –
End clearance 0.200~0.400 1.5
Ring groove width 2.025~2.040 –
2nd ring
Ring width
Min. side clearance
1.970~1.990
0.035~0.070
–
–
15
End clearance 0.200~0.400 1.5 09
Ring groove width 4.015~4.030 – 3
Ring width 3.970~3.990 –

Oil ring
Min. side clearance 0.025~0.060 –
End clearance 0.200~0.400 1.5
CONNECTING ROD
(Unit : mm)
Model 4TNE88
Crankpin bushing inside dia. 51.000~51.010 –
Crankpin metal thickness 1.492~1.500 –
Crankpin side
Crankpin outside dia. 47.952~47.962 47.91
Piston pin bushing inside dia. 26.025~26.038 26.10
Piston pin side Piston pin outside dia. 25.987~26.000 25.90
Less than 0.03

Twist and parallelism 0.08
per 100mm
E N G I N E
SERVICE DATE
CAMSHAFT
(Unit : mm)
Model 4TNE88
Camshaft journal outside dia. 44.925~44.950 44.85
Gear side
Oil clearance 0.040~0.130 –
Intermediate
Oil clearance 0.065~0.115 –
Flywheel side
15 Oil clearance 0.050~0.100 –
09
4 CRANKSHAFT
(Unit : mm)
Model 4TNE88
Crankshaft journal outside dia. 53.952~53.962 53.91
Bearing metal thickness 1.995~2.000 –
Crank journal
Crank journal and bushing
0.038~0.068 0.15
oil clearance
Bend 0.02 or less –
SIDE GAP AND BACKLASH

(Unit : mm)
Model All models
Item Standard
Crankshaft 0.090~0.271
Camshaft 0.05~0.25
Side gap
Connecting rod 0.2~0.4
Idle gear 0.1~0.3
(Unit : mm)
Model
4TNE88
Item
Crankshaft gear, Camshaft gear, Idle gear

0.07~0.15
Backlash and Fuel injection pump drive gear
L.O. pump gear 0.11~0.19

E N G I N E
SERVICE DATE
OTHERS
(Unit : mm)
Model
4TNE88
Item
Lubricating oil pump High speed operation 25.0(at 3000rpm)

l /min
discharge volume Low speed operation 8.0(at 800rpm)
Pressure control valve opening pressure kgf/cm2 3.0~4.0
L.O.pressure switch operating pressure kgf/cm2 0.4~0.6
Cooling water pump discharge volume l /min 70(at 3220~3280rpm)
Thermostat valve
Opening temperature °C 69.5~72.5
Min. 8.0
15
opening temperature Lift height mm
(at 85°C and above) 09
ON 107~113 5
Thermoswitch operating
°C
temperature OFF 100 and above
E N G I N E
TIGHTENING TORQUE
TIGHTENING TORQUE
MAIN BOLT/NUT
(Unit : kgf·m)
Model
No. Item 4TNE88
Torque
Lubricating oil applied 8.7~9.3
1 Cylinder head bolt
(Thread dia. × pitch) (M10 × 1.25)
2 Connecting rod bolt
3 Flywheel clamping bolt
4 Metal cap clamping bolt
Lubricating oil applied
(Thread dia. × pitch)
9.8~10.2
(M12 × 1.5)
15
5 Crankshaft V-pulley clamping bolt
Lubricating oil applied
11.5~12.5
(M14 × 1.5)
10
Lubricating oil not applied 0.7~0.9 1
6 Fuel injection nozzle nut
Lubricating oil not applied 6.0~7.0
7 Timer clamping nut
Lubricating oil not applied
8 Glow plug –
Lubricating oil not applied
9 Stub shaft bolt –
10 Governor weight support nut
11 High pressure pipe sleeve clamping nut
(Thread dia. × pitch (M12 × 1.5)
STANDARD BOLT AND NUT

∗ : Lubricating oil not applied
(Unit : kgf·m)
Item Thread dia.×pitch Tightening torque Remarks
M6 × 1 1.0~1.2 1) When bolting the aluminum parts,
Hexagon tighten the bolts with 80% of the
M8 × 1.25 2.3~2.9 tightening torque specified in the Table.
headed bolt
M10 × 1.5 4.5~5.5 2) 4T bolt and lock nut should be
(7T) and nut tightened with 60% of the torque shown
M12 × 1.75 8.0~10.0 in the table.
1/8 1.0
1/4 2.0
PT plug
3/8 3.0
1/2 6.0
M8 1.3~1.7
M12 2.5~3.5
Pipe joint bolt
M14 4.0~5.0
M16 5.0~5.5
E N G I N E
FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM
FUEL INJECTION PUMP FOR DIRECT INJECTION

SYSTEM
EXPLODED VIEW(YPES TYPE)
15
11
1
E N G I N E
SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY
No. Name of tool Shape and size Application
1 Side clearance Measurement of camshaft

measuring gauge side clearance
Yanmar code No.

158090-51050
15 2 Plunger insertion tool

11 Yanmar code No.
2 158090-51100
3 Tappet holder tool
Yanmar code No.

158090-51200
4 Rack lock screw
Yanmar code No.

158090-51510
5 Governor weight
extractor tool
Yanmar
code No.
Governor 158090
weight for 3 pcs. -51400
Governor 158090
weight for 4 pcs. -51450
E N G I N E
DISASSEMBLY
• Remove the bottom cover from the fuel

injection pump to drain lubricating oil from the
fuel injection pump.
• Turn the fuel injection pump upside down to
drain fuel oil.
15
• Take out the governor weight assembly using 11
the governor weight extractor tool (special
3
service tool).
* For separating the governor assembly from
the fuel injection, refer to page 15–13.
• Remove the fuel feed pump.

* Do not disassemble the fuel feed pump.
• Remove the fuel injection pump side cover.

E N G I N E
• While turning the fuel injection pump camshaft,

raise the plunger guide up to the max. stroke.
Insert the tappet holders (special service tool)
between the plunger spring lower retainer and
fuel injection pump body.
15
11
4
Special service tool : tappet holder
• Extract the woodruff key from the fuel injection

pump camshaft.
• Extract the fuel injection pump camshaft
bearing horizontally by inserting a screwdriver
into the two grooves on the face where the
bearing holder of the fuel injection pump
camshaft is installed.
* 1. Carefully avoid allowing the thread of the
fuel injection pump camshaft to damage
the oil seal.
* 2. Carefully avoid allowing the adjusting
packings and oil seal between the pump
body and bearing holder to be lost.
• Turn the fuel injection pump upside down.

Move all plunger guides toward the plunger.
Then, turn aside the fuel injection pump. While
turning the fuel injection pump camshaft, find a
position where the cams of each cylinder does
not interfere with the plunger guide oupter roller
and place the camshaft in the position.
• Apply a plate against the governor end side of
the camshaft. While tapping the plate, extract
a set of the camshaft and drive bearing.
E N G I N E
• Remove the plunger guide stopper.
• By using the handle of a hammer, etc., push

up the plunger guide from the bottom of the
pump and take out the tappet holders (special
15
service tool). 11
* Use particular care to remove the tappet 5
holder. Carefully prevent the plunger guide,
plunger, etc., from jumping out. This is
because the plunger spring is powerful
enough to force them out.
• Takle out the plunger guide assembly.

* Do not erect the fuel injection pump body,
wherever possible. Otherwise, the plunger
guide assembly falls off. Therefore, hold the
fuel injection pump body tilted and remove the
plunger guide assembly.
• Take out the plunger, plunger spring and

plunger spring lower reteiner from the lower
part of the fuel injection pump.
* Separate these parts for each cylinder.
E N G I N E
• Remove the stop screw from the fuel control

pinion.
15 * 1. When the stop screw of the fuel control

pinion is loosened, the fuel control pinion
is separated from the control sleeve.
11 Before loosening, therefore, make sure that
6 the match mark of the fuel control pinion
aligns with that of the control sleeve.
If the match mark is difficult to identify or
the match mark offsets, put new match
marks. This practice helps adjusting
injection volume later on.
* 2. Separate all these parts for each cylinder.
• Remove the fuel control pinion, control sleeve

and plunger spring upper retainer.
* Separate all these parts for each cylinder.
• Remove the control rack stopper. Extract the

control rack.
E N G I N E
* Carefully prevent the control rack spring and

spacer on the control rack from being missing.
• Loosen the bolt for the holder stopper. Remove

the delivery valve spring holder. 15
11
7
• Take out the delivery valve assembly.

* 1. Carefully prevent small parts such as the
delivery valve packing, delivery valve
spring and delivery valve stopper from
being missing.
* 2. Clearly separate the delivery valve
assembly for each cylinder.
E N G I N E
• Take out the plunger barrel toward the upper

part of the fuel injection pump.
* Keep the plunger barrel just picked up
together with the plunger which has been
taken out.
15 INSPECTION
Before inspection, thoroughly clean the parts, using new diesel oil. Be careful to avoid damage
11 to the sliding surface of the plunger and delivery valve, etc.
8
PLUNGER
• Thoroughly clean the plunger. If any plunger

lead is scratched or discolored, replace the
plunger assembly with a new one.
• To test the plunger, hold the plunger barrel

tilted approx. 60° and check to see if it slides
down smoothly. If so, the plunger is acceptable.
While turning the plunger, repeat the test
several times. If any plunger slides down too
quickly (slowly) or jams in the midway, correct
it or replace the whole plunger assembly.
Fall by gravity test of plunger
DELIVERY VALVE
• If the suck–back collar or seat of the delivery

valve is found scratched, dented, worn, or
otherwise damaged, replace the whole delivery
valve assembly.
Check for delivery valve

E N G I N E
• Stop up the hole in the bottom of the delivery

valve holder and keep the seat as it is. Insert
the delivery valve into the holder. While
releasing your upper finger, check to see if the
delivery valve springs back. If so, it is
acceptable. If not, replace it.
• Likewise as described in item 2, stop up the
holder in the bottom of the delivery vavle
holder and check to see if the delivery valve
falls by gravity perfectly, when the bottom
hole’s finger is released. If so, the delivery Fall by gravity test of delivery valve
valve is acceptabel. If not, replace it.
PLUNGER GUIDE, PLUNGER BARREL, ETC.

15
• Check to see if the sliding surface of the
11
plunger guide is free form excessive wear. 9
• Check to see if the seat of the plunger barrel
has uneven contact, burrs, the mark of blow–by
gas or other defects etc. If so, correct or
replace the plunger barrel. Otherwise,
lubricating oil in use will be thinned.
• If the surface of the plunger guide outer roller
indicates wear, flaking, etc., replace the outer
roller.
• If the plunger guide has the circumference and
Plunger guide assembly
roller pin hole worn or scratched, etc., replace
it with a new one.
• If the plunger guide assembly has a combination of the pin and roller that indicates chatters,
replace the plunger guide assembly.
FUEL INJECTION PUMP CAMSHAFT AND BEARING
Fuel injection pump camshaft

• Check for damage and wear of the camshaft surface, deformation of keyway and deformation
of threads on both ends. If the camshaft proves to be defective, replace it.
Bearing
• If the taper roller and outer race has flaking,
wear, or any other damage on the surface,
replace the bearing.
* When replacing the fuel injection pump
camshaft, replace the bearing at the same
time.
E N G I N E
CONTROL RACK AND FUEL CONTROL PINION
• Check the control rack for bends and the wear

and deformation of the portion where it is
engaged with the fuel control pinion.
• Check to see if the portion where the control
rack is engaged with the fuel control pinion is
free from wear and deformation.
* If the control rack is in trouble with the teeth
face and sliding part, it encounters increased
resistance, causing the engine to be out of
order (such as uneven revolutions and abrupt
15 revolution changes).
11 REASSEMBLY
10
• Put the plunger barrel into the fuel injection
pump from its top.
* Make sure that the plunger barrel stopper is
snugly fitted with the key way.
• Insert the delivery valve assembly, delivery

valve spring and delivery valve stopper from
the top of the fuel injection pump in that order.
* Replace the delivery valve packing and
O–ring with new ones before reassembling the
fuel injection pump.
E N G I N E
• Fit the control rack and tighten the control rack

stopper.
* 1. Never fail to install the control rack spring.
* 2. Make sure that the control rack moves
smoothly over the full stroke.
• Insert a rack lock screw (special service tool)
into the thread hole of the control rack stopper
and fix the control rack.
• Peep through the bottom of the fuel injection

pump and align the match mark of the control
rack with that of the fuel control pinion.
15
11
11
Matching mark on the control rack and

fuel control pinion
• While holding the fuel control pinion by one

hand so that its match mark may not be out
of position, reassemble the control sleeve and
lightly tighten the stop screw of the fuel control
pinion.
* Reassemble the control sleeve in the direction
in which the holes around the control sleeve
face the stop screw. At the same time, aligh
the match mark with that of fuel control
pinion.
Fuel control pinion/control sleeve match

mark
E N G I N E
• Mount the plunger spring upper retainer.

* 1. Mount the plunger spring upper retainer so
that its recess faces downward.
* 2. Once again, ascertain that the control rack
moves smoothly.
15 • Mount the plunger spring.

• Mount the plunger spring lower retainer on the
top of the plunger. While aligning the match
11 mark of the plunger flange with that of the
12 control sleeve, reassemble the plunger from the
bottom of the fuel injection pump using a
plunger insertion tool (special service tool).
Insertion of plunger with a special

service tool : Plunger insertion tool
Special service tool :

Plunger insertion tool
* Never reassemble the plunger in reverse. Otherwise, fuel injection volume increases
excessively to the point where fuel injection volume becomes uncontrollabel.
• Insert the plunger guide assembly into the fuel

injection pump from its bottom. Push up the
plunger guide using the handle of a hammer,
etc., and put a tappet holder (special service
tool) in between the lower spring retainer and
fuel injection pump body.
* 1. While keeping the plunger guide detent
groove facing upward, align with the mating
screw hole of the plunger guide stopper on
the fuel injection pump body.
E N G I N E
* 2. Check to see if the control rack moves

freely. If not, the plunger spring interferes
with something else. In this case, hold the
plunger spring in position using a
screwdriver.
* 3. When replacing the plunger guide
assembly with a new one, insert the
standard shim, and temporarily tighten it.
• Make sure that the plunger guide detent groove

is in position. Tighten the plunger guide
stopper.
15
11
13
• Place the bearings on both ends of the fuel

injection pump camshaft. Insert the bearings
while tapping them from driving side.
* Turn the fuel injection pump upside down.
Move the plunger guide toward the plunger
spring and drive in the fuel injection pump
camshaft.
• Fit the oil seal to the inner side of the bearing

holder. Mount the bearing holder.
* Apply lubricating oil to the fuel injection pump
camshaft and oil seal of the fuel injection
pump camshaft in advance so as not to
damage the oil seal.
E N G I N E
• Drive the woodruff key into the fuel injection

pump camshaft.
• Turn the fuel injection pump camshaft, and
extract the tappet holder (special service tool).
15 • Fix the fuel injection pump. Using a mallet, tap

the end of the fuel injection pump camshaft to
adjust the side clearance of the fuel injection
11 pump camshaft using an adjusting packing and
14 a side clearance gauge (special service tool).
(mm)
All models
Camshaft side clearance 0.02~0.05
[Adjustment Procedure]
If a clearance is found small, remove the Special service tool :
adjusting packing. Side clearance gauge
If a clearance is found large, add one or more
adjusting packing.
Thickness of adjusting packing : 0.5, 0.4, 0.3, and 0.15 mm.
• Mount the fuel injection pump side cover.
• Mount the fuel injection pump bottom cover.

E N G I N E
• Tighten the delivery valve spring holder to the

specified torque.
(kgf·m)
All models
Tightening torque 3.5~4.0
* 1. Tighten the delivery valve spring holder by

handas far as possible. If the bolt get hard
to turn part way, the packing or delivery
valve may be out of position. Remove,
correct, and start tighten again.
* 2. Never tighten the delivery valve holder excessively. Excessive tightening causes the control
rack to malfunction.
• Tighten the holder stopper to the specified

15
torque. 11
(kgf·m) 15
All models
Tightening torque 0.3
* Never tighten the delivery holder excessively.

Otherwise, it upsets, causing oil to leak
through it.
• Mount the fuel feed pump.

E N G I N E
GOVERNOR
GOVERNOR
EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM
15
12
1
E N G I N E
GOVERNOR
DISASSEMBLY
Disassembly and reassembly can be carried out similarly for lndirect injection system and direct
injection system.
• Remove the governor case.
15
12
2
* Loosen the stop nut on models with angleich
assembly.
Angleich assembly
• Remove the control lever hex. nut and pull out

the control lever from the control lever shaft.
E N G I N E
GOVERNOR
• Remove the governor case mounting bolt.

Remove the governor case from the fuel
injection pump while gently tapping the
governor case with a wooden hammer. Create
a gap between the governor case and fuel
injection pump by moving only the moving parts
of the governor lever.
• Pull out the governor link snap pin by inserting

long nosed pliers between the fuel injection
pump and governor case.
15
12
3
• Separate the governor and fuel injection pump

by sliding the governor case and fuel injection
pump apart and pulling out the snap pin of the
governor link from the control rack.
•
E N G I N E
GOVERNOR
• Remove the stop lever return spring from the

governor lever shaft. (Dl only)
15 • Use long nosed pliers to unhook the governor

spring from the tension lever and control lever
shaft.
12
4
• Remove the shaft retainer on the governor

lever shaft. (for IDI)
Remove the circlips on both ends of the
governor lever shaft. (for DI)
• Put a rod 8mm in dia. or less in one end of

the governor lever shaft and tap the governor
lever shaft until the O–ring comes out the other
side of the governor case.
E N G I N E
GOVERNOR
• After you remove the O–ring, lightly tap the

end of the shaft that you removed the O–ring
from, and extract the governor lever shaft.
15
12
5
E N G I N E
GOVERNOR
• Remove the governor link from the governor

lever.
15
12
6
* The governor assembly consists of the governor lever, tension lever and angleich, and is
normally not disassembled.
• When you need to pull out the stop lever,

remove the stop lever shaft stop pin, and lightly
tap the inside of the governor case. (Dl only)
• When you need to pull out the control lever

shaft, lightly tap the end of the shaft with a
wooden hammer, and extract the control lever.
* 1. Do not remove the FO limiter assembly
from the governor case unless necessary.
* 2. On models with torque springs, first
remove the box nut, stop nut, and then the
torque spring assembly.
E N G I N E
GOVERNOR
• Pull out the governor sleeve on the end of the

fuel injection pump camshaft by hand.
• Fix the bearing holder with a vise to hold the

fuel injection pump camshaft. Loosen the
governor support nut with abox spanner a few
15
turns. 12
* When the taper fit comes apart after you have 7
removed the nut, the governor weight may fly
out–Be careful.
• Remove the governor weight assembly from

the fuel injection pump camshaft using the
governor weight extractor (special service tool).
Governor weight extractor

E N G I N E
GOVERNOR
INSPECTION
INSPECTION OF GOVERNOR WEIGHT ASSEMBLY.
• Replace the governor weight if it does not open

and close smoothly.
15
12
8
• Replace the governor weight assembly if the contact surface with governor sleeve is extremely
worn.
• Replace if there is governor weight support and pin wear or the caulking is loose.
• Replace if the governor weight support stopper is excessively worn.
INSPECTION OF GOVERNOR SLEEVE
• Replace the governor sleeve if the contact surface with governor weight is worn or there is
pitching.
• Replace the governor sleeve if the contact surface with shifter is excessively worn or there is
pitching.
• If the governor sleeve does not move smoothly
on the fuel injection pump camshaft due to
governor sleeve inner dia. wear or other
reasons, replace.
E N G I N E
GOVERNOR
INSPECTION OF GOVERNOR LEVER SHAFT ASSEMBLY
• Measure the clearance between the governor lever shaft and bushing, and replace if it is near
the wear limit.
(mm)
Standard dimension Standard clearance Limit
Governor lever shaft outer dia. 8 –0.005
–0.014
0.065~0.124 0.5
Bushing inner dia. 8 +0.11
+0.06
• Inspect the shifter contact surface, and if it is worn or scorched, remove the spring pin to
disassemble and replace the shifter only.
• Check link parts for bends or kinks that will cause malfunctioning, and replace if it is faulty.
* 1. Side gap on top of governor lever shaft.
(mm) 15
Standard side gap 0.4
12
* 2. Replace the governor lever, tension lever, bushing, shifter and angleich spring as an 9
assembly.
E N G I N E
GOVERNOR
INSPECTION OF SPRINGS
• Check the governor spring and other springs

and replace if they are broken, settled or
corroded.
15 INSPECTION OF ANGLEICH SPRING ASSEMBLY

12 • Inspect the sliding surface of shifter and
10 replace if it is faulty.
• Replace the angleich spring assembly if the
angleich spring is broken.
INSPECTION OF TORQUE SPRING ASSEMBLY
• Inspect the tip of the piston and contact

surface for wear and replace if it is faulty.
• Replace the assembly if the torque spring is
broken.
E N G I N E
GOVERNOR
REASSEMBLY
Inspect all parts after disassembly and replace any parts as necessary. Before starting
reassembly, clean all parts and put them in order.
Make sure to readjust the until after reassembly to obtain the specified performance.
• Fix the bearing holder with a vise to hold the
fuel injection pump camshaft. Insert the
governor weight assembly in the taper portion
at the end of the fuel injection pump camshaft.
Mount the washer, and tighten the governor
weight support nut with the specified torque.
(kgf·m)
Governor weight support
15
nut tightening torque 12
Indirect injection system 7.0~7.5
11
Direct injection system 4.5~5.0
• Open the governor weight to the outside, and

insert the sleeve in the end of the fuel injection
pump camshaft.
* Make sure that the sleeve moves smoothly
after inserting it.
• After the stop lever is disassembled, mount the

stop lever return spring on the stop lever, tap
the stop lever lightly with a wooden hammer to
insert it, and tighten the stop lever stop pin. (Dl
only)
E N G I N E
GOVERNOR
• After the control lever shaft is removed, lightly

tap and insert the control lever shaft and
washer from inside the governor case, using an
appropriate plate.
• If the governor lever has been disassembled,
tap in the spring pin.
15 • Mount the governor lever assembly to the

governor link.
* 1. Make sure that the correct governor link
12 mounting holes are used and that it is
12 mounted in the correct direction.
* 2. Make sure that the governor link moves
smoothly.
• Put the governor lever shaft assembly in the

governor case, insert the governor lever shaft
and tap it in until the O–ring groove comes out
the opposite side of the governor case. (for Dl)
* 1. Fit the O–ring beforehand to the side you
tap in.
E N G I N E
GOVERNOR
* 2. Make sure to insert the governor lever

shaft in the correct direction.
* 3. Don’t forget to mount the washers on both

sides of the governor lever.
• After you have mounted the O–ring, tap the
15
governor lever in the opposite direction, and 12
mount the circlip on the grooves at both 13
ends. (for DI)
E N G I N E
GOVERNOR
* After mounting the governor lever assembly,

make sure the governor lever assembly
moves smoothly.
• Fit the stop lever return spring to the end of
the governor lever shaft. (Dl only)
15 • Hook the governor spring on the control lever

shaft and tension lever hook with long nosed
pliers.
12
14
• Pull the governor link as far as possible

towards the governor case mounting surface,
insert the governor link pin in the fuel control
rack pin hole and fit the snap pin on it.
• Mount the governor case to the fuel injection

pump while lightly tapping it with a wooden
hammer, and tighten the tightening bolt.
• Mount the governor case cover. On models
with idle subspring, insert the adjusting spring
and adjusting rod on the governor case cover
adjusting bolt.
* If the angleich spring assembly has been
removed, tighten the nut temporarily. The nut
should be securely tightened after adjustment.
E N G I N E
GOVERNOR
• Insert the control lever in the control lever shaft

and tighten the nut.
* Move the control lever back and forth to make
sure that the entire link moves smoothly.
15
12
15
E N G I N E
SERVICE INFORMATION FOR CARB ULG REGULATION
SERVICE INFORMATION FOR CARB ULG

REGULATION
INTRODUCTION
This chapter describes only the items designated as special specifications for servicing the TNE
engine under 25 HP that complies with CARB ULG regulation (Regulation for small Utility engines
and Lawn & Garden from California Air Resource Board, effects to the engines manufactured
on Jan. 1st 1995 and later).
EMISSION CONTROL LABEL 15

13
CONTENT OF THE LABEL 1
Size and contents of the label are as shown below.
[Example]
E N G I N E
LOCATION OF THE LABEL
The locations of the label are three types A, B, and C, where the applicable engine families
and engine models are as shown in the table below.
15
13
2
E N G I N E
LIMITING THE HIGH IDLE AND LOW IDLE ADJUSTMENT SCREW
HIGH IDLE SPEED
• First warm up the engine. Then, gradually increase the engine speed up to the high idle
speed (Refer to page 15–01, specifications and performance).
• If the present high idle speed differ from the specified one, adjust the high idle speed using
the high idle adjustment screw.
• After locking the adjustment screw with the lock nut by using the special tool, insert the plug
firmly to prevent readjustment and oil leakage.
LOW IDLE SPEED
• After warming up the engine, set the low idling

15
speed (Refer to chapter 1, specifications and 13
performance) by turning the low idle adjustment 3
screw.
* 1. Do not adjust the high idle adjustment
screw unless necessary.
* 2. The illustration shows the partial
perspective view of the governor for the
direct injection system.
E N G I N E
LIMITING THE FUEL VOLUME LIMITER SCREW
• After limiting the fuel volume, lock the fuel

volume limiter screw with the lock nut by using
the special tool.
• Then, insert the plug firmly to prevent
readjustment and oil leakage.
* Do not adjust the fuel volume limiter screw
unless necessary.
15
13
4
E N G I N E
ATTACHED DRAWING 1
EXPLODED VIEWS OF ENGINE COMPONENTS
– Engine component
1. Exhaust manifold
2. Intake manifold
3. High–pressure fuel pipe
4. Fuel return pipe
5. Fuel injection nozzle retainer
6. Fuel injection nozzle
7. Nozzle seat
15
9. Nozzle protector 13
10. Bonnet assembly
5
11. Valve rocker arm shaft assembly
12. Push rod
13. Valve cap
14. Fan mounting bolt
15. Fan
16. Adjusting bolt
17. V–belt
18. Alternator
19. Spacer
20. V–pulley
22. Dipstick
23~26. Fuel return pipe
27. Fuel filter
28. Cooling water pipe
29. Thermostat assembly
30. Cooling water pump
31. Cylinder head tightening bolt
32. Cylinder head assembly
33. Cylinder head gasket
34. Valve spring
35. Valve cotter
36. Valve retainer
37. Intake valve
38. Exhaust valve
54. Flywheel housing
55. Starting motor
56. Flywheel mounting bolt
57. Flywheel
58. Oil seal case
66. Piston
67. Connecting rod
E N G I N E
ATTACHED DRAWING 2
EXPLODED VIEWS OF ENGINE COMPONENTS
– Engine component
8. Fuel injection pump

21. Oil filter assembly
39. V–pulley clamping bolt
40. Crankshaft V–pulley
41.
42.
43.
Gear case
Oil pan mounting bolt
Gear case mounting bolt
15
44. Stiffner bolt 13
45. Oil seal
7
46. Fuel injection pump drive gear
47. Lubricating oil pump
48. Idle gear shaft
49. Idle gear
50. Camshaft gear
51. Thrust bearing
52. Mounting bolt
53. Camshaft assembly
59. Tappet
60. Oil pan
61. Spacer
62. Gear case flange
63. Lubricating oil strainer
64. Crank pin side cap
65. Crankshaft
68. Crank pin metal
69. Main bearing cap bolt
70. Main bearing cap
71. Lower main bearing metal
72. Upper main bearing metal
73. Thrust metal
TRANSAXLE 20
• 20 – 01 STRUCTURE AND – Stator support

MAINTENANCE removal from
– Construction adaptor plate
– Hydraulic circuit – Clutch assembly,
– Service maintenance idler gear & pinion
– Specification shaft removal
– Service brake • 20 – 03 ASSEMBLY
adjustment – Transaxle
• 20 – 02 SERVICE BRAKE reassembly
ADJUSTMENT – Differential
– Precaution – Pinion gear
– Remove auxiliary shimming
subassemblies – Wheel end final
– Wheel end assembly
– Brake assembly – Clutch assembly
removal – Stator support
– Separation of – Transmission
converter housing assembly
and adaptor plate

T R A N S A X L E
STRUCTURE AND MAINTENANCE
CONSTRUCTION
Torque converter Torque

converter
Gear Pump
20
Control Drum and shoe brake
valve
01
1
TA12 Transaxle assembly includes:
• torque converter
• single – speed forward and reverse powershift transmission with integral differential and
drive axle
• full – floating straight drive axle
• automotive – type drum and shoe brakes
• gear – driven pump drive
• electric shift control, hydraulic inching control
Power flow is from torque converter turbine, to turbine (clutch) shaft and gears, then through
either forward gear or reverse idler shaft, to the output gear mounted on final drive pinion shaft.
Transmission and differential are housed in a one – piece transmission case.
Torque converter housing joined to transmission case through an adaptor (or spacer) plate holds
the converter stator support and reverse idler outer bearing.
Pump drive is from converter impeller hub gear, through an idler gear to the pump gear mounted
on charging pump shaft.
Final drive pinion gear shaft, mounted in tapered roller bearings at both ends in transmission
case, is adjusted for mounting distance, and ring and pinion gear contact, by a shim pack
installed behind the pinion gear inner tapered roller bearing cup in the transmisson case. Pinion
shaft bearing preload is adjusted with shims behind outer bearing cone on the pinion shaft.
T R A N S A X L E
Final drive ring gear is bolted to differential carrier. Differential support is by opposed tapered
roller bearings mounted on inner end of wheel end housings, which are bolted to openings in
transmission case at the sides of the differential. Differential bearing preload and ring gear
clearance (backlash) is maintained by shims placed behind differential bearing cones on wheel
end housings. Adjustment of differential bearing preload or ring gear backlash requires trial
assembly, checking, and disassembly of wheel end housings until correct adjustment is obtained.
Drive axle wheel hubs/brake drums are supported by double tapered roller bearings on outer
end of wheel end housings. Drive axle shaft flange bolted to wheel hubs are full–floating in
differential. Service brake backing plates are bolted to mounting flange on wheel end housings.
Wheel bearings are lubricated from the transaxle sump.
Control valve is mounted on pad at top of transmission case. Oil from charging pump flows via
filter and pressure regulator to control valve through an external oil supply line. Oil from control
valve is delivered to clutches through passages in housing and oil distributor sleeve and seal
rings at forward–clutch end of turbine/clutch shaft. Excess pump oil volume and converter–out
20 oil, flows to oil cooler and returns to transmission housing at base of control valve, then through
center of turbine/clutch shaft back to converter.
01
2
HYDRAULIC CIRCUIT
T R A N S A X L E
SERVICE MAINTENANCE
SERVICE
The transaxle has two service openings:

1. Drain plug, in bottom of transmission case.
FLUID LEVEL CHECK
Check the transaxle fluid level with:

20
• Fork lift on a level surface 01
• Engine idling with transmission in NEUTRAL 3
• Oil at operating temperature 82~93°C (180~200°F)
Remove the transaxle oil level plug the
front of central housing of driving wheel.
The oil level is correct when the oil
reaches the full mark on dipstick.
Add recommended fluid only, as required.
FLUID AND FILTER CHANGE
It is recommended to:
• Drain and replace the transaxle fluid every 1000 operating hours.
• The oil should be drained when warmed to operating temperature, 82 ~ 93°C (180~200°F)
• Replace the transaxle oil filter every 500 operating hours. See NOTICE below.
! IMPORTANT
When the transaxle is new or rebuilt, it is recommended to change the oil filter after
the first 50 hours and again after 500 operating hours.
a Remove drain plug from bottom of transmission case. Drain old oil into suitable drain pan.
b Remove old oil filter. The oil filter is mounted near the top of converter housing above
transmission.
T R A N S A X L E
! Take special care when removing the filter to avoid oil remaining in filter from draining
onto floor. Loosen the filter using a filter wrench. Remove filter while holding a pad
of cloth or other absorbent material under the open end to absorb any excess oil that
may drain out of filter.
c Install a new oil filter. Follow the installation instructions printed on filter.
! Always use genuine SAMSUNG parts
REFILLING THE TRANSAXLE
After drive axle and transmission housing has drained completely,

• Install drain plug.
• Loosen the oil level plug and fill the oil upto the plug hole.
• Start the engine and run at idle speed (500~700rpm) in NEUTRAL for 2~3minutes to prime the
converter and cooler lines.
20
• Recheck oil level with engine running at idle speed. [82~93°C (180~200°F)]
• Check for leaks at drain plug and oil filter.
01
4 SPECIFICATION
PRESSURE SPECIFICATION
• Regulator valve pressure : 1034~1378kPa (150~200 psi) @ 1800 rpm

Check Point : Oil supply line at converter
• Converter In / Lube Pressure : 110~207kPa (16~30 psi ) @ 1800 rpm
Check Point : Return from cooler
• Converter Safety Valve Pressure : 729~827kPa (105~120 psi) @
(Trans in NEUTRAL) 1800 rpm (Refefence only)
Check Point : None with line to cooler blocked
• Clutch Pressure : 965kPa (140 psi) @
(Forward, Reverse applied) 800 rpm idle
Check Point : At control valve Normally 103kpa (15 psi) less than regulator
(1/8 NPTF) pressure 930kpa (135 psi min)
• Clutch Pressure : Regulator pressure
(in NEUTRAL)
T R A N S A X L E
! • All rpm’s noted are engine speed.

• All clutch pressures are at engine idle speed with clutch engaged, unless otherwise
noted.
• Oil at operating temperature 82~93°C(180~200°F)
• Refer to following illustrations for check point locations.
PRESSURE CHECK POINTS
20
01
5
T R A N S A X L E
SERVICE BRAKE ADJUSTMENT
Brake bleeder screw
20 Adjust clearance between

brake shoes and drum to
01 0.225-0.304mm(.010-.012in)
measured at these points.
6
PREPARATION
1. The service brakes on the transaxle may be adjusted from the inner side through the backing
plate (all models).
2. Brake clearance is measured between brake shoe and drum, with brakes fully released.
Brake clearance : 0.255~0.304mm (.010~.012 in)
! CAUTION : Be sure transmission directional control is in NEUTRAL and fork lift

prevented from moving when parking brake is released.
3. Release parking brake.
! IMPORTANT – Do not overtighten brakes.

It is very difficult to release the ratchet wheel pawl and back off adjustment of the
brake.
T R A N S A X L E
ADJUSTMENT AT BACKING PLATE
1. Remove the 4 dust plugs in brake backing plate.

2. Use a feeler (thickness) gauge to check the clearance between each shoe and drum. Use a
brake adjuster tool to rotate the adjuster ratchet wheel in the brake.
3. Use a screwdriver to push on and release the ratchet pawl when it is necessary to back off
adjustment (increase clearance) of the brake.
4. Carefully adjust clearance between brake shoes and drum to 0.255~0.304mm (.010~.012 in)
measured at dust plug openings at outer sides of backing plate.
5. Replace the dust plugs in brake backing plate when adjustment is completed.
20
01
7
T R A N S A X L E
PRECAUTION
• Before attempting any repairs or overhaul of this assembly, please read through the entire
disassembly and assembly procedures first.
! Cleanliness is of extreme importance in the repair and overhaul of this assembly.

• The exterior surface of the unit MUST be thoroughly cleaned of all dirt and foreign substances
to prevent contamination of the parts during disassembly and overhaul. Perform all disassembly
and assembly work in a clean area. Protect all components from dust and dirt while repairs
are being made.
• Keep all parts in order as disassembly progresses. Take care to properly identify each part
and its order of removal. If necessary, keep notes and put marking on parts using a
nondestructive marker such as a felt–tipped pen.
REMOVE AUXILIARY SUBASSEMBLIES

20
02
1
1. Remove torque converter assembly by carefully sliding it off the turbine (clutch) shaft and
stator support.
2. Disassemble converter drive plate and adaptor, as needed.
Remove the :
3. Oil filter
4. Charging pump
5. Oil supply line assembly
6. Transmission control valve assembly
T R A N S A X L E
WHEEL END
20
02
2
1. Loosen and remove the axle shaft fasteners.

2. Remove axle shaft.
3. Unbend (straighten) the lockplate tabs from the bolt heads of the wheel bearing retainer plate
fasteners.
4. Remove the bearing retainer plate fasteners.
5. Remove the lockplate, bearing retainer plate and wheel bearing shims.
6. Pull wheel hub out to loosen bearing (you may have to tap on hub or pry at brake backing
plate), remove outer wheel bearing, then remove the wheel hub/brake drum assembly with
inner wheel bearing and oil seal.
T R A N S A X L E
! IMPORTANT
This oil seal is a type that seals internally, and is lined with sealing compound on
the inner diameter that sticks and seals to the spindle.
Removing the wheel hub from the spindle breaks that seal. Replace with new seal
each time that the wheel hub is removed from wheel end housing.
20
02
3
7. Before removal of wheel end housing, mark the housing and the transmission case for
same–location matching at reassembly. Loosen and remove the housing bolts and washers.
8. Remove wheel end housing from transmission case.
9. If the differential bearing on the inner end of the wheel end housing is to be removed and
replaced, use a bearing puller, if necessary. Wire bearing shims to wheel end housing for
storage until reassembly.
10. Repeat procedures of Steps 1 through 9 for opposite wheel end disassembly.
11. Remove the differential assembly from transmission case.

T R A N S A X L E
BRAKE ASSEMBLY REMOVAL
Brake removal is optional for brake overhaul as necessary.
1. Remove the upper brake shoe return springs.

2. Remove lower return spring.
3. Remove brake shoe hold–down (guide)
springs.
20
02
4 4. Disconnect parking brake cable.
Remove the brake shoes.

5. Remove brake backing plate fasteners and
washers.
6. Remove backing plate and parking brake
cable assembly from wheel end housing.
T R A N S A X L E
SEPARATION OF CONVERTER HOUSING AND

ADAPTOR PLATE
20
1. Remove the fasteners and washers which mount the converter housing to transmission case 02
through the adaptor plate. 5
2. From other side, remove the bolts and washers which mount adaptor (spacer) plate to
converter housing.
3. Remove the clutch pressure–regulating valve assembly (also oil filter mounting base).
! IMPORTANT
Pry only at the dowel pins to remove adaptor plate. Dowel pins must be removed
before reassembly. See later instructions.
4. Separate converter housing from adaptor plate.

5. Remove impeller hub gear from stator support.
6. Remove pump drive idler gear and bearing, outer and inner thrust washers, and idler shaft.
7. Remove adaptor plate from transmission case.
T R A N S A X L E
STATOR SUPPORT REMOVAL FROM ADAPTOR

PLATE
1. The stator support is held in place by two

retaining rings, one on each side of the
adaptor plate.
20
2. To remove stator support :
02 – Remove front (converter end) retaining ring
6 from ring groove and move ring and impeller
gear thrust washer toward stator support
seal surface.
– Push stator support to the rear (towards
transmission side) far enough to expose
rear retainer ring.
– Remove rear retaining ring.
– From the front, pull stator support from
adaptor plate.
CLUTCH ASSEMBLY, IDLER GEAR & PINION

SHAFT REMOVAL
1. Move the reverse idler gear and clutch

assembly apart far enough to allow the idler
shaft to be pulled out of the inner bearing.
T R A N S A X L E
2. Remove the clutch assembly and reverse

idler shaft together.
3. Remove the turbine (clutch) shaft rear

bearing.
4. Remove the clutch shaft oil distributor
retaining set screw (internal hex) from valve
mounting base.
5. Remove the oil distributor. Note the recess
20
in distributor for retaining set screw.
02
7
6. Loosen and remove the pinion shaft nut.

Hold or block the pinion shaft with a brass
bar or similar soft material to prevent
turning.
7. Remove the pinion shaft outer bearing and
shims. Keep the shims with the bearing and
pinion shaft.
8. Remove output gear retaining ring from
pinion shaft (inside transmission case).
9 Remove output gear (move pinion shaft
away).
10. Remove pinion shaft and inner bearing
through differential housing.
11. If pinion bearings are to be replaced, drive
the cups from the housing inside
transmisson case.
12. Remove inner pinion bearing cup and shims from differential side.
T R A N S A X L E
! Wire shims to transmission housing for storage until reassembly.

13. As required, remove oil suction tube
assembly from transmission case.
CLUTCH DISASSEMBLY
(Forward & Reverse Clutch Procedure Are The Same)
20 • Reverse Clutch Disassembly Illustrated
02
8
1. Remove outer clutch hub gear thrust bearing and thrust washers, clutch hub gear, and inner
clutch hub thrust bearing and thrust washers.
2. Disassemble the two clutch gear bearings and spacer from internal bore of clutch gear hub.
3. Remove clutch disc end plate retainer ring and clutch disc end plate.
4. Remove inner and outer clutch discs.
5. Remove clutch return spring retainer ring.
6. Remove clutch return (release) springs (Belleville washers). Note assembly arrangement.
T R A N S A X L E
7. Remove clutch piston wear plate.

8. Remove clutch piston by turning clutch
upside down and tapping the shaft on a
block of wood.
9. Remove and discard clutch piston sealing
rings.
10. Repeat procedures, steps 1 through 9, for
forward clutch disassembly.
DIFFERENTIAL DISASSEMBLY
1. Use a small drift pin or rod to remove the

differential pinion pin, lock pin.
2. Remove the pinion pin. 20
02
9
3. Rotate the pinion gears and washers to

remove them from the differential housing.
T R A N S A X L E
ASSEMBLY
TRANSAXLE REASSEMBLY
Apply loctite
#515 sealant
Shim here for
Apply loctite bearing end play
#542 sealant
Apply loctite
#515 sealant
Apply loctite #277 to

Shim here for bearing
preload and to position
(backlash) ring gear
Total bearing end play to be.
0.013~0.076mm(.0005~.003in)
20
bearing preload to be
ring gear mounting bolt 0.08~0.16kgf.m(7~14lbf.in) 03
ring and pinion backlash of 1
0.153~0.254mm(0.008~0.011in)
to be measured with a dial
indicator
1. Use Permatex and Loctite only where specified.

2. All lead–in chamfers for oil seals, piston ring grooves and O–rings must be smooth and free
from burrs. Inspect at assembly.
3. Lubricate all piston ring grooves, clutch plates and O–rings with oil before assembly.
4. Apply a thin coating of grease between seal lips of lip–type oil seals prior to assembly.
5. Apply a very light coating of Permatex No.2 to O.D. of all seals and hole plugs before
assembly.
6. Apply a light coating of Loctite # 592 to all uncoated pipe plugs.
7. After assembly of parts using Permatex or Loctite, there must not be any free or excess
material that could enter the oil system.
8. Brush light coating of CLARK #2776236 or equivalent oil, on tapered bearings and bushing
bores.
• Oil suction Tube

1. As required, install oil suction tube assembly
in transmission case. Insert tube end through
housing opening, install seal on tube, then pull
tube with seal back into place. See enlarged
view (N) Install and tighten mounting bolt.
T R A N S A X L E
ASSEMBLY
DIFFERENTIAL
Before reassembly, clean, inspect and lubricate all parts.
20 Loctite #277
03
2
1. Position the side gears and washers in the differential assembly.

2. Locate both pinion gears and washers on the side gears.
! The pinion gears must be located across from each other and then rotated into
position to align the holes in the pinions with the hole in the housing.
T R A N S A X L E
ASSEMBLY
3. Insert pinion pin (1) in the housing aligning the hole in the pin with the hole in the housing.
4. Install the pinion pin, lock pin (2).
5. Install bearing cone in ends of differential carrier case.
6. If ring gear was removed or replaced, install the ring gear on differential. Apply Loctite # 277
to the ring gear capscrews and tighten to spec. : 12~13.2kgf·m (87~95lbf·ft)
DIFFERENTIAL BEARING PRELOAD CHECK (PINION GEAR NOT

INSTALLED)
The purpose of this trial assembly is to determine the total combined shim pack thickness to
be installed under the differential carrier bearings when replacement (new) parts have been
installed. Later procedures for checking gear backlash and tooth contact are used to determine
the individual shim pack thickness to be installed under each bearing cup.
• No New Parts Installed
If all original parts are reused, use original
shim pack thickness and proceed to : Step 4
Pinion Gear Installation 20
• New Parts Installed 03
If differential carrier, carrier bearings, or wheel 3
end housings have been replac-ed (new), use
the following procedure :
1. Install the differential bearing shims and
tapered bearing cups on the wheel end
housing. Start with original shim pack thick-
ness.
! Force a small shop cloth or rag into the

differential side gears and pinions to
prevent them from turning.
2. Position the differential in the transmission

case.
T R A N S A X L E
ASSEMBLY
3. Mount wheel end housings to the transmission

case in position as marked at disassembly. Be
sure differential and bearing cone are aligned
with bearings on wheel end housing. Install
attaching bolts and washers and tighten fully.
4. Temporarily install axle shaft into side gear of

the differential (with side gear blocked to
prevent turning)
5. Measure the differential bearing rolling–torque
preload with a torque wrench.
Correct preload
: 0.78~1.57Nm (7~14 lbf·in)
! Remove wheel end housings, remove

bearing and add or remove differential
bearing shims behind bearing come to
20 obtain the proper preload torque.

Repeat above procedure.
03
4
6. After correct bearing preload is set, remove the axle shaft and wheel end housings.
7. Remove differential assembly.
Remove shop cloth that was used to block gears from turning.
PINION GEAR SHIMMING
PINION GEAR SHIMMING
NO REPLACEMENT OF GEARS OR HOUSINGS
If the ring and pinion gear or the transmission case was not replaced, use original shim pack
thickness and proceed to Pinion Gear Installation
TRANSMISSION HOUSING REPLACED
If the transmission case was replaced, the following procedure must be used to set the correct
ring gear and pinion contact :
T R A N S A X L E
ASSEMBLY
On the new transmission case, a dimension for

the case bore depth will be stamped on the
location shown in the illustration.
• Shim Pack Thickness Calculations:
The following conditions are used to calculate
the shim pack thickness to be installed.
A = nominal pinion mounting distance 122mm (4.803 in).
B = typical pinion mounting distance (which is etched
on the outer diameter of the ring gear).
C = case bore depth (stamped on the case).
D = nominal shim pack of 0.86mm (0.034 in)
E = final shim pack to be installed under the inner pinion bearing cup to position the pinion
shaft.
! If original shim pack is lost or must be replaced, use D = Nominal shim pack thickness
of 0.86mm (0.034 in). Check new shim pack dimension by measuring thickness.
Substitute new thickness for original (old) thickness where shown.
The following examples show calculations for determining the shim pack thickness to be installed
under the pinion inner bearing :
20
Unit : inch 03
5
Example 1
D .034 B 4.809
C +.007 A – 4.803
E = ( .041 – .006) = ( .035)
Example 2
D .034 B 4.808
C – .003 A – 4.803
E = ( .032 – .005) = ( .027)
Example 3
D .034 A 4.803
C + .003 B – 4.798
E = ( .037 + .005) = ( .042)
Example 4
D .034 A 4.803
C – .002 B – 4.798
E =( .032 + .005) = ( .037)

T R A N S A X L E
ASSEMBLY
a. If the case bore depth (stamped on case) has a “+” (plus) sign, add (C) to the nominal
shim pack (D).
b. If the case bore depth (stamped on case) has a “–” (minus) sign, subtract (C) from the
nominal shim pack (D).
c. If the nomial mounting distance 122mm(4.803 in) is smaller than the mounting distance
etched on the ring gear, subtract (A) 122 mm (4.803 in) .
from (B) the etched mounting distance.
Subtract this answer from the answer of “D” and “C”. See examples 1 and 2.
d. If the mounting distance etched on the ring gear is smaller than the nominal mounting
dimension 122mm(4.803 in), this difference is added to the answer of “D” and “C”. See
examples 3 and 4.
RING AND PINION GEAR REPLACED
If only the ring and pinion were changed, the following procedure is used :
• Shim Pack Thickness Calculations
20 Use a micrometer to measure the original shim pack thickness.
A. If the new pinion mounting distance (etched on ring gear) is larger than the pinion mounting
03 distance (etched on original ring gear), you must subtract the difference (see following
6 example) :
4.813 etched on new ring gear

– 4.810 etched on original ring gear
0.003 in. difference
0.031 original shim pack

– 0.003 difference
0.028 in. FINAL SHIM PACK (E)
B. If the new pinion mounting distance is smaller than the pinion mounting distance on the
original ring gear, you must add the difference (see following example)
4.813 etched on new ring gear

– 4.809 etched on original ring gear
0.004 in. difference
0.031 original shim pack

+ 0.004 difference
0.035 in. FINAL SHIM PACK (E)
T R A N S A X L E
ASSEMBLY
PINION GEAR INSTALLATION
20
1. Install the pinion inner bearing cup shim pack and bearing cup in the transmission case.
03
7
2. If outer bearing is removed or replaced, install outer pinion bearing cup in transmission case.
3. Assemble the inner pinion bearing on the pinion shaft.
4. Position the output gear in the case with the long hub of the gear outward as shown.
5. Position the pinion shaft and inner bearing into the case and through the output gear.
6. Install the output gear retainer ring on the pinion shaft. Be sure the retainer ring is fully
seated into the ring groove.
7. Assemble the outer bearing shims and outer pinion bearing on the pinion shaft. If a new
pinion shaft is used, a nominal shim pack of 1.575mm (0.062 in). can be used initially.
8. Install the pinion shaft nut and tighten to spec : 260~325N·m (192~240lbf·ft). Hold or
block the pinion shaft with a brass bar or similar soft material to prevent the shaft from
turning.
9. With pinion shaft free to turn, use a torque wrench to measure the pinion shaft bearing
rolling–torque wrench to measure the pinion shaft bearing rolling–torque preload.
Correct preload: 0.8~1.6Nm (7~15lbf·ft).
! Remove pinion shaft nut and bearing and add or remove shims behind pinion shaft
outer bearing come to set correct bearing preload torque.
T R A N S A X L E
ASSEMBLY
TRIAL WHEEL END ASSEMBLY FOR RING & PINION GEAR CONTACT
AND BACKLASH CHECK (PINION GEAR & DIFFERENTIAL INSTALLED)
20 1. Position the differential assembly in the transmission case.

03 2. Assemble the wheel end housings on the transmission case as marked at disassembly. Align
8 with differential bearings.
3. Install the wheel end housing bolts and washers. Tighten bolts to spec :
76~84N·m (56~62 lbf·ft)
CHECK RING AND PINION GEAR BACKLASH.
Open the inspection cover on the top of the

differential case. Set up and position a dial
indicator on a ring gear tooth to check the ring
gear to pinion backlash. Hold pinion, move ring
gear within backlash freeplay range several times.
Backlash should be measured at 3 places
minimum around the ring gear (rotate ring gear).
The backlash must be between 0.153~0.254mm
(0.006~0.01in).
To set the correct backlash, shims behind the
tapered bearings on the wheel end housings are
removed from one side and added to the other.
Remove the wheel end housings, remove bearings and move shims.
Repeat above assembly and checking procedure.
T R A N S A X L E
ASSEMBLY
CHECK RING AND PINION GEAR TOOTH BEARING CONTACT PATTERN.
To check the ring gear and pinion for proper

tooth contact pattern (correct position), apply a
coating of gear checking compound, e.g., red
lead, to the ring gear teeth. Rotate the ring and
pinion gears through a minimum of one
revolution. Apply a load (hold by hand) to the
gears as they are turned. When the ring gear is
turned, the compound is squeezed away by the
contact action of the teeth, leaving bare areas
that are the exact shape, size and area of the
tooth contact pattern.
Check the tooth contact area on the drive (convex) side of the ring gear teeth. See figure above
for typical correct tooth contact pattern. If the tooth contact is not as shown, recheck the pinion
mounting procedure and also the ring and pinion backlash reading.
! IMPORTANT
Each time the ring gear or pinion is moved, the backlash and the bearing preloads
20
must be checked and reset as needed. 03
9
T R A N S A X L E
ASSEMBLY
WHEEL END FINAL ASSEMBLY
Loctite #515
20 Loctite #277
03
10
Before final assembly, clean and lubricate all parts thoroughly.

After the correct ring gear and pinion backlash and tooth contact is set :
1. Remove both wheel end housings and apply a film of Loctite #515 to the flange on housing.
Spread the material evenly on the flange around the bolt holes.
2. Position the wheel ends on transmission case.
Be sure differential bearings are aligned and fitted correctly.
3. Apply a thread locking compound, e.g., Loctite #277 as follows :
• On bolts, capscrews and studs (anchor end), apply compound on the female threaded
component part.
• On nuts, apply compound to the male thread of mating fastener.
• Apply compound to coat the full length and circumference of thread engagement.
• Remove excess compound from mating parts after fastener installation.
4. Install the wheel end housings to transmission case.
Install washers and mounting bolts. Tighten bolts to spec :
76~84N·m (56~62 lbf·ft)
T R A N S A X L E
ASSEMBLY
INSTALL BRAKE ASSEMBLIES (AS REQUIRED)
1. Insert parking brake cable (through the opening noted at disassemly) in the brake backing
plate.
2. Install backing plate. Install capscrews and washers per brake, located closest to parking
20
brake cable connection. 03
3. Tighten the fasteners in the sequence shown to spec : 11
100~111N·m (74~82 lbf·ft)
4. Connect parking brake cable to the notch in
the brake cam.
5. Assemble the brake shoes and hold–down
springs on backing plate.
6. Install lower return spring.
7. Install upper return springs.
! For brake adjustment, refer to brake

adjustment procedure.
WHEEL HUB ASSEMBLY
1. Install the retainers and retaining ring.

2. Install the outer and inner bearing cups.
3. Position inner tapered bearing in bearing cup.
4. Apply a very light coating of Loctite #515 to
outer diameter of a new wheel hub oil seal
and install seal in wheel hub.
T R A N S A X L E
ASSEMBLY
! IMPORTANT
It is mandatory to replace the wheel hub oil seal whenever the hub is removed from
spindle. This oil seal is a type that seals internally, and is lined with sealing compound
on the inner diameter that sticks and seals to the spindle. Removing the wheel hub
from the spindle breaks that seal.
The seal cannot be reused.
5. Position wheel hub assembly on the wheel end spindle. Be careful when sliding oil seal
onto wheel end housing. Support the wheel hub to avoid seal dragging over spindle.
6. Install wheel hub outer tapered bearing.
7. Install wheel bearing shims, retainer plate, retainer lockplate and capscrews.
Bend lock tabs

20 at assembly
03
12
8. Tighten bearing retainer capscrews to spec : 1.6~2.2kgf·m (12~16 lbf·ft)

9. Use a dial indicator to check bearing endplay.
Correct endplay = 0.013~0.076mm (0.0005~0.003 in)
Add or subtract shims under bearing retainer plate to obtain the correct end play.
10. When end play is correct, bend the tabs of the lock plate against the capscrew heads to
lock them.
11. Apply a film of Loctite #515 to the axle shaft flange. Spread evenly around the bolt holes.
12. Apply Loctite #277 to threaded holes in the wheel hub.
13. Install axle shaft in wheel end. Rotate shaft to align axle shaft splines with side gears in
differential.
14. Install axle shaft mounting screws. Tighten to spec: 4.5~4.9kgf·m (33~35 lbf·ft)
T R A N S A X L E
ASSEMBLY
CLUTCH ASSEMBLY
Forward clutch reassembly is the same as reverse clutch (shown). 20

! Before reassembly, clean, inspect and lubricate all parts with a light layer of
transmission fluid #2776236.
03
13
1. Install new clutch piston inner and outer oil seal rings in piston grooves.
See figure above.
! The rings must be sized before piston installation onto shaft and into the clutch drum :
• Sizing is best accomplished by rotating the piston while holding a round object against
the new seal rings.
• Rotate the piston until the seal rings are sized flush with the inner and outer diameters
of the piston.
2. Install clutch piston over turbine (clutch) shaft and into clutch drum.
3. Install clutch piston wear plate (flange towards piston).
4. Install piston return springs (Belleville washers).
Install first washer with large diameter of bevel toward wear plate.
Alternate five (5) washers.
5. Position return spring retainer ring on clutch shaft. Start ring on shaft with snap ring pliers.
6. Install retainer ring using a sleeve with the
proper inner diameter to fit over shaft and
against retainer ring. A sharp blow with a
soft hammer will compress springs and
seat retainer ring. Be sure ring is seated
fully in position in ring groove.
T R A N S A X L E
ASSEMBLY
7. Install the first outer (steel) clutch disc against clutch piston. Next, install first inner (friction)
clutch disc. Alternate outer and inner discs to install a total of 6 outer steel plates and 6
inner friction plates.
8. Install clutch disc end plate.
9. Install end plate retainer ring.
10. Check clutch disc clearance.
! Both clutch packs (Forward and Reverse) must be checked for clutch disc clearance :
• Stand the clutch assembly on end. The clutch discs on the bottom will fall to the end plate.
• Measure the distance between the clutch piston and the first steel disc by inserting a feeler
gauge through the slots in the clutch drum.
• Required clearance is 1.22~2.66 mm (.048~.105 in)
• If clearance is greater than 2.66 mm (.105 in), add one steel disc under the end plate.
11. Install inner clutch gear thrust bearing set (thrust bearing between 2 thrust washers).
12. Assemble clutch gear bearing (spacer between bearings) into clutch gear hub.
20 13. Install clutch gear into clutch assembly by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is fully in position in the clutch assembly. Do not force this
operation.
03 14. Install outer clutch gear thrust bearing set, with thurst bearing between thrust washers,
14 against clutch gear.
15. Repeat assembly procedures, steps 1 through 14, for forward clutch.
16. After forward clutch is assembled, install
new oil distributor seal rings on clutch shaft.
Apply grease to rings to facilitate assembly
into oil distributor.
T R A N S A X L E
ASSEMBLY
STATOR SUPPORT
1. Install the turbine shaft bushing and clutch outer pilot bearing into stator support. Press the
bushing to the specified depth.
2. Install stator support assembly in adaptor plate (Reverse of disassembly procedure) : 20
• Assemble front retainer ring on stator support but do not install in front ring 03
groove ; temporarily position it beyond the groove to the forward end of the rear spline.
15
Position the impeller hub gear thurst washer on stator support and against retainer ring.
• From the front, assemble stator support into spacer plate. Push stator support through plate
until rear retainer ring groove is exposed. Install rear retainer ring.
• Push stator support toward the front until rear ring shoulders against spacer plate.
• Push thrust washer back against plate and install front retainer ring in groove.
T R A N S A X L E
ASSEMBLY
TRANSMISSION ASSEMBLY
20 1. Install the clutch shaft oil distributor in transmission case with the recess in the distributor
03 lined up with retaining set screw hole in valve housing pad.
16 2. Install the oil distributor retaining set screw.
3. Install turbine (clutch) shaft inner (rear) bearing.
4. Install reverse idler shaft inner (rear) bearing.
T R A N S A X L E
ASSEMBLY
5. Install clutch and idler gear shafts. The forward and reverse clutch assembly and the reverse
idler gear must be assembled in the transmission case together. Carefully move and align
the clutch shaft oil seal rings through the rear bearing and into the oil distributor. Be sure
the reverse idler is fully installed in the inner bearing.
6. Install adaptor plate on transmission case.
• Install (position) a new adaptor plate gasket
on the transmission case.
• Carefully align the adaptor plate over the
turbine (clutch) shaft and on the transmission
case.
• Tap adaptor plate into position tight against
the transmission case. Install the dowel pins
to hold plate in position.
! Dowel pins should project 1/4” out of

adaptor plate for installation into
converter housing.
7. Turn the pinion shaft (using the nut) and the

20
turbine shaft to check if the unit is binding. 03
If both shafts turn freely with spacer plate 17
tight against transmission case, proper
assembly is completed.
If binding is detected, the unit must be
disassembled and reassembled.
8. Install impeller hub gear on stator support.
9. Install pump idler shaft in spacer plate.

Install idler gear inner thrust washer.
10. Install pump drive idler gear and bearing on

idler shaft. Install idler gear outer thrust
washer.
T R A N S A X L E
ASSEMBLY
11. Install the converter bearing and impeller hub

oil seal in converter housing, as illustrated.
Apply a thin coat of grease between seal lips
prior to further assembly.
12. Install (position) a new converter housing

gasket on the spacer plate.
13. Install converter housing on adaptor plate (fit
over dowels) and to transmission case. Be
careful not to damage converter housing oil
20 seal when moving over the stator support.

14. Install adaptor plate to converter housing
and converter housing to transmission
03 housing attaching screws and lock–washers.
18 Tighten to torque spec :
30~33N·m (22~25lbf·ft)
15. Install oil pressure regulator valve sleeve

assembly through the spacer plate and into
converter housing. Tighten regulator sleeve
to spec : 20~26N·m(15~20 lbf·ft)
16. Install oil filter on regulator sleeve as per
instructions on filter.
17. Install charging pump with attaching bolts

and washers and tighten to spec :
16~22N·m (12~16 lbf·ft)
T R A N S A X L E
ASSEMBLY
18. Install control valve assembly to transmission

case with attaching bolts and washers and
tighten to spec :
16~22N·m (12~16 lbf·ft)
19. Install oil supply tube assembly.
20. Install torque converter assembly by sliding

onto stator support.
Carefully align splines with stator and
impeller hub gear. Again use care not to
damage converter housing oil seal.
20
03
19
STEERING SYSTEM 30
• 30 – 01 FUNCTION AND MAINTENANCE

– Outline
– Operating principle during left / right turn
– Steering unit
– Operation
– Troubleshooting table
• 30 – 02 DISASSEMBLY AND ASSEMBLY

– Steering unit
– Priority valve
S T E E R I N G S Y S T E M
FUNCTION AND MAINTENANCE
OUTLINE
30
• The oil from hydraulic tank (6) is sent to priority valve (2) by steering pump (5). 01
• When the steering wheel is turned ; the movement is transmitted via the steering columm shaft 1
to steering unit (1), which activates priority valve (2).
• The distribution of the oil flow through the priority valve is controlled by the “LS” signal from
the steering unit.
• The oil flow necessary for steering flows through priority valve “CF” port to the steering unit
then to the steering cylinder.
The oil not required for the steering, flows to the main control valve through “EF” port of the
priority valve.
• When the steering wheel is not operated all the oil from steering pump (5) flows to the main
control valve, except for 0.5 l /min. which flows to the steering unit to provide an immediate
response when the steering wheel is operated.
NEUTRAL POSITION
• When the steering wheel is not operated, the neutral position springs of steering unit (1) return
the sleeve to a neutral position in relation to the spool. The spool is centered on the pin
secured in the sleeve.
• Under this condition oil from steering pump (5) flows to “P” port of priority valve (2).
Since the ports to the steering cylinders are closed in steering unit (1) pilot pressure “PP”
signals priority valve (2) and all the oil (except for 0.5 l /min.) from the steering pump flows
through the “EF” port to the main control valve.
OPERATING PRINCIPLE DURING LEFT/RIGHT TURN
• When the steering wheel is turned left/right, the spool within steering unit (1) spline–fitted to
the steering column shaft will rotate in a left/right–hand direction.
• Oil from steering pump (5) flows to “P” port of priority valve (2). The position of the valve spool
is determined when the pressure difference between the front and rear orifices is balanced with
the spool spring force.
• The high pressure oil flows through “CF” port of the priority valve to steering unit (1). The flow
is directed through the steering unit to the steering cylinder according to the rotational direction
of the steering wheel. Oil flow to the steering cylinder is in proportion to the angular rotation
of the steering wheel.
• Return oil from the left/right cylinder chamber flows through “T” port of the steering unit to
tank.
• The progression of this operation articulates the machine in the desired direction.
30
01
2
STEERING UNIT
CONSTRUCTION
30
01
3
1. Steering Column 7. Cardan shaft

2. Neutral position springs 8. Stator
3. Housing 9. Rotor
4. Check valve 10. Pin
5. Spool 11. Gerotor
6. Sleeve
FUNCTION
Breakdown of functions according to sub–assembly
ROTARY VALVE BANK
• Three positions : Neutral Position

Right hand feed position
Left hand feed position
• In neutral position it has the following function
– Lock steering cylinder power supply (no reaction)
– Lock steering unit set power supply
• In feed position (right or left hand)
– It directs the oil from the pump to the gerotor set.
– It directs the oil from gerotor set towards the steering cylinder and the cylinder return flow
towards the tank.
GEROTOR SET
• Delivers an oil flow proportional to steering wheel turning motion.
30 • Ensures steering hydraulic servo–assistance.

• Functions as a hand pump when the pump has no flow (safety), however steering wheel
operating force is very heavy.
01 Operation of the rotary valve bank is connected to the gerotor set by the cardan shaft. Each
4 of these components fulfils specific functions which are put into motion by turning the steering
wheel.
DESCRIPTION
The steering unit device consists of a rotary valve bank spool (5), sleeve (6) and gerotor set (8),
(9) flanged to main housing (3).
The steering column (1) drives spool (5) ; inside sleeve (6) and these two parts turn at ± 8° in
relation to each other.
These parts are positioned at an angle by means of neutral position springs (2). When the
steering wheel is not turned (Neutral position), the springs return the sleeve to a neutral position
in relation to the spool.
The cardan shaft (7) is intergral with sleeve (6) by pin (10) with stator (8) and rotor (9).
Steering check valve (4) enables the steering cylinder return flow to be reinjected direct for power
supplying the device (closed circuit).
During normal operation the valve is closed.
OPERATION
RIGHT–HAND TURNING
When the steering wheel is turned, selector

spool (5) turns in relation to feed sleeve (6) ;
pin (10) which is tightly secured in sleeve (6),
goes through spool (5) via a hole with a
diameter larger than that of the pin.
This enables the spool to rotate on either side
by 8°. As a result of this, the cylinder feed lines
open progressively, the return ports to the tank
close and the oil is directed towards gerotor
set (11) which directs the oil towards the steering
cylinder. The volume of fluid discharged is in
direct proportion to the angular movement of the
steering wheel. As from 8° the spool and sleeve
turn at the same speed and constitute a follow-
up system.
30
If the steering is no longer activated, the center-
ing springs push feed sleeve (6) to a neutral
position. The oil from the pump is once again
channelled towards the tank and the cylinder 01
chambers are locked.
5
NEUTRAL POSITION
The spool and sleeve are centered in relation to

each other by the springs. Aligned ports channel
the oil from the pump to the tank (centre open).
The cylinder ports are closed (no reaction), so if
the steering axle strikes an obstacle, no repercu-
ssions are felt at the steering wheel.
MANUAL CONTROL
As soon as an operating fault arises upstream

of the device (engine shut-down during travel,
damage to component, burst pipe), the gerotor
set is automatically converted to a manual emer-
gency pump which ensures closed circuit power-
supply of the steering cylinder.
When the steering wheel is turned, the selector spool turns too. When it reaches 8°, the pin
drives the feed sleeve and the gerotor set by means of the cardan shaft. Under these conditions,
the steering unit operates as a manual pump and discharges the oil towards the steering cylinder.
Pressure depends on the torque exerted by the operator on the steering wheel.
TIMING GEROTOR ASSY.
• Before disassembling for checking, mark the position of the various components.
• When reassembling :
– Position feed ports facing you.
– Mount the gears (1–2) so that the position of one of the rotor (1) teeth (4) corresponds to
that shown in relation to the slot of the cardan shaft (3).
If this timing is not observed, steering tends to turn automatically in the reverse direction to that
of the steering wheel (operates as a motor).
30
01
6
CHECKING AND ADJUSTING RELIEF PRESSURE
The steering system relief pressure is adjusted by the relief valve in the steering unit specification
92 kgf/cm2 (1308 psi). If the relief pressure setting is higher than specification it can cause defects
of the hydraulic hoses, tear the steering cylinder seal, and cause damage to the steering shaft
link. If the relief pressure setting is lower than specification, force excessive is required to turn
the steering wheel.
CHECK
! Loosen the oil filler cap on the hydraulic tank and operate the steering wheel several
times to release the pressure in the hydraulic circuit.
1. Engage the parking brake and put the transmission into neutral.
2. Block the driving wheels.
3. Remove the plug (PT 1/8)) from the fitting on the steering cylinder.
4. Install the hydraulic pressure gauge 0~350kg/cm2 (0~5000psi)
5. Start the engine and run at high idle.
6. Turn the steering wheel and measure the pressure when the relief valve is actuated.
ADJUSTMENT
30
1. Remove plug
01
7
2. Adjust the pressure.

– Specification : 92~97 kgf/cm2 (1308~1380 psi)
– To increase : turn clockwise
– To decrease : turn counter–clockwise
TROUBLESHOOTING TABLE
Steering systems with load sensing
Fault Possible cause Remedy
Steering wheel is heavy • Insufficient oil pressure. • Check the oil pressure.
to turn a pump drive defective. a Replace pump drive.
b Pump is worn out. b Replace pump.
• Pressure relief valve is stuck in • Repair or clean pressure relief

open position or setting pressure valve. Adjust the valve to the
is too low. correct pressure.
• Priority valve spool stuck. • Clean or replace valve.
• Too much friction in the mechan- • Grease/repair axle knuckle pins,

ical parts of the steering system. steering cylinder pins, steering
column bearings.
Check the hydraulic cylinder for
malfunction.
Constant steering • Leaf springs without spring force • Replace leaf springs.
30 is necessary for
straight travel.
(“Snake–like driving”)
or broken.
• Spring in relief valve broken.
• Gerotor assy worn.
• Replace relief valve.
• Replace gerotor assy.
01 • Cylinder scored or piston seals • Replace defective parts.
8 worn.
Neutral position of • Steering column and steering unit • Align the steering column with
steering wheel out of alignment. steering unit.
can not be obtained, • Too little or no end play between • Adjust the end play and if
i.e. there is a steering column and steering unit necessary, shorten the splined
tendency towards input shaft. shaft.
“motoring”. • Pinching between inner and outer • Dismantle the steering unit and
spools. repair as required.
“Motoring” effect. The • Leaf springs are stuck or broken • Replace leaf springs.
steering wheel can turn and therefore have reduced
on its own. spring force. • Dismantle the steering unit and
• Inner and outer spools sticking clean/repair as required
possibly due to dirt.
Backlash • Cardan shaft fork worn or • Replace cardan springs.

broken.
• Leaf springs without spring force • Replace leaf springs.
or broken.
• Worn splines on the steering • Replace steering
column. column/shaft.
Shimmy–abnormal • Air in the steering cylinder. • Bleed steering system, remedy

vibration of steering cause of air ingression.
wheel. • Worn axle knuckles or steering • Replace worn parts.
cylinder pins.
• Leaking relief valve and antica- • Repair/replace relief valve,
vitation valves or broken valve anticavitation valves.
springs. Replace the springs.
Steering wheel can be • Oil is needed in the tank. • Fill with clean oil and bleed the
turned continuously system.
without articulating the • Steering cylinder worn. • Replace or repair cylinder.
steering axle wheels. • Gerotor set worn. • Replace gerotor set.
• Spacer across cardan shaft • Install spacer.
missing.
Steering wheel can be • One or both anticavitation valves • Clean or replace defective valves.
turned slowly in one or leaking.
both direction without • Relief valve leaking. • Clean or replace defective valve.
articulating the axle
wheels.
Steering is too slow • Insufficient oil supply to steering • Replace pump.

30
and heavy when trying unit, pump defective. 01
to turn quickly. • Relief valve setting too low. • Adjust valve to correct setting.
9
• Relief valve sticking owing to dirt. • Clean the valve.
• Check valve in emergency steer- • Clean or replace the check valve.
ing unit stuck open allowing
pressure to return to tank.
(if equipped)
Heavy kick–back in • Incorrect setting of cardan shaft • Correct setting as shown in

steering wheel in both and gerotor set. service manual.
directions.
Turning the steering • Hydraulic hoses for the steering • Reverse the hoses.
wheel articulates the cylinders have been interchanged.
axle wheels in the • Incorrect assembly of cardan • Reassemble correctly
opposite direction. shaft and gerotor.
Hard point when start- • Pump output low. • Check pump flow.
ing to turn the steering • Relief valve set pressure to low. • Inspect relief valves and adjust.
wheel. Replace the valves if defective
• Cross–over relief valve set
pressure to low. (if equipped)
• Priority valve spool orifice blocked. • Clean spool orifice.
• Oil is too thick (cold). • Let motor run until oil is warm.
Leakage at either input • Shaft defective • Replace shaft seal, see service
shaft, end cover, gerotor manual.
set, housing or ports. • Screws loose. • Tighten screws (3±0.3 kgf·m).
• Washers or O–rings • Replace washers or O–rings.
defective.
30
01
10
DISASSEMBLY AND ASSEMBLY
STEERING UNIT
TOOLS
Holding tool
Assembly tool for O–ring and kin–ring
30
02
1
Assembly tool for cardan shaft

Assembly tool for dust seal
Torque wrench 0 ~7 kgf·m (0 ~ 50 lbf·ft)

13mm socket (12 point)
6, 8 and 12 mm hexagon sockets
12 mm screwdriver
2 mm screwdriver
13 mm ring spanner
30 6, 8 and 12 mm hexagon L wrench

Plastic hammer
Tweezers
02
2
The tools listed above are not available from SAMSUNG.

DISASSEMBLY
In repair keep all parts clean. Be sure the

steering unit is thoroughly cleaned and free of
dirt and debris prior to disassembly.
Place the steering unit in the holding tool and

remove the screws in the end cover (6–plus one
special screw).
Remove the end cover, sideways.
30
02
3
Lift the gerotor set (with spacer if fitted) off the

unit. Take out the two O–rings.
Remove cardan shaft.

Remove distributor plate.
Screw out the threaded bushing over the check

valve.
30
02
4
Remove O–ring.
Shake out the check valve ball (φ 8 mm)

Shake out the two anticavitation check valve
balls. (if equipped)
Take care to keep the cross pin in the sleeve

and spool horizontal.
The pin can be seen through the open end of
the spool. Press the spool inwards and the
sleeve, ring, bearing races and needle bearing
will be pushed out of the housing together.
Take the ring, bearing races and needle bearing

from sleeve and spool. The outer (thin) bearing
race can sometimes “stick” in the housing, there-
fore check that it has come out.
30
02
Press out the cross pin. Use the special screw
5
from the end cover.
A small mark has been made with a pumice

stone on both the spool and sleeve close to one
of the slots for the neutral position springs (see
drawing)
If the mark is not visible, remember to leave a

mark of your own on the sleeve and spool
before the neutral position springs are disassem-
bled.
Carefully press the spool out of the sleeve.
Press the neutral position springs out of their

slots in the spool.
30
02
Remove dust seal and O–ring / kin–ring.
6
Screw out the plug using an 8 mm hexagon L

wrench.
Remove seal washers.
Unscrew the relief set screw using an 8 mm

hexagon L wrench.
Shake out the spring and piston. The valve seat

is bonded into the housing and cannot be
removed.
30
02
7
The pressure relief valve is now disassembled.
ASSEMBLY
Before assembly clean all parts very carefully, replace all seals and O–rings, and lubricate all
parts with hydraulic oil.
ASSEMBLE SPOOL AND SLEEVE.
When assembling spool and sleeve only one of two possible ways of positioning the spring slots
is correct. There are three slots in the spool and three holes in the sleeve in the end of the
spool/sleeve opposite to the end with spring slots. Place the slots and holes opposite each other
so that parts of the holes in the sleeve are visible through the slots in the spool.
Place the two flat neutral position springs in the

slot.
Place the curved springs between the flat ones
and press them into place.
30
02
8
Line up the spring set.
Guide the spool into the sleeve.

Make sure that spool and sleeve are placed
correctly in relation to each other.
Press the spring together and push the neutral

position springs into place in the sleeve.
Line up the springs and center them.
30
02
9
Guide the ring down over the sleeve.
! The ring should be able to rotate free of

the springs.
'
Fit the cross pin into the spool/sleeve.

Fit bearing races and needle bearing as

illustrated.
ASSEMBLY PATTERN FOR STANDARD BEARINGS
1 ;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
2
;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
1. Outer bearing race
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
2. Needle bearing
;;;;;;;; ;;;;;;;;
Inner bearing race ∗(thicker)

;;;;;;;; ;;;;;;;;
3 3.
4. Spool
5. Sleeve
30 4
02
5
10
Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into
the bore for the spool/sleeve.
Grease O–ring and kin–ring with hydraulic oil

and place them on the tool.
Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool completely to the
bottom.
Press and turn the O–ring / kin–ring into position

in the housing.
30
02
11
Draw the inner and outer parts of the assembly
tool out of the steering unit bore, leaving the
guide from the inner part in the bore.
With a light turning movement, guide the spool

and sleeve into the bore.
! Fit the spool set holding the cross pin

horizontal.
The spool set will push out the assembly tool

guide. The O–ring and kin–ring are now in
position.
Turn the steering unit until the bore is vertical

again. Put the check valve ball into the hole
indicated by the arrow.
30
02
12
Screw the threaded bushing lightly into the
check valve bore. The top of the bush must lie
just below the surface of the housing.
Grease the O–ring with mineral oil approx.

viscosity 500 cSt at 20°C.
Place the distributor plate so that the channel

holes match the holes in the housing.
Guide the cardan shaft down into the bore so

that the slot is parallel with the connection
flange.
30
02
13
Place the cardan shaft as shown so that it is
held in position by the mounting fork.
Grease the two O–ring with mineral oil approx.

viscosity 500 cSt 20 °C and place them in the
two grooves in the gerotor assy.
Fit the gerotor assembly on the cardan shaft.
! Fit the rotor and cardan shaft so that a

tooth base in the rotor is positioned in
relation to the shaft slot as shown. Turn
the stator so that the seven through
holes match the holes in the housing.
Fit the spacer, if any.
30
02 Place the end cover in position.
14
Fit the special screw with washer and place it

in the hole shown.
Fit the six screws with washers and insert them.

Cross–tighten all the screws in several stages.
3.0 ± 0.3 kgf·m (22 ± 2 lbf·ft)
Place the dust seal ring in the housing.

The dust seal ring must be placed only after the
pressure relief valve has been fitted.
30
02
15
Fit the dust seal ring in the housing using

special tool and a plastic hammer.
Press the plastic plugs into the connection ports.

Do NOT use a hammer.
30
02
16
Fit the piston.
Fit the spring.

Screw in the relief screw with an 8 mm hexagon

L wrench. Adjust the pressure setting on a test
bench or in the vehicle.
Install the plug with dust seal into the housing

using an 8 mm hexagon L wrench.
5.1 ± 1 kgf·m (37 ± 7 lbf·ft)
30
02
17
PRIORITY VALVE
TOOLS
Torque wrench
Hexagon (Allen) socket 8 mm
Hexagon socket (12 point) 22 mm
Open–end spanner 22 mm
Nylon pin
Allen wrench 8 mm
These tools are not available from SAMSUNG.
DISASSEMBLY
30 Screw out the PP plug using the 8 mm hexagon

Allen wrench. Remove the seal ring (alu.)
02
18
Loosen the LS plug using the 22 mm open–end

spanner.
Pull out the plug with seal ring (alu.) and spring.
Press out the spool using the nylon pin.
30
02
19
CLEANING
Clean all parts carefully in cleaning solvent.
INSPECTION AND REPLACEMENT
Check all parts carefully and make any replacements necessary. All seal rings must be replaced.
LUBRICATION
Before assembly, lubricate all parts with hydraulic oil.

ASSEMBLY
Guide the spool into the bore. Use the nylon pin
to center the spool in the bore.
Put in the PP plug. Remember seal ring.
30
02
20
Guide the spring and LS plug into the bore.
Remember seal ring.
Tighten the LS plug with a torque wrench using

a 22 mm hexagon socket.
: 5 ± 1 kgf·m (36 ± 7 lbf·ft)
Tighten the PP plug with a torque wrench using

a 8 mm hexagon Allen socket.
: 5±1 kgf·m (36±7lbf·ft)
30
02
21
BRAKE SYSTEM 40
• 40 – 01 BRAKE AND INCHING SYSTEM

– General
– Brake / inching bleeding
– Disassembly and assembly
B R A K E S Y S T E M
BRAKE AND INCHING SYSTEM
GENERAL
The fork lift is equipped with a manual brake system and an inching system consisting of two
master cylinders and dual pedals. One master cylinder is for the service brakes, and the other
master cylinder operates the inching control valve for the powershift transmission. The service
brakes are the drum and shoe type mounted on the driving axle.
The parking brake is the mechanical lever and cable type connected to the service brakes.
The pedals are mounted on a common shaft and the inching pedal interlocks with the brake
pedal. The first portion of the inching pedal stroke operates the inching control valve for the
power shift transmission to vary the directional clutch pack pressure so that the travel speed
and lift speed can be independent ; then the remaining stroke operates the brake master cylinder.
The purpose of bleeding the brake system is to remove any air trapped in the brake circuit,
which can cause spongy brakes and brake fading.
BRAKE / INCHING BLEEDING
PRECAUTIONS
• Do not mix different types and brands of brake fluid.

• Do not use brake fluid that is contaminated in any way.
• Do not use brake fluid that is cloudy, opaque, an emulsion, separated into layers, or that
contains any moisture.
• Store brake fluid in original container and keep air tight.
40
• Clean off brake fluid containers before opening. 01
• Do not reuse brake fluid containers for any other purpose.
1
• Never reuse brake fluid once it has entered any brake system.
• Use only new brake fluid for bleeding and cleaning of brake/inching system parts.
• Clean off the reservoir before removing cap.
• Do not open the reservoir in a dusty area or where snow, rain, etc., can enter the fluid.
• Clean off the reservoir before removing cap.
• Do not open the reservoir in a dusty area or where snow, rain, etc., can enter the fluid.
• Clean off bleeder screws before bleeding brakes.
• Before bleeding, make all necessary repairs on lines, hoses, cylinders, etc.
• Flush the entire brake system if the fluid in the master cylinders looks dirty, cloudy, or
emulsified, separated into layers, or if it contains any foreign liquid.
! CAUTION :
Do all brake/inching bleeding with the ENGINE OFF.
ADJUSTMENT
BRAKE PEDAL AND INCHING PEDAL (CLUTCH PEDAL)
• Recommended height and free play of the

brake pedal and inching pedal.
Freeplay
4~6 mm
(0.157~0.236 in)
146~141mm (5.75~5.94 in)
! CAUTION :
Incorrect pedal stroke adjustment can cause transmission overheating.
1. Block the wheels and release the parking brake.

2. Fully depress the inching pedal to maximum stroke.
3. Put the transmission directional control lever in neutral position.
4. Accelerate the engine RPM to maximum.
5. Shift the directional control lever to Forward. If the engine RPM decreases, the inching
pedal stroke must be adjusted.
! Be prepared for the vehicle to move!

40 6. Turn the start key to “OFF”, apply the parking brake, and adjust the pedal stop bolt(A,B)
about 6mm. Start the engined and repeat above procedure.
01 If the engine RPM decreased, check the inching valve for the transmission.
2
PARKING BRAKE
The parking brake is operated by the mechanical

force of the toggle type parking brake lever.
• Check if the parking brake works properly when
you apply and release repeatedly.
• Recommended applying force range :
15~30 kgf (33~66 lbf)
SERVICE BRAKES
! CAUTION :
Use SAE DOT–3 brake fluid in the brake and inching systems.
1. Fill the brake system reservoir with brake fluid and maintain full level during the bleeding
procedures.
2. Install a clear vinyl hose onto the axle wheel end bleeder screw and place the other end
in a container.
3. Depress the brake pedal several times to build up the circuit pressure.
4. While depressing the pedal loosen the bleeder screw and observe the flow of brake fluid
for air bubbles.
5. Close the bleeder screw while the brake pedal is still depressed.
6. Repeat the procedure until there are no air bubbles in the flow of brake fluid.
7. Then bleed the opposite wheel end brake assembly.
8. When the air bleeding is completed, fill the brake reservoir to 6 mm (1/4)) from the top.
! Two workers are required for this operation, one depresses the brake pedal and the
other bleeds the system.
INCHING BRAKE
! CAUTION :
Use SAE DOT–3 brake fluid in the inching circuit.
1. Fill the inching/brake system reservoir with brake fluid and maintain full level during the
bleeding procedures.
2. Install a clear vinyl hose onto the transmission inching valve cylinder bleeder screw and
40
place the other end in a container. 01
3. Depress the inching pedal several times to build up the circuit pressure. 3
4. While depressing the pedal loosen the bleeder screw and observe the flow of brake fluid
for air bubbles.
5. Close the bleeder screw while the pedal is still depressed.
6. Repeat the procedure until there are no air bubbles in the flow of brake fluid.
7. When the air bleeding is completed, fill the brake reservoir to 6mm (1/4)) from the top.
After the inching and brake systems are properly bled and pedal freeplay correctly adjusted, the
inching valve operation must be checked and readjusted if necessary.
CONSTRUCTION
! CAUTION :
The service guide for the brake drum and shoe is included in the transaxle section.
The following procedures are for removing the brake inching pedal and master
cylinders from the cowl.
1. Brake master cylinder

2. Capscrew
3. Spring washer
4. Clevis pin
5. Split pin
6. Inching master cylinder
7. Capscrew
8. Inching pedal
9. Brake pedal
10. Pedal pad
11. Nut
12. Bearing–dry
40 13. Brake bracket

14. Brake adapter
15. Washer
01 16. Retaining ring
4 17. Woodruff key
19. Brake pedal rod
20. Brake spring
21. Inching spring
22. Bearing–dry
23. Clevis
24. Bolt
25. Nut
27. Inching rod
28. Nut
(A,B) Inching stroke
adjustment bolt
DISASSEMBLY
1. Prior to disassembling shut off the engine, engage the parking brake and block the wheels.
2. Remove the hydraulic line from each master cylinder.
3. Remove the brake assembly unit from the cowl by removing capscrews (7).
4. Remove the split pins, clevis pin, and capscrews (2), then cylinder (1) and inching cylinder (6).
5. Loosen brake return spring (20) and inching return spring (21).
6. Push retaining ring (16) to one side, and remove the woodruff key.
7. Push retaining ring (16) to opposite side, and remove the woodruff key.
8. Remove brake pedal rod (19) from bracket (13), and disassemble the brake pedal and inching
pedal.
ASSEMBLY
1. Put bracket (13) on a flat surface, and assemble dry bearing (12) to each rod bore in the
bracket.
2. Install retaining rings (16), washers (15), inching pedal (8), brake pedal (9), and adapter (14) to
the brake pedal rod.
3. Assemble woodruff keys (17) to the brake pedal and adapter.
4. Fix the brake spring and inching spring to the bracket.

40
5. Install brake master cylinder (1) and inching cylinder (6) with capscrews (2) 01
: 6~6.5 kgf·m (43~47 lbf·ft). 5
6. Connect the hydraulic line to each cylinder.
7. Fill the reservoir with clean SAE DOT–3 brake fluid.

HYDRAULIC
STSTEM 50
• 50 – 01 MAIN PUMP
– Specification
– Troubleshooting
– Start–up
• 50 – 02 MAIN HYDRAULIC VALVE

– Valve disassembly
– Cleaning, inspection and repair
– Main hydraulic valve assembly
– Hydraulic system pressure setting
– Troubleshooting
• 50 – 03 HYDRAULIC CYLINDERS
• 50 – 04 MAIN HYDRAULIC VALVE (BK16)

– Operation of hyd. control valve ass’y
– Disassembly of hyd. control valve ass’y
– Reassembly of hyd. control valve ass’y
– Special tool of hyd. control valve ass’y
• 50 – 05 MAIN HYDRAULIC VALVE (MC4)

H Y D R A U L I C S Y S T E M
MAIN PUMP
SPECIFICATION
PUMP MODEL P315 (SHI)
DISPLACEMENT 22.8 cc/rev (1.39 cu.in/rev)
MAX. PRESSURE 235 kgf/cm2 (3340 psi)
MAX. SPEED 3000 rpm
50
1. Shaft cover 01
2. Bushing 1
3. Gear housing
4. Port cover
5. Bushing
6. Gear set
7. Thrust plate
8. Channel seal
9. Square seal
10. Lip seal
11. Dowel pin
12. Bolt
13. Washer
MAIN PUMP
DISASSEMBLY
• Clean the pump thoroughly prior to disassembly.

• Secure the pump in a vise with the drive shaft facing downward.
! Use soft material jaw liners, i.e copper or lead.

• Scribe marks on shaft cover, gear housing and port cover prior to dismantling.
• Remove bolts and port cover. Use a soft faced hammer to loosen the cover.
• Remove the square seal and channel seal.
• Remove the thurst plate and gear set.
! Prior to removal mark the driving gear and driven gear so as to mesh the same teeth
when reassembling.
• Remove the gear housing from the shaft cover.

• Remove the lip seal from the shaft cover.
! Do not score the shaft cover seal bore.
ASSEMBLY
• Inspect all parts for damage and wear, replace as required.
! Lubricate all parts prior to installation.

• Install a new lip seal in the shaft cover.
! Use a proper driver to install the seal, make sure the lip faces to the inside of the
50 pump.
• Install square seals to the gear housing.

01 • Install the channel seals to the thrust plates.
• Install a thrust plate with the seal against the shaft cover.
2
! Do not use force to install it, hold the thrust plate level and slide it into position in
the gear housing.
! Install the thrust plates with the alignment marks (grooves) on the outlet side of the
gear housing.
! Also note that the seal is shaped like a “3”, ensure the open side of “3” faces the
inlet port.
• Install the gear set.
! Be sure to align/mesh the marked teeth.

• Install a thrust plate with the seal facing the port cover.
• Install the port cover and bolts. Torque the bolts to specification.
MAIN PUMP
INSPECTION AND ASSESSMENT
Each component should be thoroughly cleaned,

carefully examined and assessed for suitability of
re–use. Below is a guide for inspecting the
various components.
GEAR HOUSING
Inspect the body bore cut–in where both gears

wipe into the body.
The body can only be re–used if the ‘cut–in’ is
bright and polished in appearance and the depth
does not exceed. 0.18 mm (0.007 in).
If the length of the contact traces is a half of
the internal length of the gear hole, it is normal.
The body should be inspected to ensure that
there is no superficial damage which may
adversly affect performance or sealing. Pay
particular attention to the port threads and body
O–ring seal recesses.
GEAR
The gear teeth should be carefully examined to

ensure that there are no signs of bruising, pitting
or that a wear step can be felt.
The journal bearing surfaces should be com-
pletely free from scoring or bruising.
The surface should appear highly polished and
smooth to touch. Gear set should be changed if 50
the φd size is below φ 23.887 mm (0.94 in).
Examine the area where the shaft seal lips 01
run on the drive shaft, this shows up as a 3
polished ring or rings. If a noticeable groove can
be felt or there is scoring the shaft should be
replaced.
MAIN PUMP
THRUST PLATE
The surface of the thrust plate is coated with a

gray colored Teflon. In normal operation, a soft
trace is left at the point of gear contact as
shown in the figure.
A regular trace is not a problem, but any
irregular scratch or roughness felt by rubbing
with a finger nail, or if the thickness is less than
4.894 mm (0.1927 in) the plate should be replaced.
If a hollow dowel pin is damaged it must be

replaced.
If a new pin is loose in the bore of the gear
housing, port cover or shaft cover, that part must
be replaced.
SEALS
All seals should be replaced in reassembly.
50
01
4
BUSHING
New bushings must be installed when the gear

set is replaced.
Always replace the bushings as a set.
MAIN PUMP
TROUBLESHOOTING
Trouble Probable cause Remedy
Pump not Driven in the wrong direction of The drive direction must be changed
delivering fluid. rotation. immediately to prevent seizure.
Coupling or shaft sheared or Inspect auxiliary drive and pump input shaft.
disengaged. Replace the necessary parts.
Fluid intake pipe in reservoir Check all strainers and filters for dirt and sludge.
restricted. Clean if necessary.
Fluid viscosity too heavy to pick Completely drain the system. Add new
up prime. filltered fluid of the proper viscosity.
Air leaks at the intake, pump Check the inlet connections to determine
not priming. where air is being drawn in. Tighten any
loose connections. See that the fluid in the
reservoir is above the intake pipe opening.
Check the minimum drive speed which may
be too slow to prime the pump.
Relief valve stuck open. Inspect and clean the relief valve.
Relief valve spring broken. Replace relief valve assembly.
Damaged internal pump parts. Disassemble and inspect gears, thurst

plates, seals and pump body.
Repair or replace pump.
System relief valve Use a pressure gauge to correctly adjust

Insufficient set too low. the relief valve.
pressure
build–up.
Loss of flow
from pump.
Worn pump parts.
Damaged inlet or pressure line. 50
Pump intake Service the intake strainers. Check the fluid 01
Pump partially condition and, if necessary, drain and flush 5
making blocked. the system. Refill with clean fluid.
noise.
Air leaks at the intake or shaft Check the inlet connections and seal to
seal causing cavitation. (oil in determine where air is being drawn in.
reservoir would probably be Tighten any loose connections and replace
foamy). the seal if necessary. See that the fluid in
the reservoir is above the intake pipe opening.
Pump drive speed too slow or Operate the pump at the recommended
fast. speed.
Auxiliary driveshaft misalignment. Check if the shaft seal bearing or other

parts have been damaged. Replace any
damaged parts. Realign the coupled shafts.
MAIN PUMP
Trouble Probable cause Remedy
External Shaft seal leakage. Damaged or worn seal.

leakage. Damaged or work bushings.
Damaged shaft seal housing bore or
sealing area of output shaft grooved.
Replace parts as required.
Leakage between pump sections. Damaged O–rings or damaged surfaces in

O–ring groove.
Replace parts as required.
START–UP
Whenever it is possible to do so, fill the pump ports with system hydraulic fluid. This will make
it easier for the pump to prime when it is first started.
Self Priming : With a minimum drive speed of 600 RPM, a pump should prime immediately.
Failure to prime within a short length of time may result in damage due to lack of lubrication.
Inlet–lines must be tight and free from air leaks. However, it may be necessary to loosen a
fitting on the outlet side of the pump to purge entrained air.
No Load Starting : These pumps are designed to startup with no load on the pressure ports.
They should never be started against a load or a closed center valve.
50
01
6
MAIN HYDRAULIC VALVE
VALVE DISASSEMBLY
Clean the outside of valve before starting

disassembly.
Position valve as shown and as you remove

each part, arrange it in a line exactly as
removed so reassembly will be easy. On the top
of each spool is a letter designation:
W = Lift Spool
A = Tilt Spool
D = Aux. Spool
Remove the retainer, sleeve and O–ring.
2 ± 0.6 N·m (1.5 ± 0.4 lbf·ft).
50
02
1
Tap lightly on the top of the valve spool to drive

it out of the valve body.
Arrange the parts in the order of removal.
Loosen and remove the bolts on the next

retainer.
Arrange the parts in the removal sequence.
50
02
2
Remove the hydrostat valve
34N·m (25 lbf·ft)

Remove the relief valve. To remove the relief

valve parts, loosen the lock nut and then
remove (turn) the adjusting screw out of the
valve body.
Remove flow control cartridge valve – tilt

function. This screw is left hand thread.
34 N·m (25lbf·ft).
Remove the load hold check valve.
34 N·m (25lbf·ft)
50
02
3
! Important
Arrange the parts in the correct order, be careful not to drop the springs for the
spools and valves during the disassembly and assembly procedure.
Note
The pressure relief setting must be reset after reassembly and installation in the fork lift.
CLEANING, INSPECTION AND REPAIR

• Discard all old seals. Wash all parts in a clean mineral oil solvent and place them on a clean
surface for inspection.
• Carefully remove burrs by light stoning or lapping. Be certain there is no paint or burring on
mating surfaces of valve bodies.
• Inspect valve spools and bores for burrs and scoring. If scoring is not deep enough to cause
objectionable leakage, the surfaces can be polished with a fine oil stone or crocus cloth. If
scoring is excessive, valve body and spool must be replaced. Check the valve spool for freedom
of movement in the bore.
• Check the relief valve for smooth movement in its bore. Valve should move from its own
weight.
MAIN HYDRAULIC VALVE ASSEMBLY

Assembly is in reverse order of disassembly.
Coat all parts with clean hydraulic oil to facilitate assembly and provide initial lubrication.
Petroleum jelly can be used to hold seal rings in place on assembly. Install seal rings and the
seal ring retainer in the grooves in the body of each inlet and center section. Use petroleum
jelly to hold the seals in which they were removed.
HYDRAULIC SYSTEM PRESSURE SETTING

! CAUTION
• To perform this service procedure, it is
recommended that:
• The fork lift is parked on a level
50 surface.
• The park brake is engaged.
• The forks are fully lowered.
02 • The steer & drive wheels are blocked.
4
MAIN VALVE RELIEF PRESSURES:
SF12/15/CMP15 : 193 kgf/cm2 (2750 psi)

SF18/CMP18/20S : 210 kgf/cm2 (2990 psi)
AUXILIARY VALVE RELIEF PRESSURE
(Refer to attachment specifications.)

Adjustable dependent upon application from 70~140 kgf/cm2 (1000~2000 psi).
• Stop the engine
! Loosen the hydraulic tank cap slowly to

release the pressure inside the reservoir.
! Operate the control levers several times
to release the remaining pressure in the
hydraulic piping.
• Remove the plug (PT1/8) at the control valve,

pump port.
• Install a suitable range pressure gauge.
• Start and operate the engine at high idle(max.
rpm).
• Move the tilt control lever to full back–tilt until
over relief pressure reading is obtained.
! IMPORTANT
Do not operate system over relief pressure any longer than necessary to read the
pressure gauge.
Do not exceed the specified pressure setting!
• On the main valve, the main hydraulic system

relief (1) and auxiliary relief(2) are shown in the
figure. To adjust, loosen the lock nut, reset and
tighten lock nut. Turn adjustment clock-wise to
increase pressure. Turn counter-clockwise to
decrease pressure.
50
• Recheck the pressure relief setting to verify it 02
is correct. 5
! Do not exceed the relief valve specification.
! When removing the hydraulic pressure
gauge, release the pressure in the same
way as when installing the gauge.
TROUBLESHOOTING
TROUBLE CAUSE REMEDY
• Leaks at either end of Defective O• rings in valve Replace O• rings.

spool. body.
Spring• centered
spools do not return to Broken springs. Replace springs.
neutral.
Bent spool. Replace with new section of
same size and type.
Foreign particles. Clean system and valve.
Misalignment of operation Check linkage for binding

linkage. condition.
Valve bank improperly set, or Retorque nuts to specified

stuck in base and /or worn. torque.
• No motion, slow or jerky Relief valve not properly set, Repair, clean and readjust.
action of hydraulic system. or stuck in base and/or
worn.
Dirt or foreign particles Disassemble, clean and

lodged between relief valve reassemble.
control poppet and seat.
Valve body cracked inside. Replace valve section.
Spool not moved to full Check travel.

stroke.
• No relief valve action (high Small particle of dirt plugging Remove relief valve and
50 pressure) orifice in relief valve sub•
assembly.
check orifice. If blocked,
clean carefully.
02 Relief valve sub• assembly Install properly.

6 installed backwards.
• Load will not hold. Oil bypassing between spool Replace valve.
and body.
Oil bypassing piston in Repair or replace cylinder.

cylinder.
Spool not centered. Refer to above spool

remedies.
• Load drops when spool is Dirt or foreign particles Disassemble, clean and
moved from neutral to a lodged between check valve reassemble.
power position. poppet and seat.
Scored or sticking check Replace poppet.

valve.
HYDRAULIC CYLINDERS
LIFT CYLINDER
DISASSEMBLY
Prior to disassembly, thoroughly clean the exterior of the cylinder.

Remove the hydraulic oil from the cylinder by stroking the pistion rod to force the oil out.
When overhauling the cylinder, ensure that contamination does not enter the cylinder. The
smallest particles are capable of severely damaging the hydraulic system.
• Hold the cylinder securely in a vise ; do not use

excessive force.
• Remove the gland with a hook wrench.

Carefully pull the gland assembly from the
cylinder tube, and slide it off the cylinder rod.
50
03
1
• After the gland is removed, pull the piston rod

assembly from the cylinder barrel.
HYDRAULIC CYLINDERS
• Remove the piston packing and wear ring from

the piston.
• Remove the retaining ring from the gland, then

remove the dust wiper, bushing, and rod
packing.
Remove O–ring and back–up ring.
CHECKING LIFT CYLINDER
• Carefully wash all parts with clean solvent, and store in a clean place.
• Check whether the piston rod is damaged, minor scratches of the mirror surface can be repaired
50
with a fine oil stone. But it must be replaced in the case of deep score marks.
• Check whether the cylinder barrel is damaged.

03 Replace it in the case of deep scoring or damage.
Check the threads for the gland and port fittings.
2
• Lightly coat all parts with hydraulic oil. If the parts are to be stored for a long time, cover
with a clean rag.
HYDRAULIC CYLINDERS
ASSEMBLY
Install the new retaining ring, dust wiper,

bushing, and rod packing in the gland. Install the
new back–up ring and O–ring.
Install the new packing and wear ring.
Lightly lubricate the piston with hydraulic oil and

carefully push the piston rod into the cylinder
barrel.
50
03
3
Lightly lubricate the gland assembly, then screw

the gland into the cylinder barrel with a hook
wrench. When tightening, don’t damage the seal.
30 ± 3 kgf·m (216 ± 22 lbf·ft)
! Thoroughly test the cylinder for smooth

operation and oil leaks.
HYDRAULIC CYLINDERS
TILT CYLINDER
DISASSEMBLY
Prior to disassembly, thoroughly clean the exterior of the cylinder. Remove the hydraulic oil from
the cylinder by stroking the piston rod to force the oil out.
When overhauling the cylinder, ensure that contamination does not enter the cylinder. The
smallest particles are capable of severely damaging the hydraulic system.
• Hold the cylinder securely in a vise ; do not use

excessive force.
• Remove the gland with a hook wrench.

Carefully pull the gland assembly from the
cylinder tube and slide it off the cylinder rod.
50
03
• After the gland is removed, pull the rod
4
assembly from the cylinder barrel.
HYDRAULIC CYLINDERS
Remove the nut and piston from the rod.

Remove the piston packing and wear rings.
Remove the retaining ring from the gland, and

remove the dust wiper, bushing and rod packing.
Checking
• Carefully wash all ports with clean solvent, and store in a clean place.
• Check whether the piston rod is damaged, minor scratches of the mirror surface can be repaired
with a fine oil stone. But it must be replaced in the case of deep score marks.
• Check whether the barrel is damaged. Replace in the case of deep scoring or other damage.
Check the threads for the gland and port fittings.
50
03
• Lightly coat all parts with hydraulic oil. If the parts are to be stored for a long time, cover
5
with a clean rag.
HYDRAULIC CYLINDERS
Assembly
• Install the new retaining ring, dust wiper,

bushing, and rod packing in the gland. Install
the new back–up ring and O–ring.
• Install the new piston packing and wear ring,

install the piston to the piston rod, and tighten
the nut.
33 ± 3 kgf·m (238 ± 22 lbf·ft)
• Lightly lubricate the piston with hydraulic oil

and carefully push the piston rod assembly into
the cylinder barrel.
50
03
6
• Lightly lubricate the gland assembly, then

screw the gland into the cylinder barrel with a
hook wrench. When tightening, don’ t damage
the seal.
60 ± 6 kg·m (433 ± 43 ft.lbs)

HYDRAULIC CYLINDERS
Thoroughly test the cylinder for smooth operation

and oil leaks.
STEERING CYLINDER
DISASSEMBLY
Prior to disassembly, thoroughly clean the exterior of the cylinder. Remove the hydraulic oil from
the cylinder by stroking the piston rod to force the oil out. When overhauling the cylinder, ensure
that contamination does not enter the cylinder. The smallest particles are capable of severely
damaging the hydraulic system.
• Make a match mark on the cylinder glands,

cylinder tube and cylinder rod, to correctly align
the parts for reassembly.
• Remove the nuts on the cyliner tie rods and
carefully extract each tie rod.
50
03
• Disassemble the gland from the cylinder tube 7
by tapping the cylinder gland with a soft faced
hammer(plastic, mallet).
• Remove the gland, and pull the piston from the
cylinder tube.
• Remove all the seals and packing.
• Inspect the cylinder gland for damage.
HYDRAULIC CYLINDERS
• Confirm whether scratch marks or corrosion is

present inside the cylinder tube.
! A light honing is permissible.
• Check the cylinder gland for damage, and

replace the seal with a new one.
• Check the piston rod and piston surface for

damage.
• If any damage is evident, provided the flaw is
minor it may be polished with fine emery and
crocus cloth. However if the flaw is excessive
50 the part must be replaced.
03
8
Assembly
• Install new seals in the cylinder gland and on
the piston rod assembly.
• Push the piston and the rod assembly into the

cylinder tube.
! Ensure that the match marks are aligned.

HYDRAULIC CYLINDERS
• Install the cylinder gland to the cylinder tube.

Confirm that the gland and tube mating
surfaces are not damaged.
! Ensure that the match marks are aligned.
• Install the tie rods to the cylinder, and tighten

the nuts.
5.0 ± 0.5 kg·m (36 ± 4 lbf·ft)
! Thoroughly test the cylinder for smooth

operation and oil leaks.
50
03
9
MAIN HYDRAULIC VALVE (BK16)
OPERATION OF HYD. CONTROL VALVE ASS’Y
LIFT VALVE
LIFT UP
If you pull the lift lever, valve spool move to up, at that time opening the flow line which is
from pump to lift cylinder, that make to move the lift cylinder.
50
04
1
LIFT DOWN
If you push the lift lever, valve spool move to downward, at that time opening the flow line of
valve inside, which connect lift cylinder head and hydraulic tank, the oil in cylinder return to
tank due to the falling of weight of fork and inner mast.
50
04
2
TILT VALVE
To prevent tilt out, there are 2 kinds of safety valve–Check valve and Tilt lock valve.
Check valve prevent oil reversing that occur when cylinder load is bigger than pump pressure.
And tilt lock valve which is inside of tilt spool prevent tilt out when engine stopped.
TILT OUT THE MAST TO THE FORWARD
If you push the tilt lever, valve spool move down. at that time opening the flow line from pump
to the tilt cylinder head, and pump pressure push the tilt lock valve, and opening flow line of
cylinder rod and tank line that makes tilt cylinder make to tilt out the mast.
50
04
3
TILT IN THE MAST TO THE BACKWARD
If you pull the tilt lever, valve spool move up, at that time opening the flow line from pump to
tilt cylinder rod, and same time cylinder head and tank line open and tilt cylinder move backward.
50
04
4
TILT LOCK
The tilt lever is pushed conditions, suddenly engine stopped, pump oil pressure is “0” which is
pushed tilt lock valve. This time return spring push the tilt lock spool to neutral position. And
tank oil line which is connected with tilt rod, closed. so Mast does not tilt out any more.
50
04
5
RELIEF VALVE
This valve is pilot piston type, and prevent breakdown the pipe and hydraulic components.
and also this valve is keeping hydraulic system pressure.
Relief valve is change about 140kg/cm2 for the one revolution.
Relief valve type Pilot piston type
Max. Pressure of relief valve 350 Kgf/cm2
Used pressure of hyd. control valve 210 Kgf/cm2
Structure
50 1.
2.
Back–up ring
O–ring
9.
10.
Spring
Seal
04 3. Back–up ring 11. O–ring
4. O–ring 12. Plug
6
5. Sleeve 13. Pilot piston
6. Main poppet 14. Main spring
7. Piston 15. Screw
8. Spring 16. Nut
HYDRAULIC SYSTEM
Inner chamber (S2) is filled with

oil through the piston gorifice and
to the area difference (S1) and
(S2) main poppet fmake keep up
theseating condition.
a
When the pressure of cylinder

port (S1) reach to the pressure
setted by main spring, and that
time mpilot piston is opended
and oil flow to the low pressure
b
line “T” through the drill hole of
plug l
Due to the pilot piston mopening

pressure of chamber (S2)
decrease and piston be pushed
to the right and contact with pilot
c
piston that time flow of piston
orifice decrease and pressure of
chamber fall down.
50
04
7
The pressure of chamber (S2) is

lower than pressure difference of
area ratio (S1) and (S2) of cylinder
port, pressure unbalance makes
main poppet (6) goes to right. So,
d
the hydraulic oil of (S1) flow to low
pressure line “T”directly.
DISASSEMBLY OF HYD. CONTROL VALVE ASS’Y
HYD. Control valve ass’y is composed subass’y and parts as follow.

Disassembly limited subass’y and parts.
IN/OUTLET – Main relief valve
– Secondary relief valve

LIFT ASS’Y
– Load check
Flow control – Tilt lock valve

TILT ASS’Y
valve – Load check
AUX. ASS’Y – Load check
END COVER
50 Upper figure base on 3 section valve.

• 4 section valve add one more AUX. ass’y
• 2 section valve composed lift and tilt ass’y, and there has not 2nd pressure adjusting relief
04 valve.
8
Disassembly method Disassembly Picture
1. Hold the nut of side “B” by the socket

wrench. and disassemble the nut and
washer of side “A”.
2. Disassemble each section from the stud

bolt, and put down to the clean working
stand by orderly. and that time the
O–ring of section put down the beside
of disassemble section.
Main relief valve disassemble

3. Disassemble main relief from IN/OUT
section.
Note
To prevent damage of contact face, you
must work on the vise which is adhered
50
alumium or brass or etc.
04
9
Disassembly of secondary relief valve

4. Disassemble secondary relief valve from
lift section.
Note
∗ This work applicable to over 3 section
HYD. control valve.
Disassembly of lift main spool ass’y

5. Hold the section ass’y and vise, and
disassemble socket bolt of spool cab.
Note
6. Disassemble the spool cab.

Disassembled parts put down on the
clean work–stand by disassembly order.
7. Disassemble main spool ass’y from

section body slowley
! Caution
If the spool can not come out smoothly,
50 push in and again pull the spool with

turning.
04
10
Note
• Body and main spool assembled pair fitting
mutually so each one is not exchangable
• Be careful not to mix the body and main
spool.
(You bettor adhere the identification tag.)
8. Hole section reversely and vise, and

disassemble socket bolt. (2 places)
9. Disassemble retainer plate, back–up ring

O–ring.
Disassembled parts be put down on the
clean work-stand by disassembly order.
10. The spool ass’y which is disassembled

on 7 paragraph, is vised with jig
11. Disassemble retainer bolt, and
disassemble spring retainer, shim,
spring, retainer plate, back–up ring,
O–ring.
Disassembly parts be put down on the
50
clean work–stand by disassembly order. 04
11
! Caution
Be careful, Not to come out parts by
spring force.
Note
Disassembly of load check refer to paragraph
26, 27.
Disassembly of tilt main spool ass’y

12. Hold the section ass’y and vise and
diassemble the socket bolt of spool
cap.
Note
13. Disassemble of spool cab.

Disassembled parts be put down on
the clean work-stand by disassembly
order.
14. Disassemble the main spool ass’y from

the section body slowly.
! Caution

turning.
04
12
Note
mutually so each one is not exchangable.
spool.
(You better adhere the identification tag.)
15. Hold the section reversely and vise and

disassemble socket bolt. (2places)
16. Disassemble retainer plate, back-up

ring O–ring.
order.
17. The spool ass’y, which is disassembled

on paragraph 14, is vised with jig.
spring, retainer plate, back–up ring,
O–ring.
50
clean work-stand by disassembly order. 04
13
! Caution
• Be careful, Not to come out parts by
spring force.
• “SHIM”,whick is disassembled on
paragraph 18, is different only tilt
section. so, put down differently.
Note
• Disassembly of loadcheck refer to
paragraph 26, 27.
Disassembly of aux. main spool ass’y

19. Hold the section ass’y and vise and
diassemble the socket bolt of spool
cap.
Note
• To prevent damage of contact face, you
20. Disassemble of spool cab.

order.
21. Disassemble the main spool ass’y from

the section body slowly.
! Caution

turning.
04
14
Note
mutually, so each one is not exchangable.
spool.
(You better adhere the identification tag.)
22. Hold the section reversely and vise and

disassemble socket bolt. (2 places)
23. Disassemble retainer plate, back–up

ring O–ring.
the clean work–stand by disassembly
order.
24. The spool ass’y which is disassembled

on paragraph 21, is vised with jig.
spring, retainer plate, back-up ring,
O–ring.
50
clean work–stand by disassembly order. 04
15
! Caution
Be careful, Not to come out parts by
spring force.
Note
Disassembly of load check refer to paragraph
26, 27.
Disassembly of loadcheck
LIFT, TILT, AUX. is same
26. Hold the section and vise and
disassemble the plug of body upper
with socket of socket wrench.
27. Disassemble plug, spring and check

poppet, and put down on the clean
work-stand orderly.
! Caution
Disassembled check poppet and body
take care not to mix because they are
seated during the using.
50
04
16
REASSEMBLY OF HYD. CONTROL VALVE ASS’Y
HYD. Control valve ass’y composed of following subass’y and components.

Assembly limited needed subass’y and components.
IN/OUTLET – Main relief valve
– Secondary relief valve

LIFT ASS’Y
– Load check
Flow control – Tilt lock valve

TILT ASS’Y
valve – Load check
AUX. ASS’Y – Load check
END COVER
Upper figure base on 3 section valve.

• 4 section valve add one more AUX. ass’y
• 2 section valve composed lift and tilt ass’y, and there has not 2nd pressure adjusting relief
50
valve. 04
17
Assembly method Assembly Picture
Assembly of loadcheck
LIFT, TILT, AUX is same
1. For the assembly, arrange the check
poppet spring, plug by orderly.
! Caution
Confirmed O–ring state by naked eyes.if
it is damaged, replace it.
2. Vise the body, section, and put in the

check poppet through the hole of upper
side by arranged order in 1 paragraph
and next assemble the spring and tighten
the plug by socket wrench with following
torque.
Tightening torque 5.0~6.0 kg·m

Needed Tool Socket HEX.27
! Caution
When assembly the plug, After assemble
the plug 3~5 pitch by hand, use the tool.
Assembly of lift main spool

3. For the assembly, arrange, O–ring,
back–up ring, retainer plate, spring
50 retainer, spring, shim, spring retainer,

retainer bolt orderly.
! Caution
04 Confirmed O–ring state by naked eyes.
18 If it is damaged, replace it.
4. Vise the lift spool by jig.

Assemble the arranged parts orderly and
apply the loctite to the retainer bolt and
tight by socket wrench with following
torque.
Tightening torque 1.4 ± 0.14 kgf · m

Needed tool Socket wrench 5mm
Loctite No. TL 277 or equivalent
5. For the assembly, arrange O–ring, back

up ring, retainer plate, spring washer,
socket bolt orderly.
6. Vise the body and assemble the

arranged parts orderly and tighten the
socket bolt using socket reach with
following torque. (2 places)
Note
Location of assembly is upper spool hole of
2nd pressure relief valve ass’y.

Needed Tool Socket wrench 5mm
7. Hold the body reversely and vise

assemble. The lift spool ass’y refer to
paragraph 4 to the body.
! Caution
This time it is assembled smoothly.
When assembling do not use excessive
50
force and be careful not to damage the
body.
04
19
8. After apply the grease to the return spring

of spool ass’y and tighten the socket bolt
using socket wrench with following torque.
(2 places)

Needed tool Socket wrench 5mm
Assembly of 2nd pressure relief valve

9. Hold the lift section with holder and vise
reversely and assemble 2nd pressure
relief valve with following torque.
Tightening torque 5.0~6.0 kgf · m

Needed Tool Long Socket HEX. 24mm
• This work is limited more than 3 section

HYD. control valve.
Assembly of tilt main spool

10. For the assembly, arrange tilt lock
spool, spring, O–ring back–up ring,
retainer plate, spring retainer, spring,
shim, spring retainer, retainer bolt
orderly.
! Caution
Check the O–ring state which is
assembled on retainer bolt by naked
eyes. If it is damaged, replace it.
11. Hold the tilt spool using jig with holder

and vise in order of paragraph 10, put
the tilt lock spool and spring in to the
spool inside and assemble the other
components orderly and apply loctite to
50 retainer bolt and tighten with following

torque using socket wrench.
04 Tightening torque 1.4 ± 0.14 kgf · m
20
Loctite NO. TL 277 or equivalent
12. For the assembly, arrange orderly,

O–ring, back up ring, retainer–plate,
spring washer, and socket bolt.
13. Vise the body and assemble the arranged

parts orderly and tighten the socket bolt
using socket wrench. (2 places)
Note
Assembly location is spool hole which in
opposite side of gage port.


assemble the tilt spool ass’y refer to
! Caution
body.
15. After apply the grease to the return

spring of spool ass’y and tighten the
socket bolt using socket wrench with

50
Needed Tool Socket wrench 5mm 04
21
Assembly of AUX. main spool

16. For the assembly arrange O–ring back–up
ring, retainer plate, spring retainer, spring,
shim, spring retainer, retainer bolt orderly.
! Caution
Check the O–ring of retainer bolt by
naked eyes.
If it’s damaged, replace it.
17. Hold the Aux. spool using jig with

holder and vise.
Assemble the arrange parts orderly on
paragraph 16, and apply loctite to the
retainer bolt and tighten with following
torque using socket wrench.
Tightening torque 1.4 ± 0.14 kgf·m

Loctite No TL 277 or equivalent
18. For the assembly, arrange orderly,

O–ring, back up ring, retainer plate,
spring washer, and socket bolt.
19. Vise the body and assemble the

arranged parts orderly and tighten the
socket bolt using socket wrench by
orderly. (2 places)
50 Note
Assembly location is the left spool hole,
when you see in front of O–ring groove of
04 body contact area.
22

assemble. The aux. spool ass’y refer to
! Caution
body.
21. After apply the grease to the return

spring of spool ass’y and tighten the
socket bolt using socket wrench with

Assembly of main relief valve

22. Assembl the main relief valve to the
in/outlet section with following torque.
Tightening torque 5.0~6.0 kgf·m

Needed Tool Long Socket 5mm
Assembly of ass’y
23. Assemble the O–ring to the each section
area. and arrage in/outlet, lift, tilt, Aux.
endcover orderly and assemble the stud bot.
! Caution
Take care not to come out the O–ring of
body contact area when stud bolt
assembly.
50
• There are no Aux. valve in 2nd section
04
valve 23
24. Assemble the nut and spring washer with

following torque.
! Caution
• Tightening be done to the diagonal
direction.
• Tightening torque must be devided two
times.
Tightening 1nd 3.0~3.5 kgf · m

torque 2nd 4.0~4.5 kgf · m
Needed Tool Socket HEX. 17mm, 2EA
TESTS OF HYD. CONTROL VALVE ASS’Y
1. CHECK FOR SPOOL MOVEMENT
1) Does the spool move smoothly?

2) Does the spool return to neutral by spring force smoothly?
2. CHECK FOR RELIEF VALVE SETTING PRESSURE
For the pressue check, connect the pressure gauge to the nipple which is assembled tilt
section of Hyd. control valve. and checked followings orderly.
1) Check of main relief pressure.
(1) Relief the valve by tilt in
(2) Close the adjusting bolt of 2nd pressure relief valve slowly
(3) When the pressure can not go up more, this pressure is main relief pressue.
(4) Adjust pressure with adjusting bolt of main relief and close the lock not
(Tightening torque : 2 ~ 0.5 kgf · m)
(5) Change the tilt spool neutral/in two or three times check the adjusted relief pressure
with reliefing.
2) Check the pressure of 2nd relief

(1) Relief the valve by tilt in.
(2) Seeing the pressure of pressure gauge, releasing the adjusting bolt of 2nd pressure
of relief valve and adjust pressure of 2nd relief pressure and close the lock nut
(Tightening torque : 2 ~ 0.5 kgf · m)
(3) Change the tilt spool neutral/in two or three times, check the adjusted relief
pressure with reliefing.
! Caution
50 You must obey the proper pressure which is regulated by “operator manual” because
relief pressure influence to life time of hydraulic components and other parts directly.
04
24 3. CHECK FOR EXTERNAL LEAKAGE OF CONTROL VALVE
Check at unload and high rpm condition.

1) Relief 1~2 minute with lift up and check the external leakage of valve
2) Relief 1~2 minute with tilt in and check the external lealcage of valve
4. CHECK FOR SPOOL LEAKAGE OF CONTROL VALVE
Do the spool in neutral with lift up, tilt in condition check whether cylinder lowering speed
satisfied following spec or not
Test condition ➝ rated load, oil temperature base on 50 ± 5!C
1) Lift : within 20mm/5min

2) Tilt : within 10mm/5min
5. CHECK FOR LOAD CHECK LEAKAGE OF CONTROL VALVE
1) LIFT SECTION
On low idle condition, lift lever be fixed on 1/3 position to the upward.)
This time, check whether lift cylinder lowering or not
2) TILT SECTION
On low idle condition, tilt lever be fixed on 1/3 position toword in
This time, check whether tilt cylinder out or not
6. CHECK FOR LEAKAGE OF TILT LOCK
On max. tilt in condition, spool be in neutral and off the E/G.

Change the spool toward tilt out, and check tilt out or not.
50
04
25
SPECIAL TOOL OF HYD. CONTROL VALVE ASS’Y
For Spool
Clamp
50
04
26
MAIN HYDRAULIC VALVE (MC4)
OPERATION OF HYDRAULIC VALVE
LIFT VALVE
LIFT-UP
If you pull the Lift valve, valve spool will move upwards. At this time, the oil passage from pump to lift
cylinder opens and the lift cylinder will start to work.
Lift-Down
If you push the Lift valve, valve spool will move downwards. At this time, the oil passage in the valve,
which connects the cylinder head and hydraulic tank, opens and the fork and the inner mast will drop due
to their own weights. So the oil in cylinder will return to tank.
The flow regulator valve controls the lifting down speed.
50
05
1
TILT VALVE
TILT-OUT
If you push the Tilt lever, the valve spool will move downwards. At this time, the oil passage
facing tilt cylinder head opens, and the passages facing cylinder rod and tank open as well. So
the tilt cylinder start to work and the mast will tilt out.
TILT-IN
If you pull the Tilt lever, the valve spool will move upwards. At this time, the oil passage facing
tilt cylinder rod opens, and the passages facing cylinder head and tank open as well. So the
tilt cylinder start to work and the mast will tilt in.
50
05
2
RELIEF VALVE
It is a kind of pilot piston type. It prevents the pipe and hydraulic functional parts damaged
against the pressure on hydraulic circuit rising up to dangerous level. It maintains the pressure
level under the specified limit.
The value of Relief valve will be changed as a degree of 130kgf/cm2 per turning of the adjust
screw.
Relief valve type Pilot piston type

Max. Pressure of relief valve 250kgf/
Used pressure of hydraulic valve 210kgf/
STRUCTURE
No. Part name No. Part name

1 Housing 11 Main spring
2 Body 12 O-ring
3 Socket 13 O-ring
4 Main poppet 14 O-ring
5 Plunger 15 O-ring
6 Pilot poppet 16 Back up ring
7 Adjust screw 17 O-ring
8 Nut 18 Back up ring
9 Cap nut 19 Wave washer
10 Pilot spring
15
16
14 1 6 12 10 7 9
50
5 05
3
11
19 2 8 13
17
18
TEST OF HYDRAULIC VALVE
WORKING CONDITION OF SPOOL
- Does the spool work smoothly?

- Does the spool return to neutral position smoothly by the spring force?
PRESSURE OF RELIEF VALVE
When you check the pressure of relief valve, connect the pressure gauge to gauge port on PT
block and proceed as following steps.
PRESSURE OF MAIN RELIEF VALVE
- Tilt in the spool to make relief condition.

- Close the adjust screw of secondary pressure relief valve slowly.
- The main relief pressure can be read at the moment the pressure of pressure gauge stops
to rise. Check the pressure at that time.
- Adjust the pressure by regulating the adjust screw of main relief valve, and close the lock
nut. (Tightening torque: 2 0.5kgf.m)]
- Switch over the tilt spool Neutral/In as 2 or 3 times to make relief condition, and check the
adjusted relief pressure again.
EXTERNAL LEAKAGE OF VALVE
Perform the test without load.

- Make relief for 1~2minutes as Lift-up condition, and check the external leakage of valve.
- Make relief for 1~2minutes as Tilt-in condition, and check the external leakage of valve.
50
05
4
DISASSEMBLY OF HYDRAULIC VALVE
The hydraulic control valve ass'y is constructed as the following sub-ass'ys and parts.
The disassembling procedure will be limited to the sub-ass'ys and parts which must be
disassembled.
PT Block Main Relief Valve
Lift Assy
Hydraulic Control Valve Tilt Assy
Aux. Assy
End Cover
The above structural diagram is based on 3-series valve.

- Supplementary ass'y will be additionally assembled to 4-series valve.
- The replaceable single parts are O-ring and dust seal.
- The other parts can only be replaced as form of sub ass'y.
50
05
5
Disassembly Photo
1. Disassemble the spool cap. Arrange the

disassembled parts in good order on
clean working table.
2. Disassemble the socket bolts on opposite

side (2pcs).
3. Disassemble the spool ass'y from section

body carefully.
If the spool can't be smoothly come out,
push it again and draw out while turning
slowly.
50 If excessive force is applied, the body
may be damaged.
05
6
4. Put the spool ass'y on vice by use of jig.

Loose the space bolt, and remove the
spring seat, spring, seal plate, O-ring, and
dust wiper.
Arrange the disassembled parts in good
order on clean working table.
Disassembly Photo
5. Disassembly of Main Relief Valve

Disassemble the main relief valve from PT
block section.
6. Disassemble the tightening nut of stud

bolt.
Never disassemble the stud bolt with
exception of replacing the section ass'y,
O-ring between section joining faces and
rod check poppet.
7. Disassemble each section from stud bolt,

and arrange them in good order on clean
working table.
At this time, put O-ring between section
joining faces shall be next to relevant
section.
50
05
7
8. Disassembly of Rod Check

Disassemble the check poppet and spring
from the block.
Do not mix the disassembled check
poppet and body, because their seats are
specifically formed while using.
Assembly Photo
1. Assembly of Rod Check

Assemble the check poppet and springs
to section ass'y (3, 4, 5) in good order.
Assemble O-rings to section ass'y (2, 3,
4, 5) in good order.
2. Arrange PT block, lift block, tilt block, aux

block and end cover in that order, and
install the stud bolt.
When installing the stud bolt, pay
attention not to fall off O-rings and springs
among section joining faces.
3. Install the nuts and tighten them.

Tighten them diagonally.
Observe the specified tightening torque.
Tightening torque
M10: 2.7~3.3kgf.m(19.5~23.9lbf.ft)
50 M8: 2.4~2,9kgf.m(17.4~21.0lbf.ft)(2EA)
05
8
4. Put the spool on vice by use of jig.

Install O-ring, dust wiper, seal plate,
spring seat, spring and space bolt in that
order.
Tightening torque
1.8~2,2kgf.m(13.0~16.0lbf.ft)
Assembly Photo
5. Assemble the spool ass'y to section body.

After assembled, it shall be smoothly
operated.
If excessive force has applied while
assembling, the body may be damaged.
6. Install the return cap to return spring of

spool ass'y, and fasten the socket bolts
by use of socket wrench.
Tightening torque
0.9~1.1kgf.m(6.5~8.0lbf.ft)
7. Assemble O-ring, dust wiper and seal

plate on opposite side of return cap, and
fasten the socket bolts.
Tightening torque
0.9~1.1kgf.m(6.5~8.0lbf.ft)
50
05
9
8. Assemble the main relief valve to main

relief valve assembling PT block.
Tightening torque
4.5~5kgf.m(32.5~36.2lbf.ft)
MAINTENANCE 60
• 60 – 01 MAST
– General
– Standard mast
– Full free lift mast
– Triple mast
• 60 – 02 OTHER COMPONENT
– Carriage
– Cylinder racking
– Lift chains
– Forks
– Counterweight
– Lifting, jacking and blocking
M A S T M A I N T E N A N C E
MAST
GENERAL
PRECAUTION
! Before performing any visual inspection or maintenance of the mast, carriage or forks,
strictly adhere to the following :
• Do not reach through the open areas of the mast.
• Do not walk or stand under raised forks.
• Use only hardwood blocks with square cut ends, that are not cracked or damaged.
• Ensure that all chains / slings and lifting equipment is in good condition and of
adequate load rating.
• Read the entire check and adjustment procedure before starting any maintenance or
service function.
Failure to comply with these warnings can result in severe injury.
VISUAL INSPECTION
A visual inspection should be conducted daily, however a thorough inspection of the mast
assembly must be done at a minimum of every 500 hours.
MAST
Check rail roller clearance and wear pattern.

Check mast for alignment, looseness and smoothness of operation.
Check mast mounting brackets and trunnions for loose bolts.
Check hydraulic hoses for leaks and interference with the mast.
CARRIAGE
Check rail to roller clearance.

Check fork bar notches for excessive wear and damage.
Check smoothness of operation.
CHAINS 60
Check for uniform tension. 01
Check for proper lubrication. 1
Check for corrosion, bent or cracked links.
Check chain mounting components for wear and damage.
CYLINDERS – LIFT, TILT
Check for seal leakage.

Check cylinder rods for nicks and scratches.
Check cylinder racking(uneven stroking of lift and tilt cylinder rods).
MAST
CLASSIFICATION ACCORDING TO MAST TYPE
STANDARD 2–STAGE MAST
Construction : An outer and inner rail with dual

lift cylinders.
Free lift : The distance that the carriage can be
raised before the inner rail begins to lift.
This distance 400–500 mm(16 ~ 20 in) is
obtain-ed by making the inner rail shorter
than the outer rail. The carriage moves
at twice the speed of the lift cylinder
rod.
FULL FREE LIFT 2–STAGE MAST
Construction : An outer and inner rail with dual

lift cylinders and a separate
larger diameter hydraulic cylinder
(primary) to raise the carriage.
Free lift : The distance from the lowest
carriage position to the top of the
mast. The inner rail does not begin
to lift until the carriage reaches the
top of the mast.
FULL FREE LIFT 3–STAGE MAST
Construction : An outer, intermediate and inner

rail with dual lift cylinders (secon-
dary) and a separate larger dia-
meter hydraulic cylinder (primary)
to raise the carriage. The inner
rail is raised via the lift chains
60 connected to the outer rail. The
action of these chains is controll-
01 ed by the lift cylinders(secondary)
attached to the intermediate rail.
2
Free lift : The distance from the lowest carriage position to the top of the mast. The inner rail
does not begin to lift until the carriage reaches the top of the mast.
The carriage and the inner rail move at twice the speed of the intermediate rail.
FULL FREE LIFT MAST OPERATION :
Since the diameter of the primary cylinder is larger than the secondary cylinder and the load
on the secondary cylinders is greater by the weight of the inner rail (intermediate rail–3 stage)
primary cylinder and the carriage, the primary cylinder extends first.
MAST
STANDARD MAST
REMOVING AND INSTALLING MAST
REMOVAL
• Park the fork lift in a suitable place, and set the steer wheels and the chassis in line.
• Apply the parking brake, and remove the forks.
• Tilt the mast completely forward.
• Block the steering and driving wheels and turn
the key switch to “ OFF ”.
• Put a drain pan under the rails.
• Disassemble the hose connected between the
M.C.V and the regulator valve.
• Sling the outer rail at the center of the top tie
bar using an overhead crane.
(Before the mast is completely disassembled
from the fork lift, balance the weight so the
rail does not tilt.)
• Apply a small amount of tension by lifting with
the overhead crane.
• Remove the bolt and tilt cylinder mounting pin
on both sides. If the tension of the chain sling
hanging on the overhead crane is not applied,
the mast may fall forward at the last moment,
when the tilt mounting pin is removed.
Be especially careful, pay attention to safety.
• Remove the bolts of the trunnion bracket at the
mast lower mounting.
• Carefully move the mast forward from the fork
lift with the overhead crane.
INSTALLATION
• Carry out the reinstalling of the mast in the

reverse order of removal.
60
• When reconnecting the hoses pay attention to 01
the installation direction of the flow limiting
3
valve and the flow regualtor valve.
! CAUTION
If the flow limiting valve is incorrectly
installed, a hose failure will result in an
uncontrolled drop of the carriage assembly,
causing serious injury or death. : 8.0 ± 2 kgf·m
(58 ± 1.5 lbs·ft)
Loctite#271
MAST
TRUNNION BUSHING
To check the trunnion mounting

• Check for missing, broken, bent, or loose trunnion cap fasteners. Replace any damaged parts.
• Lift the mast 305–610 mm (1–2 ft) and tilt the mast fully forward.
• Check for trunnion bushing or cap wear by inserting a feeler gauge between the trunnion cap
and the axle mounting bushing surface.
• The gap should not exceed 0.75 mm (0.030 in.)
• If the gap exceeds specification the bushing or cap may need replacement.
FLOW LIMITING VALVE
The flow limiting valve is connected directly to one rail lift cylinder and the carriage lift
cylinder(Full free lift mast) to control the descent speed of the cylinder in the event that the
flow regulator valve malfunctions or a hydraulic hose ruptures.
Under normal descent speeds the pressure inside the cylinder and in the hose are approximately
equal. Therefore the flow limiting valve does not operate, and the flow regulator valve controls
the descent speed.
However if the flow regulator valve malfunctions or a hose ruptures, a pressure difference occurs
between the cylinder and the output side of the valve. The pressure in the valve pushes the
plunger in the valve, throttling the output port which reduces the descent speed.
! CAUTION
The valve must be installed with the arrow pointing away from the cylinder.
If installed in the reverse position the valve does not function.
1. O–ring
2. Nipple
3. Nipple stopper
4. Body
5. Spring
60 6. Plunger
01
4
MAST
FLOW REGULATOR VALVE
The flow regulator valve in the hydraulic circuit to the rail lift cylinders(secondary) and the carriage
lift cylinder (primary full free lift mast) is mounted on the mast assembly. This valve regulates
the flow rate of the return oil from the lift cylinders to control the descent speed of the cylinders.
When the return circuit is activated the check valve in the flow regulator valve is closed by the
return oil and all return flow passes though the variable orifice, restricting the flow thereby
regulating the descent speed of the cylinders.
! CAUTION
The valve must be installed with the arrow pointing in the direction of flow to the
cylinder.
1. Housing
2. Tee
3. Valve
4. O–ring
60
01
5
MAST
CHECKING CARRIAGE AND MAST SHIM
• Park the fork lift where the forks can be lifted

to the maximum height.
• Apply the parking brake and set steer wheels
and chassis in line, then place wood blocks at
the front and rear of both steer wheels.
The tilt angle should be 0° and the forks
should be about 50 mm (2.0 in) below the
maximum height. Turn the key switch to OFF.
• Prepare a feeler gauge 0.5mm (0.020 in), and a
“C” type clamp.
• To check the gap, catch one side bearing with

a “C” type clamp. Insert a block at the clamp
contact position to transmit the force equally to
the two bearings without damage and defor-
mation of the rail surface.
• Don’t exceed the tightening torque :
27 kgf·m (195 lbf·ft)
• Put a feeler gauge 0.5mm (0.020 in)
between the rail surface and the bearing
surface on the opposite side tightened by the
“C” type clamp.
• When a feeler gauge is not available, use a
shim of the same specification.
NOTE
Be sure to check rail–to–roller clearance at the tightest point. If a 0.5mm (0.020 in.) feeler gauge
goes in and a 1.0mm (0.040 in.) does not, no shims are needed.
60
01
6
MAST
CHECKING AND ADJUSTING CARRIAGE SIDE ROLLER
It is possible to check the clearance of upper

and lower end bearing of the carriage, but it is
impossible to check and adjust the middle and
side bearing. After checking the carriage upper
and lower end bearing clearance, check the
middle bearing and side roller as follows after
the carriage is disassembled.
• Disassemble the carriage.

• Check and adjust the carriage upper and lower bearing shims using a carpenter's same method
as described for the mast. Ensure that the side thrust roller does not interfere with checking
the clearance.
• Adjust the middle and side roller using a carpenter’s square, as shown.
• Set the square against the upper and lower bearing and adjust (shim) the middle bearing and
side roller to be in line with the vertical edge of the square.
ADJUSTING MAST SHIM
! This job must be done by a qualified

technician.
DISASSEMBLY
To adjust the rail roller clearance the mast must

be partially disassembled as follows :
• Remove the carriage from the mast.
60
01
7
MAST
• Place the drive wheels on blocks high enough

so that the lower end of the outer rail will clear
the floor by 153~203 mm (6~8 in).
• Apply the parking brake and block the steering
wheels.
• Tilt the mast to 0° vertical.
• Place a drain pan under the mast and remove

the tilt cylinder hydraulic hoses.
• Temporarily tie the lift cylinder supply hose to
the outer rail near the overhead guard to
minimize the loss of oil.
• Attach a sling to the inner rail top tie bar and

lift it approx. 203mm (8 in).
• Place two blocks under the inner rail.
• Remove the bolts securing the lift cylinder rods
to the inner rail top tiebar.
• Remove the bolts securing the lift cylinder to
the outer rail support bracket.
• Remove the double nuts and cushion rubber.
• Raise the inner rail using an overhead crane.
• Remove the lift cylinder from the mast.
60 ! When disassembling the lift cylinders, note the number of shims on the end of each
lift cylinder rod.
01 • Remove the blocks under the inner rail and

8 lower the inner rail slowly.
Now the outer rail and inner rail rollers will

be exposed.
• Take out the bearing and shim the rollers as
required.
! Take care that the number of shims

assembled at each side is the same if
possible.
MAST
SHIM INSTALLATION
• Gently pry the rollers off the posts. Pry at different points around the bearing to work it off.
• If the clearance check indicated an even number of shims needed, split the quantity evenly
between the rollers on either side of the rail.
• However if the clearance check indicated an odd number of shims needed, split the quantity
of shims so that the odd number are placed one side and the even number are on the opposite
side. i.e. 3 shims needed, place 2 on the left side roller and 1 on the right side roller.
• Check the rollers and replace if the bearings do not operate smoothly.
• Install the rollers on to the posts using a rubber mallet to firmly seat the roller against the
shims.
REASSEMBLY
• When the shim adjustment is completed, raise

the inner rail with the hoist crane.
• Install the lift cylinders. When fully seated in
the lower mount install the lower lock bracket.
• Install the shims which were removed from the
rod end of the lift cylinders when disassem-
bling, and secure each cylinder rod to the tie
bar with the capscrews.
! Use same quantity shims as removed

from each rod when disassembling.
• Tighten the cylinder clamp bracket and the rubber cushion bolt.
1~2 kgf·m (7~14 lbf·ft)
• Install the hydraulic hoses and sheaves.
• Install the lift chain assemblies.
• Install the carriage.
• Adjust the chain.
• Check the level of the hydraulic oil. Add if required.
• Confirm for the interference by moving the mast up and down.
• Lift cylinder rod end lock capscrew torque : 18.7 kgf·m(135 lbf·ft)
60
01
9
MAST
FULL FREE LIFT MAST
Checking mast shim, carriage shim and adjusting carriage shim procedure is same as that of
the standard mast.
ADJUSTING MAST SHIM
This job must be done by a qualified technician.
DISASSEMBLY

• Apply the parking brake and place the drive
wheels on blocks high enough so that the
lower end of the outer rail will clear the floor
by 153~203mm (6~8 in).
• Tilt the mast 0° vertical.
• Push the lift lever fully forward.
• Attach a sling to the top tie bar of the inner
rail.
• Place a drain pan under the primary cylinder
and disconnect the supply hose.
• Remove the bracket of hose sheave from the
free bar.
• Temporarily tie the supply hose to the upper
side of the outer rail to prevent the excessive
leakage.
• Disassemble the lift chains.
• Lower the inner rail slowly using overhead
crane so that the upper and lower rollers are
exposed.
• Take out the bearing and shim the rollers as
60 required.
! Take care that the number of shims

01 assembled at each side is the same if
10 possible.
MAST
TRIPLE MAST
CHECKING MAST AND CARRIAGE SHIM
The procedure for checking the mast and carriage rail roller clearance is the same as that
described for the standard mast.
60
01
11
MAST
ADJUSTING MAST SHIM
DISASSEMBLY
To adjust the rail roller clearance the mast must be partially disassembled as follows:

• Lower the inner and intermediate rails completely.
• Place the drive wheels on blocks high enough so that the lower end of the outer rail will clear
the floor by 153~203mm (6–8in).
• Tilt the mast to 0° vertical. (Fig 1)
• Place a drain pan under the mast and remove the hydraulic hoses, tubes and sheave
assemblies for the primary (centered mounted) cylinder and the lift cylinders.
(Match mark the hoses if removed from the “limiting valve”)
• Temporarily tie the lift cylinders supply hose to the outer rail.
! Temporarily tie both lift cylinders to the outer rail.

• Attach a sling to the top tie bar of the inner rail and lift it approximately 203 mm (8 in) above
the intermediate rail.
• Place two blocks under the inner rail, then lower it until the rail rests on the blocks.
• Remove the inner rail lift chain assemblies and the capscrews securing the cylinder rods to
the intermediate rail top tie bar.
• Attach the sling to both the inner rail and intermediate rail top tie bars.
• Raise the inner and intermediate rails, remove the two blocks previously installed and place a
1m (3 ft) heavy wood block under the base of both the intermediate and inner rails. Ensure
that the block is large enough to hold both of the rail bases.
• As you raise the rails take note of the shims on the lift cylinder rods.
• Lower the inner and intermediate rails on to the block. Ensure they are firmly seated.
• Attach a sling to a lift cylinder and take up the slack.
• Remove the lower lock bracket from the lift cylinder, collapse the cylinder rod into the barrel
and carefully lift the cylinder out of the mast. (Fig.2)
• Repeat the procedure and carefully remove the other lift cylinder.
• Attach a sling to both the inner and intermediate rail top tie bars, raise the rails, then remove
the support block and lower both rails to the floor. Ensure that both rails are on the floor.
• The intermediate rail lower rollers and outer rail upper rollers are now exposed, shim the rollers
60 as required. (Fig.3)
• Attach a sling to the intermediate rail top tie bar, raise the rail and insert a
01 100×100×610mm(4×4×24 in.) block between the upper or lower tie bars of the inner and
intermediate rails.
12
• The intermediate rail upper rollers and inner rail lower rollers are now exposed, shim the rollers
as required. (Fig.4)
MAST
Fig. 1 Fig. 2
Fig. 3 Fig. 4
SHIM INSTALLATION
The procedure for removing the rollers and installing additional shims is the same as that
described for the standard mast.
REASSEMBLY
• Raise the intermediate rail and remove the block between the upper or lower tie bars of the
inner and intermediate rails.
• Lower the intermediate rail to the floor.
60
• Attach a sling to the top bar of both the inner and intermediate rails, then raise the rails 01
carefully guiding the lower rollers into position. 13
• Continue to raise both rails until a 1m (3ft) block can be placed under the base of both the
intermediate and inner rails. Ensure that the block is large enough to hold both of the rail
bases.
• Lower the inner and intermediate rails on to the block.
Ensure they are firmly seated. Install a safety chain from the inner and intermediate lower tie
bars to the outer rail top tie bar.
MAST
• Attach a sling to a lift cylinder and carefully position it in the mast.

• When fully seated in the lower mount install the lower lock bracket.
• Repeat the procedure and install the other lift cylinder.
• Raise the inner and intermediate rails, remove the safety chain and the support block.
• Carefully lower the rails, guide each lift cylinder rod into the intermediate rail top tie bar,(do
not forget to install the rod shims) and install capscrews to secure the cylinder rod.
18.7 kgf·m (135 lbf·ft)
• Raise both rails enough to place a block under the base of the inner rail, then lower the rails
until inner rail rests on the block.
• Install the lift chain assemblies and the hydraulic hoses and sheaves.
• Remove the support block from under the inner rail and lower the rail completely.
60
01
14
OTHER COMPONENT
CARRIAGE
The standard mast carriage and the full free lift mast carriage are very similar, the only difference
being that the full free lift carriage is operated by a center mounted hydraulic cylinder rather
than the rail lift cylinders.
REMOVAL
• Apply the park brake, place directional lever in neutral and block the steer wheels.
• Adjust the tilt angle of the mast to 0° vertical. (Fig.1)
• Raise the carriage 153~203 mm (6–8 in) then place a heavy pallet under the forks.
• Lower the carriage until the forks rest on the pallet, use two “C” clamps to clamp the forks
to the pallet. (Fig.1)
• On the standard mast continue to lower the lift cylinders until the chain tension is released.
• Turn the start switch to “OFF”
• On the full free lift mast continue to lower the center mounted (primary) cylinder until the chain
tension is released.
• Remove the carriage chain clevis pins from the chain anchors on the rear side of the carriage
(std. mast) or remove the clevis pins at the primary cylinder, pull the chain out of the sheaves
and lay them over the carriage (full free lift mast).
• Raise the inner rail until the carriage upper rollers are clear. (Fig. 2)
• Start the engine, release the park brake and slowly back away from the carriage. (Fig. 2)
60
02
1
OTHER COMPONENT
Fig. 1 Fig. 2
INSTALLATION
• Ensure that the carriage is securely clamped to the pallet.

• Slowly drive the fork lift up to the carriage assembly with the inner rail centered on the carriage.
• Raise the inner rail until it is high enough to clear the carriage upper rollers.
• Tilt the mast until it is at the same angle as the carriage assembly.
• Slowly move the fork lift forward until the inner rail is centered over the carriage rollers.
• Carefully lower the inner rail over the carriage rollers until the rail lift cylinders are completely
collapsed.
• Apply the parking brake, place directional lever in neutral, turn “OFF” the start switch and block
the steer wheels.
• Reinstall the lift chains. Always use new cotter pins.
CYLINDER RACKING
60
02 CHECKING
2
The phenomenon referred to as racking occurs when the stroke of the lift cylinders or the tilt
cylinders are not equal.
Lift cylinder racking–If lift cylinder racking occurs it can be felt when the rail reaches maximum
lift, since there is shock loading on one cylinder when it stops and the other cylinder continues
stroking.
Tilt cylinder Racking–If tilt cylinder racking occurs it can be visibly noticed when tilting reaches
maximum forward or backward position, since there is a twisting motion of the mast as one
cylinder stops and the other continues stroking.
OTHER COMPONENT
ADJUSTING
LIFT CYLINDER
• Raise the forks approximately 100 mm (4 in) off the floor.

• Check the tension of both chains, if necessary adjust so that the tension is equal.
• To adjust lower the carriage until the heel of the forks is 13 mm off the floor. Adjust each chain
anchor until the carriage just starts to lift. Tightening torque of lock nut :
10 kgf·m (72 lbf·ft)
• Raise the lift cylinders to maximum stroke and check if both cylinder rods stop at the same
time.
• If racking occurs even after adjusting the chains, remove the cylinder rod of the lift cylinder
which stopped first (shorter stroke) from the rail tie bar, add shims and reinstall.
• Recheck for racking and adjust shimming if required.
• Tightening torque of cylinder rod lock capscrew : 18.7 kgf·m (135 lbf·ft)
TILT CYLINDER
• Tilt the mast fully forward and fully backward and check it both cylinders start and stop at the
same time.
• If racking occurs adjust the cylinder with the longest stroke.
• Loosen the bolt clamping the rod end yoke and rotate the cylinder rod to shorten the stroke.
(Adjust forward tilt first.)
• When no racking is evident tighten the clamping bolt. Tightening torque 9.5 kgf·m (68 lbf·ft)
LIFT CHAINS
The lift chains are very important components in the mast assembly. The safe, efficient, reliable
transfer of lifting force from the hydraulic cylinders to the carriage (forks) depends on proper care
and periodic maintenance. To obtain maximum chain life, correct chain adjustment and regular
lubrication with the correct lubricant is essential.
LUBRICATING CHAIN
60
02
Inspect and lubricate the chains every 250 hours 3
with a quality chain spray lubricant or SAE 20
grade engine oil.
In adverse working conditions inspect and
lubricate every 50 hours. The lubricant must be
absorbed into the joint and between the links to
gain maximum chain life. Lubricating the outer
surface prevents rust and corrosion. (Fig.1)
Fig. 1
OTHER COMPONENT
CHAIN FAILURES
Excessive chain overload particularly without

sufficient lubrication causes protruding pins and
crushed links. (Fig.2)
Fig. 2
Cracked and broken links are a result of fatigue

caused by exceeding the rated capacity of the
equipment. (Fig.3)
Insufficient or improper lubrication contributes to
this type of failure due to seized joints.
Fig. 3
• Wear
Replace the chain if the chain length is longer than the new chain length by 3% or more.
Always replace the two chains in a set for consistent lift operation.
• Rust (corrosion)
It is very important to protect the lift chain from corrosion whether the equipment is being
used or stored. The corrosion causes cracks in the chain, which reduce the rated capacity
60 of the lift chain.
• Fracture and crack

02 Chain fractures occur because of overloads that considerably exceed the rated capacity of
4 the equipment or by sudden impact loading. The most common reason for chain cracks is
fatigue failure. Replace with new chains when fractures or cracks are found. Always replace
all chains of the equipment at the same time.
• Seized joint
The joints of the lift chain must bend freely. A tight joint is caused by a bent pin and plate,
or rust. Do not repair a chain by cutting out a worn section and joining in a new piece.
OTHER COMPONENT
• Chain anchor/clevis bolt

Check wear, damage, and general condition of the chain anchors. If there is wear in the
anchor or damaged to the clevis bolt thread, replace the anchor assembly.
• Cleaning
It is preferable to clean the chains with a biodegradeable solvent, however if steam cleaned
do not use a caustic solution.
Immediately upon completion, thoroughly blow dry and lubricate the chains.
CHECKING CHAIN TENSION
• Place the mast at 0° vertical.

• Pick up a load and raise the forks approxi-
mately 153mm (6 in).
• Push the chains forward and pull them
backward to check the amount of tension on
each chain.
• If one chain moves more than the other, lower
and adjust the chain anchor bolts for equal
tension on both chains.
• Raise the load and recheck the chain tension,
adjust if required.
• Chain anchor lock nut :
10 kgf·m (72 lbf·ft).
ADJUSTING LENGTH OF LIFT CHAINS
STANDARD AND FULL FREE LIFT 2–STAGE MAST
The standard mast has two chains, one on eash side of the mast anchored from the top tie
bar of the outer rail to the carriage.
The full free lift mast has two chains anchored from the base area of the primary cylinder (center
mounted on the inner rail). 60
• Ensure that the tires are inflated to specification.
• Pick up a rated load (to obtain maximum chain stretch).
02
• Set the tilt angle of the mast to 0° vertical. 5
• Lower the carriage and inner rail completely.
• Adjust the carriage chains so that the heel of each fork is approximately 13mm (1/2″) off the
floor.
• Recheck the chain tension.
• Check anchor lock nut : 10 kgf·m (72 lbf·ft).
OTHER COMPONENT
FULL FREE LIFT TRI MAST
The full free lift 3–stage mast has four chains, 1 set anchored from the base of the inner rail
to the top tie bar of the outer rail, and the other set anchored from the base area of the primary
cylinder (center mounted) to the carriage.
• Ensure that the tires are inflated to specification.

• Pick up a rated load (to obtain maximum chain stretch).
• Set the tilt angle of the mast to 0° vertical.
• Lower the inner and intermediate rails completely.
• Adust the back chains so that the inner rail is 3.1mm (1/8″) above the intermediate rail.
• Next adjust the carriage chains so that the heel of the forks is approximately 13mm (1/2″) off
the floor.
60
02
6
OTHER COMPONENT
FORKS
REMOVAL AND INSTALLATION
• Release the lock latch on the fork, then slide

the fork over the notch in the lower carriage
fork bar.
• Lift the end of the fork, the lower fork hanger

will separate from the lower carriage fork bar.
• Place a block of wood under the heel of the
fork.
• Press the end of the fork downward, the upper

fork hanger will disengage from the upper
carriage fork bar.
! CAUTION
When the fork disenages it is not
supported by the carriage and can fall to
the side.
60
02
7
Repeat the above procedure to detach the other fork.

Installing the forks is carried out in the reverse order of removal.
OTHER COMPONENT
INSPECTION
The forks should be inspected regularly to ensure component integrity.
VISUAL INSPECTION
• Fork Alignment : Compare fork arms to be sure they are straight, on the same plane (level),
and the same length.
• Fork Latch : Check for damage and holding ability.
• Fork Stops : Inspect the carriage fork stop for wear and or damage.
• Unusual Wear : Check for visible wear caused by improper operation or abuse.
• Physical Damage : Check for impact damage which could weaken the forks.
• Cracks : Inspect the forks for cracks at the heel, toe, and hanger areas.
FORK WEAR AND HEEL WEAR
Industrial Standards require that a fork be removed from service when the blade or heel thickness
is reduced by 10% from its original thickness.
• Use a pair of calipers (fork wear calipers are recommended) to gauge the thickness on an
unworn portion of the arm.
Move the calipers to the worn, heel area of the fork and make a measurement.
If the heel is 10% smaller than the arm, the load capacity could be reduced by 20%. A
3,500 kg (7700 lbs.) capacity fork with 10% wear can only safely handle 2,800 kg (6170 lbs.)
FORK FATIGUE
• Fatigue cracks normally start in the heel area or on the underside of the top hanger.
If cracks are found, the fork should be replaced. Dye penetrants or magnaflux can be used
for a more accurate inspection.
FORK ALIGNMENT
60 • Park the fork lift on a flat, even surface, tilt mast to vertical position, and set forks
25–50 mm (1–2 in) above the ground.
02 • Compare fork arms to be sure they are straight, on the same plane(level), and the same length.
• Measure the distance from the fork tips to the ground. The height difference between the forks
8
tips should be no more than 3% of the fork length. For example, a 1070 mm (42 in) fork should
not vary more than 30.5 mm (1.2 in) up or down from its mate.
• If the fork tips are not aligned within the specified 3% difference, the cause of the problem
must be determined and corrected before returning the unit to service.
If replacement is necessary, always replace the forks in a set.
OTHER COMPONENT
FORK BENDING
Overloading, glancing blows against solid objects, or picking up loads unevenly can bend or twist
a fork. Use the following procedure to check for fork bending.
• Place a 50 × 100 × 6100 mm (2 × 4 × 24 in) wood block flat on the fork. Make sure the block is
not resting on the heel radius.
• Set a carpenter's square on the block against the fork shank.
• Check the fork 508 mm (20 in) above the blade to make sure it is not bent more than
14.5 mm (0.6 in) at the maximum.
• If blades are bent over the 14.5 mm (0.6 in) allowance they should be replaced as a set.
60
02
9
OTHER COMPONENT
COUNTERWEIGHT
The counterweight should be inspected regularly to ensure that it is securely mounted and for
cracks, particularly around the mounting bolts and tow pin areas.
! CAUTION
Do not operate the fork lift without a counterweight or with loose mounting bolts.
Failure to comply can result in severe injury or death.
REMOVAL
! CAUTION
To lift the counterweight use wire ropes or chains that are certified and in good
condition and of adequate load rating and length.
! Stand clear of the counterweight as it is being hoisted, moved, or mounted.
• Install two eye bolts of adequate size and load

rating into the counterweight.
• Connect the lift chains or wire rope slings to

the eye bolts and using an overhead hoist of
60 sufficient lifting capacity slowly lift the chains

until the slack is removed.
02
10
OTHER COMPONENT
• Remove the mounting capscrews, then raise

the counterweight from the fork lift frame.
• Slowly lower the counterweight on to a sturdy

pallet. As a precaution block the counterweight
to prevent it from shifting when the pallet is
moved.
INSTALLATION
Installing the counterweight is the reverse procedure of removal.
• Install the shims in the original position, or set

the counterweight on the frame and determine
the thickness of shims required (1).
• Remove the counterweight and install the

shims on the frame.
• Set the counterweight on the frame, and adjust

capscrew (2) to level the counterweight. Lock
the jam nut.
60
02
• Insert the mounting capscrews (3) and install washer (4) as required between the frame plate 11
and counterweight.
• Tighten mounting capscrews to specification.

Apply loctite #277 : 45–50 kgf·m (325~362 lbf·ft)
OTHER COMPONENT
LIFTING, JACKING AND BLOCKING
! CAUTION
Do not raise the fork lift by jacking on the counterweight.
Only use a hydraulic jack that is certified, in good condition and of adequate load rating.
SAFE PARKING
Carry out the following procedures first before raising and blocking the machine.
• Park the fork lift on a hard flat surface such a as concrete floor without gaps or holes.
• Put the mast to the vertical position, and lower completely the forks or attachment.
• Put all control levers in neutral position and turn the start key to “OFF”.
• Engage the parking brake and block the wheels.
LIFTING THE DRIVING WHEELS
Use the mast to lift the driving wheels from the floor.
• Start the engine, and tilt the mast backward

completely. If needed, lift the mast a little for
2nd stage, and turn the start switch key to
“OFF”.
60 • Put a hardwood block 100 × 100 mm (4 × 4in.)

below the mast rail. Set an iron plate approxi-
02 mately 6.4 mm (1/4″) thick on each wood block.
12
OTHER COMPONENT
• Turn the start key to “ON”, and tilt the mast

forward completely.
Release the tilt control lever, and check the
gap between the drive wheels and floor.
• Turn the start key to “OFF”.
• Confirm that the support blocks under the mast

rails are securely positioned.
• Carry out the above procedures in reverse order to remove the support blocks.
60
02
13
OTHER COMPONENT
LIFTING THE STEERING WHEELS
PARK THE FORK LIFT SAFELY
• Install the jack under the rear part of the fork

lift frame.
! Do not install the jack under the counter-

weight.
• Raise the fork lift just enough to conduct

repairs.
• Place hardwood blocks under both sides of the
frame close to the steering wheels to ensure
maximum stability.
• Put an equal amount of blocking under each
side to keep the fork lift horizontal.
• The length of the blocking should be equal to
the width of the fork lift.
• Lower the fork lift to the blocks and confirm
machine stability prior to performing any repairs.
When repairs are completed lower the steering wheels to the floor, by carrying out the
procedure in reverse order.
60
02
14
OTHER COMPONENT
LIFTING THE ENTIRE FORK LIFT
! CAUTION
SIDE–TO–SIDE TIPOVER. When jacking the side be sure the mast is lowered fully and
do not raise one side of the fork lift more than about 50 mm (2 in) higher than the
other, to avoid tipping it over laterally.
END–TO–END TIPOVER. If the mast and transaxle are removed while the fork lift is
blocked up, it will tip backwards due to the heavy counterweight. Both mast and
counterweight must be removed before attempting to raise the fork lift for transaxle
removal. The back of the unit must be supported by blocking under the steer axle to
prevent movement.
The reverse is also true. If the counterweight is removed while the fork lift is up on
blocks, the weight of the mast and transaxle will cause it to tip on the front blocks
and fall forward.
• Place the jack under the side frame near the center of the fork lift. Get as close as possible
to the point of balance.
! CAUTION
Ensure that the jack is properly
positioned under the side frame.
• Carefully lift one side of the fork lift at a time,

to a maximum height 150 mm (6 in.)
! CAUTION
When raising the fork lift do not exceed
the point of stability.
The fork lift could tip over causing
serious injury or death.
60
02
• Place the blocks under the side frame close to 15
the driving wheels and steering wheels for
maximum stability.
• Lower the fork lift on to the blocks and move
the jack to the opposite side. Repeat the lifting
procedure.
• Use the same size blocks under each side, so
the fork lift will be level and have maximum
stability.
OTHER COMPONENT
• When working on components other than the

drive axle or steering axle raise the fork lift and
put wheel cradles of adequate load rating and
stability under the wheels.
• Lower the fork lift in the reverse order of the lifting procedure.
To prevent side–to–side tipover, lower one side of the fork lift at a time by 50 mm(2 in) then
repeat the process on the opposite side.
60
02
16
CIRCUIT DIAGRAM 70
• 70 – 01 HYDRAULIC & ELECTRIC CIRCUIT DIAGRAM

– Hydraulic circuit diagram
– Electric circuit diagram (for LPG & gasoline engine)
– Electric circuit diagram (for diesel engine)
C I R C U I T D I A G R A M
HYDRAULIC & ELECTRIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
70
01
1
ELECTRIC CIRCUIT DIAGRAM (FOR LPG & GASOLINE ENGINE)
1. Battery
4 2.0W
2. Start motor
AA
3. Relay
WNCT 22mm2 4. Alternator
Y
SLOW-BLOW 800
FUSE (40,60)
40A
6. Distributer
1A 5.0R
60A
7. Start switch
F4(10A) F10(5A) F1(10A) F11(15A)
8. Fuse box ass'y
BATTERY 11 1B
5.0R 5.0W
1.25L 51 L
B
9. Cluster
14 R
GY RW
YG
Z1 136
GBr
143 105 10. LPG sensor
10 5.0W CLUSTER 4 16 12 1 8 2 S/W-P.C.B
S 5.0R OFF
B+ BR C ACC IGN
CHECK SW 11. Water temp sender
B 9 2X3.0W HOUR
C
ON
START
50 METER W/TEMP FUEL T/M
OIL
PRE
ENG CHARG T/M
OIL
PRE
OIL
TEMP
PARK T/M
WARN GLOW T/SIG T/SIG
-L -R
ILL.
12. S/W–oil press
E
3.0W
50A
3.0W
50A 13. T/M oil temp sw
7 1.25BW 14 UNIT
CRANKING MOTOR
DC 12V.1.2Kw
7 3 10 11 6 17 15 9 13 GND 5
14. Parking brake sw
B+ 5 70A
1.25RG 725
R 109
A 1.25RW
H I
GY
15. Rear work lamp
H I
L 12 1.25RB
792 Z2 17. T/sig. lamp
S 32 1.25W YG Y
I.C
53
YR
58
YL
63
YW
55 70
YB 18. Head lamp
REG
ALTERNATOR W/TEMP FUEL

SENSOR E/OIL
T/M
OIL PARK
19. Combi. sw
DC 12V,65A 3 TEMP
DISTRIBUTOR
1 4 21. Combi. lamp ass'y
2
IGNITION
COIL
22. S/w–brake stop
04 05 03 08 014
B B B B B
23. Flasher unit
24. Directional lever
1 2 3 4 42 6 7 8 9 11 10 12 13 14
25. Relay–3 point
26. T/M solenoid
27. Relay–3 point
1.25R 28. Back buzzer
AA 801
S 0.85R
801A
RG
30
29. Horn relay
RW 121A ANTENNA
30. Horn sw
F14(15A) F9(10A) F3(10A) F7(10A) F5(10A)
F12(20A) F13(10A)
7.5A
31. Horn
2.0R 100 700 32. Beacon lamp
R DIRECTION 1.25RY RADIO &
131 LEVER
101 2.0RL LW 132
B+
FLASH B SOL.
-F
SOL.
-R NEU
551
R
501 1.25GB 201 1.25R 401 1.25R
301 1.25L L
307
CASSETTE ROOM
33. Heater switch
L UNIT LAMP
POWER RELAY
B T H LH FU RH
E FWD
HEATER SW
P C E B+ L H E W 34. Heater
A OFF LH NEU OFF
NEU
RG REV B+ A C 1ST P 035A
B
807
L
808
B
805
G 35. Wiper & Washe switch
RH OFF
151 2ND
HZR POWER RELAY 719-2 719-1
1ST TURN
LW L 720-1
GY
750
G 1.25RB
202 2ND LB
BR
SPEACKER
36. Wiper motor & BRKT. ass’y
302 305 033
308
S 555
LR
502
G
503
1.25GR
402
LW B
37. Washer pump
730 719 720 809 G
1.25L
B RW 1.25L 1.25GY
G LR
38. Cassette
303 302
L X
70
SPEACKER
YL 736 732 RG
BEACON 403 39. Antenna
R BACK LAMP 1.25LR
1.25 D3 D4
1.25RW
111 RG 123 YR 135
1.25RW RW YR
121 122 141
W Y RG
134 102 152
Y RG W
103 153 142
UP
ALARM 40. Speaker
Y 737 733 RY
T/SIG TAIL TAIL STOP C
REAR LIC T/SIG HEAD HEAD T/SIG STOP T/SIG
1.25GB
713
HORN M 41. Room lamp
WORK
010 015 016

LH FRT
017 018
RH FRT
019 020
LH COM
021 022
RH COM
023 024 025

028 029
030
1.25B
POWER RELAY
RW
Z1 034
1.25B
031
B
HEATER
032
1.25B
032
0.85B
035
1.25
42. Slow-blow fuse 01
B 1.25B B B 2.0B 1.25B B B B B B B 791
B B
RB
793
B
09
B
010
3 a
031 Z2
1.25B
15 17 18 19 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41
30
ELECTRIC CIRCUIT DIAGRAM (FOR DIESEL ENGINE)
1. Battery
2. Cranking motor
3. Timer
4. Relay
5. Alternator
6. Timer(lsec)
7. Key switch
8. Air heater
9. Fuse box
10. Eng. stop sol
11. Cluster
12. Fuel sender
13. Water temp sender
14. Oil press switch
15. T/M oil temp S/W
16. Micro switch
17. Rea work lamp
18. Licence lamp ass’y
19. T/sig. lamp
20. Head lamp
21. Combi. S/W
22. Combi. lamp
23. Switch–brake stop
24. Flasher unit
25. Directional lever
26. Power relay
27. T/M Solenoid
28. Back–up alarm
29. Horn Relay
30. Horn S/W
31. Horn
32. Beacon lamp
33. Heater S/W
34. Heater
35. Wiper & washer S/W
36.
37.
38.
Wiper motor & BRKT ass’y
Washer pump
Cassette
70
39. Speaker 01
40. Antenna
5
41. Room lamp
42. Slow-blow fuse
43. Relay-solenoid

CMP158 SM687

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CMP158 SM687

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SF12-20SD/L/G,SF15-20SLC

RATED CAPACITY : 1200~2000kg

Manufactured by #40–1, Ungnam-Dong,

Revision Revision Revision Revision Revision

00–01–10 01–04–10 10–05–90 10–07–18 15–06–10

00 Revision Revision Revision Revision Revision

2 15–07–27 15–12–12 (20–03–20) 50–02–30 50–05–90

HOW TO READ THIS MANUAL

CHAPTER AND SECTION

Section number (01 : Structure and function)

Chapter number (10 : Engine)

For the revision status in this manual, refer to REVISION HISTORY.

Symbol Item Remarks

Special safety precautions are necessary when

! Special technical precautions or other precautions for

Tightening Places that require special attention for the tightening

Places that require proper tools used in assembling

Adhesive Places to be applied with adhesive.

Lubricating Places where oil or lubricant must be added.

SAFETY CLOTHES AND HELMET

• Wear the specified work clothes in the correct manner.

00 PREPARE FOR EMERGENCIES

HANDLE FLUIDS SAFELY–AVOID FIRES

• Handle fuel with care it is highly flammable.

DISPOSE OF FLUIDS PROPERLY

• Improperly disposing of fluids can harm the

relevant environmental protection regulations

AVOID HARMFUL ASBESTOS DUST

• Unexpected machine movement can cause

USE TOOLS PROPERLY

• Use a tool only for its designed application.

• Turn the engine OFF, remove the start key,

• Illuminate your work area adequately but safely.

USE HANDHOLDS AND STEPS

• Never operate with wet or oily hands and feet.

OPERATE FROM THE OPERATOR’S SEAT

• Do not operate the fork lift from any place

• Hot coolant can burn you. Let it cool down.

AVOID HIGH-PRESSURE FLUIDS

• When raising heavy components, use a hoist or crane.

• When working on the battery, wear goggles or

• Keep sparks, lighted matches, and open flame

• Battery posts and cables touched by metal

• If water gets to the electrical system, abnormal

00 CAUTIONS DURING OPERATION

• Do not allow anyone to stand or walk under

ROTATING PARTS / ALIGNING HOLES

• Never touch rotating parts such as the fan

NEVER RIDE ON FORKS

• Never use the forks to lift people.

PINCHING AND FALLING

• Do not add air pressure immediately to the

• The tire must be inflated by trained personnel

00 ! IN CASE OF TIP – OVER

! the fork lift is improperly operated.

joule (J) × 0.239 = calorie × 4.19 = J

meter per sec2 (m/s2) × 3.28 = ft/s2 × 0.305 = m/s2

kilometer per hour (km/h) × 0.62 = mph × 1.61 = km/h

BHP × 5252 R.P.M. = TQ (lb·ft) TQ × R.P.M. 5252 = B.H.P.

°C = (°F – 32) v 1.8 °F = (°C × 1.8) + 32

l /min (dm3/min) × 0.264 = US gal/min × 3.785 = l /min

Note : ( ) Non–SI Unit