August 2 0 0 8 SERVICE M ANUAL SERVICE M ANUAL for HYUNDAI HEAVY INDUSTRIES CO.,LTD. for HYUNDAI HEAVY INDUSTRIES CO.,LTD. Pub. No. Pub. No. 99616-25000 99616-25000 Printed in Japan August 2 0 0 8 Pub. No.
INTRODUCTION This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
INTRODUCTION How to use this manual This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use).
INTRODUCTION Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured. Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance. Therefore, the values shown are not in agreement with the design values. Limit means that, if this value is reached, the part must be repaired or replaced with a new part.
INTRODUCTION Safety Cautions WARNING Fire and explosion Keep flames away Care about fuel, oil and exhaust gas leakage Store fuel and engine oil in a well ventilated designated area. Make sure that the caps of fuel and engine oil containers are tightly closed. Do not use flames, do not smoke, and do not work near a heater or other fire hazard where fuel or oil is handled or when cleaning solvent is being used for washing parts. Wipe off spilled fuel, oil and LLC immediately and thoroughly.
INTRODUCTION WARNING Stay clear of all rotating and moving parts Install protective covers on rotating parts Lockout and tagout Make sure the protective covers for engine rotating parts are properly installed as intended. Repair loose or damaged protective covers as necessary. Never remove the covers guarding personnel from rotating parts, when the engine is operating.
INTRODUCTION WARNING Be careful of burns Do not touch the engine during or immediately after operation Do not touch the engine during or immediately after operation to avoid risk of burns. To conduct maintenance and inspection work, wait until the engine has cooled sufficiently, checking the temperature gauge. Slowly and carefully open radiator cap Never attempt to open the radiator cap while the engine is running or immediately after the engine stops.
INTRODUCTION WARNING Be careful of falling down Lift engine correctly To lift the engine, always use a correct wire rope capable of withstanding the engine weight. Attach the wire rope to the lifting hangers provided on the engine using a correct sling. During lifting process, keep the engine in a well-balanced position by taking the center of gravity of the engine into consideration.
INTRODUCTION CAUTION CAUTION Service battery When abnormality occurs Handle the battery correctly Stop overheated engine after cooling run • Never use flames or allow sparks to generate near the battery. The battery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity could cause an explosion. • Do not use the battery the fluid level of which is lowered below the lower limit line. Sustained use of the battery could result in an explosion.
INTRODUCTION CAUTION Other cautions Modification of engine prohibited Warming-up operation Unauthorized modification of the engine will void the manufacturer’s warranty. Modification of the engine may not only cause engine damage but also produce personal injuries. After starting the engine, run the engine at low idling speeds for 5 to 10 minutes for warming-up. Start the work after this operation is completed. Warm-up operation circulates the lubricant through the engine.
INTRODUCTION Maintenance of air cleaner or pre-cleaner The major cause of abnormal wear on engine parts is dust entering with intake air. Worn parts produce many problems such as an increase of oil consumption, decrease of output, and starting difficulties. For effective removal of dust from intake air, conduct maintenance of the air cleaner according to the following instructions. • Do not conduct maintenance of the air cleaner/precleaner while the engine is operating.
INTRODUCTION CAUTION About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened. Replace damaged or fractured labels with new ones.
GENERAL CONTENTS Group Name Contents Group No.
GENERAL 1. External view...................................1-2 2. System flow diagrams .....................1-4 2.1 2.2 2.3 2.4 Fuel system - flow diagram ...................... 1-4 Lubrication system - flow diagram ........... 1-4 Cooling system - flow diagram................. 1-5 Inlet and exhaust system - flow diagram.. 1-5 3. Engine serial number location.........1-6 4. Main specifications ..........................1-7 5. Tips on disassembling and reassembling.................................1-10 5.
GENERAL 1.
GENERAL S6S-Y3T62HF Oil cooler Magnet valve (Stop solenoid) Oil level gauge Fuel filter Water pump (Coolant inlet) Coolant drain plug Flywheel Rear Front Fuei injection pump Oil filter Relief valve Oil drain plug Engine left view S6S-Y3T62HF Oil filler Turbocharger (Exhaust outlet) Air inlet Oil filler Coolant outlet Hanger Hanger Thermostat case Rear plate Alternator Rear Front V-belt Damper Starter Oil pan Engine right view 1-3
GENERAL 2. System flow diagrams 2.1 Fuel system - flow diagram Fuel filter Fuel inlet Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel outlet Fuel injection pump Fuel system - flow diagram 2.
GENERAL 2.3 Cooling system - flow diagram Thermostat Cooling outlet Oil cooler Cylinder head Bypass hose Water jacket Water pump Cooling inlet Cooling system - flow diagram 2.
GENERAL 3. Engine serial number location The engine serial number is stamped on the right side of cylinder block.
GENERAL 4. Main specifications Table 1-1 Main specifications (1 / 3) Engine model S6S-Y3T61HF Type Water cooled, 4 cycle diesel engine, turbocharged No. of cylinders - arrangement 6 cylinder in-line Combustion system Swirl chamber type Valve mechanism Overhead Cylinder bore × stroke 94 × 120 mm [3.70 × 4.72 in.] Displacement 4.996 L [305 cu. in.] Compression ratio Main specification 22.0 : 1 ASTM diesel fuel oil No.2-D (JIS K2204 gas oil specification No.
GENERAL Table 1-1 Main specifications (2 / 3) Engine model S6S-Y3T62HF Forced circulation type (pressure feed by oil pump) Lubricating method Standard Engine oil Engine oil capacity Type Speed ratio to crankshaft Lubrication system S6S-Y3T61HF Oil pump Discharge capacity Type Relief valve Valve opening pressure Class CF-4 oil SAE No.30 (API service classification) Engine total: approx. 16.5 L [4.36 U.S. gal.] (approx. 15.5 L [4.10 U.S. gal.] in oil pan) Trochoid 0.74 38.7 L [10.22 U.S. gal.
GENERAL Table 1-1 Main specifications (3 / 3) Engine model Voltage - polarity M008T60373 Pinion meshing type Pinion shift Output 24 V - 5 kW Qty Ring gear and pinion ratio Type Electrical system S6S-Y3T62HF 24V - negative (-) ground Model number Starter S6S-Y3T61HF 1 10/122 3-phase alternating current, with rectifier Output 24 V - 35 A Speed in use to 8000 min-1 Alternator Rated generating speed 5000 min-1 Permissible speed 10000 min-1 Speed ratio to crankshaft Type 1.
GENERAL 5. Tips on disassembling and reassembling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. The manual also specifies the special tools that are required for the work, and the basic safety precautions to follow when working. Note that this manual does not exhaustively cover potential hazards that could occur during maintenance, inspection and service work of engine.
SERVICE DATA 1. Maintenance service data ...............2-2 1.1 1.2 1.3 1.4 1.5 1.6 1.7 General .................................................... 2-2 Basic engine ............................................ 2-3 Fuel system.............................................. 2-6 Lubrication system ................................... 2-6 Cooling system ........................................ 2-7 Inlet and exhaust system ......................... 2-7 Electrical system ......................................
SERVICE DATA 1. Maintenance service data 1.1 General Table 2-1 Maintenance service data table - General Inspection point Nominal Standard Limit 2570 ± 50 min Minimum rotation speed (No-load) 820 ± 25 min-1 3.2 MPa {33 kgf/cm²} [469 psi] or more 2.8 MPa {29 kgf/cm²} [412 psi] or less Rotated speed at 1500 min-1 0.3 to 0.5 MPa {3 to 5 kgf/cm²} [43 to 71 psi] 0.15 MPa {1.5 kgf/cm²} [21 psi] or less Idling speed 0.10 MPa {1.0 kgf/cm²} [14 psi] or more 0.05 MPa {0.
SERVICE DATA 1.2 Basic engine Table 2-2 Maintenance service data table - Basic engine (1 / 4) Inspection point Rocker Nominal Standard Rocker bushing inside diameter ø 19 [0.75] 19.010 to 19.030 [0.7484 to 0.7492] Rocker shaft outside diameter ø 19 [0.75] 18.980 to 19.000 [0.7472 to 0.7480] Clearance between rocker bushing and shaft Clearance between valve stem and guide 0.010 to 0.050 [0.0004 to 0.0020] 0.070 [0.0028] Inlet ø8 [0.31] 7.940 to 7.955 [0.3126 to 0.3132] 7.900 [0.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (2 / 4) Inspection point Nominal STD Outside diameter (at piston skirt) 0.25 [0.0098]/OS ø 94 [3.70] 0.50 [0.0197]/OS Piston Limit 93.955 to 93.985 [3.6990 to 3.7002] 93.770 [3.6917] 94.205 to 94.235 [3.7089 to 3.7100] 94.020 [3.7016] 94.455 to 94.485 [3.7187 to 3.7199] 94.270 [3.7114] -0.25 to 0.15 [-0.0098 to 0.0059] Protrusion from crankcase Remark Bearing clearance check. 5g [0.2 oz.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (3 / 4) Inspection point Nominal Runout Standard Limit 0.04 [0.0016] or less 0.10 [0.0039] Unit: mm [in.] Remark TIR Inlet 6.682 [0.2631] 6.382 to 6.782 [0.2513 to 0.2670] 6.182 [0.2434] Exhaust 6.722 [0.2646] 6.422 to 6.822 [0.2528 to 0.2686] 6.222 [0.2450] No. 1, 2, 3 ø 54 [2.13] 53.94 to 53.96 [2.1236 to 2.1244] 53.90 [2.1220] No.4 ø 53 [2.09] 52.94 to 52.96 [2.0842 to 2.0850] 52.90 [2.0827] 0.07 to 0.11 [0.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (4 / 4) Inspection point Main bearing Nominal Standard Limit Remark 0.050 to 0.110 [0.0020 to 0.0043] 0.200 [0.0079] crank journal outside diameter (ø 78 [3.0709]) -0.9 [-0.0354] Replace bearings before limit is reached. Regrind crank journal and use next undersize bearings if limit is exceeded; -0.25 [-0.0098], -0.50 [-0.0197], -0.75 [-0.0295] 0.05 [0.0020] or less 0.20 [0.0079] Reface minimum thickness.
SERVICE DATA 1.5 Cooling system Table 2-5 Maintenance service data table - Cooling system Inspection point Nominal Standard Unit: mm [in.] Limit Temperature at which valve starts opening 76.5 ± 1.5°C [170 ± 3.5°F] Temperature at which valve lift is 9 [0.35], minimum 90 ± 1.5°C [194 ± 2.7°F] Remark Thermostat 1.
SERVICE DATA 1.7 Electrical system Table 2-7 Maintenance service data table - Electrical system Inspection point Outside diameter Commutator Nominal ø 32 [1.26] 0.10 [0.0039] Undercut depth 0.4 to 0.6 [0.016 to 0.024] 0.2 [0.008] 18 [0.71] 11 [0.43] 29.4 to 39.4 N {3.0 to 4.0 kgf} [6.6 to 8.8 lbf] 13.7 N {1.4 kgf} [3.1 lbf] Voltage 23 V Armature current 85 A or less Rotational speed 3300 min-1 or more Voltage Load characteristics 34 N {3.5 kgf} [7.
SERVICE DATA 2. Tightening torque table 2.1 Major bolt tightening torque 2.1.1 Basic engine Table 2-8 Tightening torque table - Basic engine Threads Dia × Pitch (mm) N·m kgf·m lbf·ft Cylinder head 12 × 1.75 118 ± 5 12 ± 0.5 87 ± 3.6 Cylinder head plug 16 × 1.5 44.1 ± 5 4.5 ± 0.5 32.5 ± 3.6 Rocker cover 8 × 1.25 11.3 ± 1.5 1.15 ± 0.15 8.5 ± 1.1 Rocker shaft bracket (long) 8 × 1.25 17.5 ± 2.5 1.75 ± 0.25 12.7 ± 1.8 Main bearing cap 14 × 2.0 103 ± 5 10.5 ± 0.5 76 ± 3.
SERVICE DATA 2.1.3 Lubrication system Table 2-10 Tightening torque table - Lubrication system Threads Dia × Pitch (mm) N·m kgf·m lbf·ft Oil pan 8 × 1.25 11.3 ± 1.5 1.15 ± 0.15 8.3 ± 1.1 Oil pan drain plug 20 × 1.5 78 ± 5 8 ± 0.5 57.9 ± 3.6 Oil pump gear 10 × 1.25 33 ± 5 3.4 ± 0.5 24.6 ± 3.6 Oil pressure relief valve 22 × 1.5 49 ± 4.9 5 ± 0.5 36.2 ± 3.6 Safety valve 18 × 2.0 69 ± 5 7 ± 0.5 50.6 ± 3.6 Description 2.1.
SERVICE DATA 2.2 Standard bolt and nut tightening torque 2.2.1 Metric automobile screw thread Table 2-14 Metric automobile screw thread Threads Dia × Pitch (mm) Width across flats (mm) [in.] Strength classification 4T 7T 4 10.9 10 7 N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft M6 × 1.0 10 [0.39] 3.9 0.4 2.9 8.8 0.9 6.5 12.7 1.3 9.4 M8 × 1.25 12 [0.47] 11.8 1.2 8.7 18 1.9 13 30 3.1 22 M10 × 1.25 14 [0.55] 21.1 2.15 16 35 3.6 26 60 6.1 44 M12 × 1.
SERVICE DATA 3. Regarding submission of parts for EPA exhaust gas regulation CAUTION When replacing parts, be sure to use OEM designated parts. If OEM parts are not used, the exhaust emission's warranty be voided. New parts may be updated due to improvement. Fuel and exhaust system repairs should only be conducted by an authorized Mitsubishi forklift truck dealer. Tampering or adjusting the fuel system components will void the warranty and could be in violation of the EPA regulations.
SERVICE TOOLS 1. Special tool......................................
SERVICE TOOLS 1. Special tool Table 3-1 Special tool list (1 / 3) Tool name Part No. Shape Use Compression gauge 33391-02100 Engine compression pressure measuring 0 to 7 MPa {0 to 71.4 kgf/cm²} [0 to 1015.
SERVICE TOOLS Table 3-1 Special tool list (2 / 3) Tool name Part No.
SERVICE TOOLS Table 3-1 Special tool list (3 / 3) Tool name Part No.
DETERMINATION OF OVERHAUL 1. Determining overhaul timing ...........4-2 2. Testing compression pressure ........
DETERMINATION OF OVERHAUL 1. Determining overhaul timing In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in engine oil consumption and blow-by gas are also considered to evaluate the engine condition.
DETERMINATION OF OVERHAUL 2. Testing compression pressure CAUTION (a) Be sure to measure the compression pressure for all the cylinders. It is not a good practice to measure the compression pressure for only one cylinder, and presume the compression for the remaining cylinders. (b) Also be sure to check engine speed when measuring the compression pressure, as compression pressure varies with engine speed. (c) Measuring the compression pressure at regular intervals is important to obtain correct data.
DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism ............5-2 1.1 1.2 1.3 1.4 1.5 1.6 Removing rocker shaft assembly............. 5-3 Disassembling rocker shaft assembly...... 5-3 Removing cylinder head bolt.................... 5-3 Removing cylinder head assembly .......... 5-4 Removing valve and valve spring ............ 5-4 Removing valve stem seal ....................... 5-4 2. Disassembling and inspecting flywheel ........................................
DISASSEMBLY OF BASIC ENGINE 1.
DISASSEMBLY OF BASIC ENGINE 1.1 Removing rocker shaft assembly Adjusting screw CAUTION Always loosen shorter bolts first. Failing to do so may cause the damage to the rocker shaft bracket. (1) Loosen the rocker arm adjusting screws by rotating about one turn. (2) Loosen the shorter rocker bracket bolts first. (3) Then, loosen the longer rocker bracket bolts. (4) Remove the rocker bracket bolts, and remove the rocker shaft assembly from the cylinder head. (5) Remove push rods. 1.
DISASSEMBLY OF BASIC ENGINE 1.4 Removing cylinder head assembly CAUTION Cylinder head When removing the cylinder head gasket, be careful not to damage the cylinder head or crankcase surface with tools such as a screwdriver. (1) Remove the cylinder head bolt. (2) Remove the cylinder head assembly by lifting it up. Note: If the cylinder head assembly cannot be removed due to crimping of the cylinder head gasket, tap the thick area on the side of the cylinder head using a plastic hammer to give a shock.
DISASSEMBLY OF BASIC ENGINE 2.
DISASSEMBLY OF BASIC ENGINE 2.1 Removing flywheel CAUTION (a) Be careful not to cut yourself with the ring gear when pulling out the flywheel. Be careful not to drop or hit the flywheel when removing. (b) The person who holds the pulley must be very careful to assure safety by communicating with the person who is removing the flywheel. (1) One personnel must firmly hold the pulley with a wrench to prevent the flywheel from turning. (2) Remove one bolt from the flywheel.
DISASSEMBLY OF BASIC ENGINE 3.
DISASSEMBLY OF BASIC ENGINE S6S-Y3T62HF Wear, damage Flaking, uneven contact, damage, key groove defect, abnormal wear bushings 11 Replace Clogging of oil hole, wear 5 Wear, damage 13 12 Clogged oil hole 10 15 Wear 14 9 4 Flaking, uneven contact, damage, key groove defect, abnormal wear bushings 7 Replace Replace 8 Replace 6 Lip wear, damage or aging Replace Worn belt groove Crack, abnormality of knock hole Crack, abnormality of knock hole 2 3 1 Disassembling and inspecting damper, gear
DISASSEMBLY OF BASIC ENGINE 3.1 Removing crankshaft pulley and damper CAUTION The bar that stops the crankshaft from turning may come off. Pay special attention to safety. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft. Stick a bar across the guide bolts to prevent the crankshaft from turning. (2) Remove the crankshaft pulley and damper. Removing damper Prevent crankshaft 回り止めをする from rotating Guide bolt (M12×1.
DISASSEMBLY OF BASIC ENGINE 3.3 Removing timing gear case S6S-Y3T62HF CAUTION The front plate is bolted to the crankcase from inside the gear case. Do not attempt to remove the front plate together with the gear case by tapping. (1) Remove bolts from the timing gear case. (2) Remove the timing gear case. Note: Bolts have different lengths. Pay attention to the positions of bolts to ensure correct reassembling.
DISASSEMBLY OF BASIC ENGINE 3.5 Measuring idler gear and camshaft gear end play Using a feeler gauge or dial gauge, measure the end play of idler gear and camshaft gear. If the measured value exceeds the limit, replace the thrust plate with a new one. Item Standard Limit Idler gear 0.05 to 0.20 mm [0.0020 to 0.0079 in.] 0.35 mm [0.0138 in.] Camshaft 0.10 to 0.25 mm [0.0039 to 0.0098 in.] 0.30 mm [0.0118 in.] End play Measuring idler gear and camshaft gear end play 3.
DISASSEMBLY OF BASIC ENGINE 3.9 Removing oil pump gear (1) Remove the oil pump gear tightening nut. (2) Remove the oil pump gear. Oil pump gear Removing oil pump gear 3.10 Removing idler gear (1) Remove the thrust plate bolt. (2) Remove the idler gear while turning the gear. Idler gear Removing idler gear 3.11 Removing PTO drive gear Remove the PTO drive gear tapping lightly with plastic hammer. S6S-Y3T61HF Removing PTO drive gear 3.
DISASSEMBLY OF BASIC ENGINE 3.13 Separating camshaft gear Using hydraulic press, remove the camshaft gear and thrust plate from the camshaft. Note: Do not remove the camshaft gear from the camshaft unless the camshaft gear or the thrust plate is defective. Punch out with hydraulic press Camshaft gear Thrust plate Camshaft Separating gear from camshaft 3.14 Installing camshaft gear and thrust plate (1) Install the woodruff key and the thrust plate on the camshaft.
DISASSEMBLY OF BASIC ENGINE 4.
DISASSEMBLY OF BASIC ENGINE 4.1 Removing connecting rod cap (1) Lay the engine on its side. (2) Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling. (3) Remove the connecting rod caps. Note: Mark the cylinder No. and upper/lower on connecting rod bearings to ensure correct reassembling. Removing connecting rod cap 4.
DISASSEMBLY OF BASIC ENGINE 4.4 Removing piston ring Remove the piston rings using piston ring pliers. Piston ring pliers P/N:31391-12900 Removing piston ring 4.5 Removing piston pin and piston (1) Using ring pliers, remove the snap ring. (2) Using a wooden block and mallet, remove the piston pin, and separate the piston from the connecting rod. Note: (a) Do not tap the piston pin directly with a mallet. (b) If the piston is stubborn, heat the piston with a piston heater or in hot water.
DISASSEMBLY OF BASIC ENGINE 4.7 Removing crankshaft CAUTION Be careful not to damage bearings when removing the crankshaft. (1) Slowly lift the crankshaft straight up. (2) Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling. Note: (a) When raising the crankshaft, do not allow wire or chain to come into contact with the crankshaft. To avoid damage to the crankshaft when raising, use a cloth belt or pad.
INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism .....................6-2 1.1 Measuring clearance between rocker bushing and rocker shaft.......................... 6-2 1.2 Measuring valve stem outside diameter and valve guide inside diameter ..................... 6-2 1.3 Replacing valve guide.............................. 6-3 1.4 Inspecting valve face ............................... 6-4 1.5 Refacing valve face.................................. 6-4 1.
INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism 1.1 Measuring clearance between rocker bushing and rocker shaft Measure the rocker assembly inside diameter and the rocker shaft diameter. If the clearance exceeds the limit, replace either rocker assembly or rocker shaft with a new one. Item Nominal Standard Limit Rocker bushing inside diameter ø 19 mm [0.75 in.] 19.010 to 19.030 mm [0.7484 to 0.7492 in.] - Rocker shaft outside diameter ø 19 mm [0.
INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Replacing valve guide CAUTION Valve guide remover P/N:32A91-00300 Because valve guides must be inserted to the specified amount, be sure to use a valve guide installer. (1) To remove valve guides, use a valve guide remover. (2) To press-fit valve guides, use a valve guide installer. (3) Check contacts between valves and valve seats after replacing valve guides. Pulling out valve guide Press Valve guide installer P/N:32A91-00100 13.9 to 14.1 mm [0.547 to 0.
INSPECTION AND REPAIR OF BASIC ENGINE Nominal Standard Limit 30° - - Inlet 0.4 mm [0.016 in.] 0.3 to 0.5 mm [0.012 to 0.020 in.] 1.0 mm [0.039 in.] Exhaust 1.4 Inspecting valve face Apply a thin coat of lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a valve lapper to check for contact condition. If the contact is not even, or any defects are found, or if the limit is exceeded, reface or replace the valve.
INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Refacing valve seat (1) Use the valve seat cutter or valve seat grinder to reface the valve seat. After refacing, sand the valve seat lightly using 400 grit sandpaper, inserting it between the cutter and valve seat. (2) Lap the valve in the valve seat. Note: (a) Valve seat refacing should be kept to an absolute minimum. (b) If the valve seat width exceeds the limit due to wear or refacing, replace the valve seat with a new one.
INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Replacing valve seat (1) To remove the valve seat, weld a stud to the valve seat as illustrated. Then, insert a rod into the valve guide hole from the top of the cylinder head, and press out the valve seat with the rod. Note: Be careful not to allow spatters to adhere to the machined surface of the cylinder head during welding.
INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Lapping valve and valve seat Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve. (1) Apply a thin coat of lapping compound evenly to the valve face. Note: (a) Do not allow the compound to adhere on the valve stem. (b) Compound spreads more evenly if it is mixed with a small amount of engine oil.
INSPECTION AND REPAIR OF BASIC ENGINE 1.10 Measuring distortion of the bottom surface of the cylinder head CAUTION Refacing of cylinder head should be kept to an absolute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve). With a straight edge placed on the bottom face of the cylinder head, measure the bottom face distortion using a feeler gauge.
INSPECTION AND REPAIR OF BASIC ENGINE 1.12 Removing combustion jet Replace the combustion jet only when it has a defect or crack. (1) Insert a round bar (approx; ø6 mm [0.24 in.]) into glow plug hole, and tap the combustion jet inner face perimeter lightly to pull out the combustion jet. Round rod Combustion jet Removing combustion jet (2) When installing the combustion jet, align the positioning hole and jet nozzle with the center of cylinder, press fit by tapping with plastic hammer.
INSPECTION AND REPAIR OF BASIC ENGINE 2. Inspecting and repairing flywheel 2.1 Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge on the friction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the limit is exceeded. Item Flywheel flatness Standard Limit 0.15 mm [0.0059 in.] or less 0.50 mm [0.0197 in.] Measuring flatness of flywheel 2.
INSPECTION AND REPAIR OF BASIC ENGINE 3. Inspecting and repairing timing gear and camshaft 3.1 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth-to-tooth contacting area.
INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Measuring camshaft runout Measure the camshaft runout using a dial gauge. If the limit is exceeded, correct the camshaft using a press, or replace the camshaft with a new one. Note: With a dial gauge set on the camshaft, rotate the camshaft one turn and read the gauge indication. Item Camshaft runout Standard Limit Remark 0.04 mm [0.0016 in.] or less 0.10 mm [0.0039 in.] TIR Measuring camshaft runout 3.
INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Replacing camshaft bushing 3.7.1 Removing camshaft bushing (1) Install a camshaft bushing installer set to the camshaft bushing. (2) Remove the camshaft bushing by tapping the end of the rod of camshaft bushing installer set. Bushing Adapter Camshaft bushing installer set P/N:30691-00010 Rod Removing camshaft bushing 3.7.2 Installing camshaft bushing (1) Install the camshaft bushing to a camshaft bushing installer set.
INSPECTION AND REPAIR OF BASIC ENGINE 3.9 Replacing idler shaft To remove the idler shaft, use the idler shaft puller. Note: When installing the idler shaft into the crankcase, orient the idler shaft so that its oil hole faces the upper crankcase. Item Nominal Standard Interference between shaft and crankcase hole ø 35 mm [1.38 in.] 0.035T to 0.076T mm [0.0014 to 0.0030 in.] Idler shaft puller P/N:MH061077 Replacing idler shaft 3.
INSPECTION AND REPAIR OF BASIC ENGINE 3.12 Inspecting V-belt groove wear Check the V-belt groove of the pulley for wear. Attach a new V-belt around the pulley, apply high tension and measure the sinkage of V-belt. If the wear appears excessively, and the belt top surface sinks 1.6 mm [0.06 in.] or more down from the top edge of groove, replace the pulley with a new one.
INSPECTION AND REPAIR OF BASIC ENGINE 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase 4.1 Measuring crankcase top surface distortion CAUTION Refacing of cylinder head should be kept to an absolute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve). Apply a straight edge to the top surface of the crankcase and measure its distortion using a feeler gauge.
INSPECTION AND REPAIR OF BASIC ENGINE Item Standard Limit Cylinder inside diameter 94.000 to 94.035 mm [3.7008 to 3.7022 in.] Repair limit: 94.200 mm [3.7087 in.] Replace limit: 94.700 mm [3.7283 in.] Circularity 0.01 mm [0.0004 in.] or less - Cylindricity 0.015 mm [0.0006 in.] or less - 150 [5.91] Measuring directions 11 [0.43] 80 [3.15] 4.2 Measuring cylinder inside diameter (1) Measure the inside diameter of the cylinder at three levels, i.e.
INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Measuring piston outside diameter (1) Measure the piston outside diameter of the piston skirt at right angles to the piston pin. If it exceeds the limit, replace the piston with a new piston. When replacing piston, be sure to select a piston so that the piston weight difference in one engine is kept within the permissible range.
INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Measuring clearance between piston ring groove and piston ring CAUTION Remove carbon deposits from pistons and check the entire circumference of the piston. (1) Remove deposits such as carbon from each ring groove. (2) Check each ring groove for wear or damage. If it is worn or damaged, replace the piston with a new one. (3) Insert the piston ring into the piston ring groove.
INSPECTION AND REPAIR OF BASIC ENGINE 4.7 Measuring piston protrusion CAUTION Piston protrusion must always meet the standard, as the amount of protrusion not only influences on the engine performance, but also it is important to prevent valve interference. Measure the protrusion of each piston following the instructions below. If the measured value does not meet the standard, inspect the clearances between various parts involved. (1) Bring the piston to top dead center.
INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Measuring clearance between connecting rod bearing and crankpin Measuring directions Measuring points CAUTION 54 ± 5 N·m {5.5 ± 0.5 kgf·m} [40 ± 3.6 lbf·ft] When grinding crankpins, be sure to grind all the pins to the same size. Finish the fillet radius to the specified dimension. (1) Reassemble the bearing into the big end of the connecting rod. (2) Tighten the connecting rod cap bolts to the specified torque.
INSPECTION AND REPAIR OF BASIC ENGINE 4.10 Replacing connecting rod bushing Use a connecting rod bushing installer to replace the connecting rod bushing. (1) With the bushing joints oriented as shown in the illustration, align the oil hole of bushing with the oil hole of connecting rod, and press-fit the connecting rod bushing into the connecting rod. (2) After press-fitting, insert the piston pin, and check for smooth movement of the connecting rod and piston without looseness.
INSPECTION AND REPAIR OF BASIC ENGINE 4.12 Inspecting connecting rod bearing Inspect the connecting rod bearings. If any defect is found, replace it with a new one. Scratches Flaking Fusion Inspecting connecting rod bearing 4.13 Measuring connecting rod end play (1) Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque. (2) Measure the clearance of the crank arm (end play) at two positions (above and below the crankpin).
INSPECTION AND REPAIR OF BASIC ENGINE 4.15 Measuring crankshaft journal outside diameter Measure the crankshaft journal diameter using a micrometer. Check the crankshaft journal for circularity, cylindricity and clearance between the bearing and journal. If the measurement value is below the repair limit, grind the journal to fit the undersize bearing. If the measurement value is below the service limit, replace the crankshaft with a new one. Item Standard Limit ø 78 mm [3.07 in.] 77.955 to 77.
INSPECTION AND REPAIR OF BASIC ENGINE 4.17 Grinding crankshaft R3 mm [0.12 in.] CAUTION R3 mm [0.12 in.] (a) When grinding crank journals, be sure to grind all the journals to the same size. (b) Finish the fillet radius to the specified dimension. Grind the crankshaft journal (or pin) to the diameter that fits the inside diameter of the next undersize main (or connecting) bearing. By doing so, the fitness check with an actual bearing can be omitted.
INSPECTION AND REPAIR OF BASIC ENGINE 4.18 Measuring crankshaft end play (1) Measure the crankshaft end play (clearance between the crank arm at the thrust force receiving journal and the bearing cap with thrust plate attached). If the limit is exceeded, replace the thrust plate with a new one. (2) If the limit is still exceeded after a new thrust plate has been installed, use an oversize thrust plate. Note: In general, the rear thrust bearing wears faster than the front thrust bearing.
INSPECTION AND REPAIR OF BASIC ENGINE 4.20 Replacing crankshaft gear 4.20.1 Removing crankshaft gear Using a gear puller, remove the gear from the crankshaft. Note: Do not strike the gear with a hammer. Crankshaft gear Puller P/N:MH061326 Removing crankshaft gear 4.20.2 Installing crankshaft gear (1) Install the key on the crankshaft. (2) Press-fit the gear fully in alignment with the key. Key Aligning position Crankshaft gear Installing crankshaft gear 4.
INSPECTION AND REPAIR OF BASIC ENGINE 4.22 Installing oil seal sleeve Oil seal sleeve installer set P/N:30691-13010 CAUTION Be careful not to dent or damage the oil seal sleeve circumference. When installing the oil seal sleeve, apply the oil to the inside of the oil seal sleeve, and drive it into the crankshaft by using oil seal sleeve installer set.
INSPECTION AND REPAIR OF BASIC ENGINE 4.24 Inspecting main bearing surface Check the inside surface of each main bearing shell for abnormal contact, scratches, corrosion and peeling from foreign material. Also check the outside surface of each bearing shell which comes into contact with the crankcase or main bearing cap for abnormal seating. Scratch on the inner and outer circumference, corrosion, and detachment Inspecting main bearing surface 4.
REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, crankshaft and crankcase ...............7-2 4. Reassembling cylinder head and valve mechanism ................................... 7-16 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Installing main bearing ............................. 7-2 Installing thrust plate ................................ 7-2 Installing tappet........................................ 7-2 Installing crankshaft ...........
REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, crankshaft and crankcase 1.1 Installing main bearing Main bearing upper CAUTION Do not apply oil to the bearing outer surface, as the oil may cause bearing seizure. (1) Press the upper main bearing into position by aligning its lug to the lug groove on the crankcase. Note: The oil hole of the main bearing is aligned with the oil hole of the crankcase by installing the upper main bearing in alignment with the lug groove.
REASSEMBLY OF BASIC ENGINE 1.5 Installing main bearing caps CAUTION Apply ThreeBond 1212 to corner of cap The foremost and rearmost caps should be installed so that they are flush with the crankcase surface. Install the main bearing caps from the front side in the order of the numbers marked on them. (1) Apply engine oil to lower main bearings and install them to the main bearing caps.
REASSEMBLY OF BASIC ENGINE 1.8 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play. If the end play deviates from the standard value, loosen the main bearing cap bolts and retighten. Make sure that the crankshaft turns freely. Item Standard Limit Crankshaft end play 0.100 to 0.264 mm [0.0039 to 0.0104 in.] 0.300 mm [0.0118 in.] Measuring crankshaft end play 1.
REASSEMBLY OF BASIC ENGINE 1.10 Installing piston ring CAUTION A marking is stamped near the end gap to indicate the top face of piston ring. Install all piston rings with this mark facing upward. If the rings are installed upside down, it could cause malfunctions such as excessive oil consumption or an engine seizing. Piston ring plier P/N:31391-12900 No.1 compression ring Top mark No.2 compression ring Oil ring (1) Install the piston rings to the piston with a ring expander.
REASSEMBLY OF BASIC ENGINE 1.12 Installing connecting rod bolt and connecting rod bearing (1) Press fit the connecting rod bolts into the connecting rod. Note: When press fitting the bolt, make sure that the bolt fully contacts its seating position without any interference with the shoulder of mounting surface. (2) Install the upper connecting rod bearing with its lug fitted in the lug groove of connecting rod.
REASSEMBLY OF BASIC ENGINE 1.14 Installing connecting rod cap (1) Install the connecting rod cap with its match mark facing on the same side as the match mark on the connecting rod. (2) Tighten the connecting rod cap nuts evenly and progressively to the specified torque. (3) Inspect end play of the connecting rod. If end play is small, loosen and retighten the cap nuts. 54 ± 5 N·m {5.5 ± 0.5 kgf·m} [39.8 ± 3.
REASSEMBLY OF BASIC ENGINE 2. Reassembling timing gear and camshaft 2.1 Installing oil pump Install a new O-ring to the oil pump case, and install the oil pump to the crankcase. Oil pump O-ring Installing oil pump 2.2 (1) (2) (3) Installing front plate Clean the gasket mounting surface. Apply sealant to the gasket to prevent it from falling. With aligning to the dowel pin, install the gasket and the front plate. (4) Secure the front plate with mounting bolts.
REASSEMBLY OF BASIC ENGINE 2.3 Installing camshaft gear and thrust plate Press fit with hydraulic press CAUTION Be careful not to damage the cam of the camshaft or bushing. Warm the camshaft gear and insert the thrust plate without fail when installing the gear. Camshaft gear Thrust plate Camshaft Installing camshaft gear and thrust plate 2.4 Installing camshaft CAUTION Be careful not to damage camshaft journals, cams and camshaft holes during insertion.
REASSEMBLY OF BASIC ENGINE 2.6 Installing idler gear (1) Apply engine oil to the idler gear shaft. (2) Install the idler gear with its match marks aligned with the marks on the crankshaft gear and camshaft gear. (3) Attach the thrust plate to the idler gear and tighten the mounting bolt to the specified torque. Idler gear 34 ± 5 N·m {3.5 ± 0.5 kgf·m} [25 ± 3.
REASSEMBLY OF BASIC ENGINE 2.7 Installing oil pump gear (1) Install the oil pump gear to the oil pump shaft. (2) Tighten the jam nut to the specified torque. Oil pump gear 33 ± 5 N·m {3.4 ± 0.5 kgf·m} [24.6 ± 3.6 lbf·ft] Installing oil pump gear 2.8 Installing fuel injection pump (1) Install the fuel pump gear with its match marks aligned with the marks on the fuel injection pump and idler gear. (2) Tighten the fuel injection pump mounting bolts evenly.
REASSEMBLY OF BASIC ENGINE 2.10 Installing front oil seal Using an installer, install new oil seal in the timing gear case. Make sure the oil seal is flush with the gear case. Installer Installing front oil seal 2.11 Installing timing gear case (1) Aligning with the dowel pins, install the gasket to the crankcase. (2) Apply engine oil to the oil seal lip. (3) Install the timing gear case and tighten the bolts. (4) Cut the gasket protruding from crankcase bottom side with cutter.
REASSEMBLY OF BASIC ENGINE 2.13 Installing oil pan (1) Clean the mount surfaces of the crankcase, timing gear case, and oil pan. (2) Squeeze ThreeBond 1207C (32A91-05100: liquid gasket) in a 4 mm [0.16 in.] diameter bead all around the oil pan flange periphery, and spread it. (3) Install the oil pan to the crankcase within five minutes of applying the liquid gasket. (4) Tighten the mounting bolts to the specified torque.
REASSEMBLY OF BASIC ENGINE 2.14 Installing cover Tighten the cover mounting bolts evenly. S6S-Y3T62HF Cover Installing cover S6S-Y3T61HF Bearing case Cover Installing cover 2.15 Installing crankshaft pulley and damper Prevent crankshaft from rotating CAUTION The bar could come off. Be very careful. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft. Place a bar across the two guide bolts so that the crankshaft does not turn.
REASSEMBLY OF BASIC ENGINE 3. Reassembling flywheel 3.1 Installing oil seal Apply a small quantity of grease to the new oil seal, and install the oil seal to the rear plate. Be careful of the oil seal installation direction. Note: Use an oil seal with a sleeve if the oil seal contacting surface of the crankshaft is worn. Rear plate Apply grease Engine side Flywheel side Oil seal Installing oil seal 3.2 Installing rear plate (1) Clean the mounting surface of the gasket.
REASSEMBLY OF BASIC ENGINE 4. Reassembling cylinder head and valve mechanism 4.1 Cleaning cylinder head bottom surface CAUTION Do not use liquid gasket on the cylinder head. Taking care not to damage the cylinder head bottom surface, remove residue of old gasket. Note: First, roughly scrape off residue of old gasket using a scraper. Then, grind off the remaining residue using an engine-oil immersed oil stone. Cleaning cylinder head bottom surface 4.
REASSEMBLY OF BASIC ENGINE 4.4 Installing cylinder head gasket CAUTION Do not use liquid gasket on the cylinder head. (1) Make sure that there is no dirt or dents on the top surfaces of the crankcase and pistons. (2) Place new gasket on the crankcase by aligning it with dowel pins on the crankcase. 4.5 Installing cylinder head assembly Install the cylinder head to fit the dowel pins on the crankcase top surface with guide. Note: (a) Be careful not to displace the cylinder head gasket when installing.
REASSEMBLY OF BASIC ENGINE 4.7 Inserting push rod (1) Insert each push rod into its hole in the cylinder head. (2) Make sure that the ball end of each push rod is placed correctly on the tappet cup. Push rod Tappet Inserting push rod 4.8 Reassembling rocker shaft assembly (1) Apply engine oil to the rocker shaft. (2) When reassembling, install the rocker shaft assembly in the same position as it was.
REASSEMBLY OF BASIC ENGINE 0 40 4.10 Determining top dead center of No. 1 cylinder compression stroke 4.10.1 When reusing the damper (1) Attach a socket and ratchet handle to the nut of crankshaft pulley, and rotate the crankshaft in the normal direction (clockwise when viewed from the front of the engine.) (2) Stop turning the crankshaft when the notch mark stamped on the damper is aligned with a "0" mark on the pointer. 4.10.
FUEL SYSTEM 1. Removing fuel system.....................8-2 1.1 Removing fuel filter .................................. 8-2 1.2 Removing fuel injection pipe .................... 8-3 1.3 Removing fuel injection pump.................. 8-4 2. Disassembling, inspecting and reassembling fuel system................8-5 2.1 Disassembling and inspecting fuel filter... 8-5 2.2 Changing fuel filter ................................... 8-6 2.3 Disassembling and inspecting fuel injection nozzle..........................
FUEL SYSTEM 1. Removing fuel system CAUTION Cover the openings on the injection pump, nozzle inlet connector and injection pipe to prevent dust from entering the fuel system. 1.
FUEL SYSTEM 1.2 Removing fuel injection pipe 5 Replace 8 6 9 7 1 3 4 2 Removing fuel injection pipe Removing sequence 1 Fuel return pipe 6 No. 5 fuel injection pipe 2 No. 1 fuel injection pipe 7 No. 6 fuel injection pipe 3 No. 2 fuel injection pipe 8 Fuel leak-off pipe 4 No. 3 fuel injection pipe 9 Fuel injection nozzle 5 No.
FUEL SYSTEM 1.
FUEL SYSTEM 2. Disassembling, inspecting and reassembling fuel system 2.1 Disassembling and inspecting fuel filter Crack and damaged threads 3 Replace 2 Clogged, cracks. Replace: Every 500 hrs.
FUEL SYSTEM 2.2 Changing fuel filter WARNING (a) When handling fuel, make sure no open flames are nearby. (b) Wipe off any spilled fuel. Spilled fuel becomes a fire hazard. (1) Clean the outside of the fuel filter and the area around it. (2) Disconnect the fuel filter level sensor from its connector. (3) Place a drip pan under the fuel filter. (4) Loosen the drain plug and drain fuel from the fuel filter. (5) Remove the level sensor from the fuel filter. (6) Remove the fuel filter element.
FUEL SYSTEM 2.
FUEL SYSTEM 2.4 Inspecting and adjusting fuel injection valve opening pressure Nozzle tester CAUTION Never touch the spray hole during injection (1) Mount the nozzle on the nozzle tester. (2) Pump the tester handle at a rate of approximately one cycle per second while observing the pressure at which injection starts. If the pressure is not in the standard range, make an adjustment by changing shim. (3) To adjust the valve opening pressure, remove the retaining nut, and change the shim.
FUEL SYSTEM 2.6 Cleaning and inspecting nozzle tip (1) Clean the needle valve and body of the nozzle tip in a clean wash oil. (2) After cleaning, assemble the needle valve and the body in a clean diesel oil. Note: The needle valve and body are precision parts. Handle them carefully, and do not change the combination of the valve and body. (3) Tighten the nozzle tip tightening retainer nut to the specified torque.
FUEL SYSTEM 2.7 Reassembling fuel injection nozzle 36.8 ± 2.5 N·m {3.75 ± 0.25 kgf·m} [27.1 ± 1.8 lbf·ft] 58.8 ± 5.9 N·m {6 ± 0.6 kgf·m} [43.4 ± 4.
FUEL SYSTEM 2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump WARNING Keep flames away when handling a diesel fuel. Wipe off any spilled fuel thoroughly. Spilled fuel could cause a fire. CAUTION Cover the openings on the fuel injection pump to prevent dust from entering the fuel system. When output shortage and/or hunting of the engine occurred, the gauze filter may be dirty. Clean the gauze filter accordingly. (1) Clean around the injection pump.
FUEL SYSTEM 3. Installing fuel system 3.
FUEL SYSTEM 3.2 Installing fuel injection pipe 29.4 ± 2.9 N·m {3 ± 0.3 kgf·m} [21.7 ± 2.2 lbf·ft] 22.6 ± 1.9 N·m {2.3 ± 0.2 kgf·m} [16.6 ± 1.4 lbf·ft] 19.6 ± 1.9 N·m {2 ± 0.2 kgf·m} [14.5 ± 1.4 lbf·ft] 58.8 ± 5.9 N·m {6 ± 0.6 kgf·m} [43.4 ± 4.
FUEL SYSTEM 3.
LUBRICATION SYSTEM 1. Removing lubrication system ..........9-2 1.1 Removing oil filter and relief valve ........... 9-2 1.2 Removing oil cooler ................................. 9-3 1.3 Removing oil pump, oil pan and oil strainer ................................................ 9-4 2. Disassembling, inspecting and reassembling lubrication system .....9-5 2.1 Disassembling and inspecting oil pump... 9-5 2.2 Inspecting oil pump .................................. 9-6 2.2.
LUBRICATION SYSTEM 1. Removing lubrication system 1.
LUBRICATION SYSTEM 1.
LUBRICATION SYSTEM 1.
LUBRICATION SYSTEM 2. Disassembling, inspecting and reassembling lubrication system 2.
LUBRICATION SYSTEM 2.2 Inspecting oil pump 2.2.1 Measuring clearance between outer rotor and inner rotor Measure the clearance between the outer rotor and the inner rotor. If measured value exceeds the limit, replace the oil pump with new one. Item Clearance between outer rotor and inner rotor Standard Limit 0.13 to 0.15 mm [0.0051 to 0.0059 in.] 0.20 mm [0.0079 in.] Feeler gauge Measuring clearance between outer rotor and inner rotor 2.2.
LUBRICATION SYSTEM 2.2.4 Measuring clearance between main shaft and pump case Measure the diameter of the shaft and the inside diameter of the bore in the case for the shaft to find the clearance between the two. If the clearance exceeds the limit, replace the oil pump assembly. Item Standard Limit Main shaft outside diameter (between case) 15.985 to 16.000 mm [0.6293 to 0.6299 in.] - Clearance between main shaft and pump case 0.032 to 0.074 mm [0.0013 to 0.0029 in.] 0.150 mm [0.0059 in.
LUBRICATION SYSTEM 2.
LUBRICATION SYSTEM 2.
LUBRICATION SYSTEM 2.5 Inspecting oil filter Apply engine oil to the gasket when installing Clogged, cracks. Replace: Every 500 hrs.
LUBRICATION SYSTEM 2.6 Inspecting relief valve (1) Check the relief valve and its seat for contact. Check the spring for fatigue and damage. If faulty, replace the relief valve with a new one. (2) Measure the relief valve opening pressure. If the pressure does not fall within the standard range, replace the relief valve with a new one. Item Relief valve opening pressure Standard 0.35 ± 0.05 MPa {3.5 ± 0.5 kgf/cm²} [49.8 ± 7.1 psi] 44 ± 4.9 N·m {4.5 ± 0.5 kgf·m} [32.5 ± 3.6 lbf·ft] 49 ± 4.9 N·m {5 ± 0.
LUBRICATION SYSTEM 3. Installing lubrication system 3.1 Installing oil pump, oil pan and oil strainer 69 ± 5 N·m {7 ± 0.5 kgf·m} [50.6 ± 3.6 lbf·ft] 11.3 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.3 ± 1.1 lbf·ft] 78 ± 5 N·m {8 ± 0.5 kgf·m} [57.9 ± 3.
LUBRICATION SYSTEM 3.
LUBRICATION SYSTEM 3.3 Installing oil filter and relief valve Replace Replace 49 ± 4.9 N·m {5 ± 0.5 kgf·m} [36.2 ± 3.
COOLING SYSTEM 1. Removing cooling system .............10-2 1.1 Removing thermostat............................. 10-2 1.2 Removing water pump, water pump pulley and V-belt...................................................... 10-3 2. Disassembling, inspecting and reassembling cooling system ........10-4 2.1 Disassembling and inspecting thermostat .............................................. 10-4 2.2 Inspecting thermostat............................. 10-5 2.3 Disassembling water pump....................
COOLING SYSTEM 1. Removing cooling system 1.
COOLING SYSTEM 1.
COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.
COOLING SYSTEM CAUTION Be careful of burns or a fire when measuring temperature, as it involves a high-temperature and open flame. To test the thermostat operation, immerse the thermostat in a container filled with water. Heat the water, while measuring the water temperature. Record the temperature at the conditions shown in the table below. If the temperatures are not within the standard range, replace the thermostat.
COOLING SYSTEM 2.3 Disassembling water pump Crack, water leakage, deformation Replace Crack, water leakage, damage, impeller and shaft rotation 1 2 3 Disassembling water pump Disassembling sequence 1 Water pump cover 2 Gasket 2.4 Inspecting water pump Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities. If faulty, replace the assembly.
COOLING SYSTEM 3. Installing cooling system 3.1 Installing water pump, water pump pulley and V-belt Water pump and water pump cover fixing bolts (×3) 9.8 ± 1 N·m {1 ± 0.1 kgf·m} [7.2 ± 0.7 lbf·ft] Replace Crack, deformation, damage Replace 32.4 ± 2 N·m {3.3 ± 0.2 kgf·m} [23.9 ± 1.4 lbf·ft] Crack, extension, wear, damage Water pump and crankcase fixing bolts (×5) 18.1 ± 3.4 N·m {1.85 ± 0.35 kgf·m} [13.4 ± 2.
COOLING SYSTEM 3.2 Installing thermostat 18.1 ± 1.5 N·m {1.85 ± 0.15 kgf·m} [13.4 ± 1.
INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems ...........................11-2 1.1 Removing turbocharger ......................... 11-2 1.2 Removing inlet manifold......................... 11-3 1.3 Removing exhaust manifold................... 11-4 2. Disassembling, inspecting and reassembling inlet and exhaust systems ...........................11-5 2.1 Measuring exhaust manifold distortion .. 11-5 2.2 Disassembling and inspecting turbocharger.................................
INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems 1.
INLET AND EXHAUST SYSTEMS 1.
INLET AND EXHAUST SYSTEMS 1.
INLET AND EXHAUST SYSTEMS 2. Disassembling, inspecting and reassembling inlet and exhaust systems 2.1 Measuring exhaust manifold distortion (1) Check the flange for crack. (2) Check the flange surface for distortion. If the distortion exceeds the standard, retouch the surface or replace it. Item Exhaust manifold distortion Straight edge Standard 0.2 mm [0.008 in.
INLET AND EXHAUST SYSTEMS 2.
INLET AND EXHAUST SYSTEMS 2.2.1 Removing turbine housing Loosen the coupling assembly as shown, and separate the turbine housing. Note: The positional relationship between the turbine housing and the cartridge assembly is very important. Therefore before disassembling, mark the components with a punch or felt-tip pen to ensure correct reassembly. Compressor cover Cartridge assembly Coupling assembly Turbine housing Removing turbine housing 2.2.
INLET AND EXHAUST SYSTEMS 2.2.4 Installing compressor cover Install the compressor cover, paying attention to its orientation. Compressor cover Installing compressor cover 2.2.5 Installing snap ring CAUTION (a) Be sure to install the snap ring in the correct direction. (b) Lightly drive both ends of the snap ring using a screwdriver and a hammer to insert the ring securely into the groove on the bearing housing.
INLET AND EXHAUST SYSTEMS 2.3 Cleaning CAUTION (a) When using a commercial neutral detergent, be sure to use non-corrosive type. (b) Be careful not to damage components. Combined use with an ultrasonic cleaning unit can help to remove contaminants easily. When cleaning the compressor cover and the turbine housing, observe the followings: (1) Visually check the parts condition before cleaning to note any burns or abrasions, which may not be observable after cleaning.
INLET AND EXHAUST SYSTEMS 2.3.2 Reassembling turbocharger 8.3 ± 0.5 N·m {0.85 ± 0.05 kgf·m} [6.1 ± 0.4 lbf·ft] Replace Reassembling turbocharger CAUTION (a) Change the following parts at reassembling · O-ring (b) Replace the compressor cartridge assembly if its vanes are distorted or cracked. Minor distortion or minor scratches on one piece of the vane may not require replacement of cartridge assembly, however, do not attempt to re-shape a distorted vane.
INLET AND EXHAUST SYSTEMS 2.3.3 Installing turbine housing Install the turbine housing to the cartridge assembly by aligning the marks put during disassembly. Turbine housing Cartridge assembly Installing turbine housing 2.3.4 Installing coupling assembly Apply Molykote grease or equivalent to threads of the coupling assembly nut, and tighten the nut to the specified torque. Coupling assembly 8.3 ± 0.5 N·m {0.85 ± 0.05 kgf·m} [6.1 ± 0.
INLET AND EXHAUST SYSTEMS 3. Installing turbocharger, inlet and exhaust systems 3.1 Installing exhaust manifold Replace 18.1 ± 3.4 N·m {1.85 ± 0.35 kgf·ft} [13.4 ± 2.
INLET AND EXHAUST SYSTEMS 3.
INLET AND EXHAUST SYSTEMS 3.3 Installing turbocharger 16.2 ± 2.5 N·m {1.65 ± 0.25 kgf·m} [11.9 ± 1.8 lbf·ft] Replace Replace 4 ± 0.5 N·m {0.41 ± 0.05 kgf·m} [3.0 ± 0.37 lbf·ft] Replace 4 ± 0.5 N·m {0.41 ± 0.05 kgf·m} [3.0 ± 0.
ELECTRICAL SYSTEM 1. Removing electrical system ..........12-2 1.1 Removing starter.................................... 12-2 1.2 Inspection before removing alternator ... 12-3 1.2.1 Inspecting alternator operation.................12-3 1.2.2 Handling precaution .................................12-3 1.3 Removing alternator............................... 12-4 1.4 Removing glow plug............................... 12-6 2. Disassembling, inspecting and reassembling electrical system .....12-7 2.
ELECTRICAL SYSTEM 1. Removing electrical system 1.
ELECTRICAL SYSTEM 1.2 Inspection before removing alternator 1.2.1 Inspecting alternator operation Locate the cause of faulty charging from malfunctions described below. Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine. Adjusted value of voltage regulator is high. Overcharge Faulty battery. Low adjusted value of voltage relay. Faulty alternator output. Over discharge Electric power consumption is extremely high.
ELECTRICAL SYSTEM 1.
ELECTRICAL SYSTEM S6S-Y3T62HF 2 1 3 Removing alternator Removing sequence 1 Alternator 2 Adjusting plate 3 Bracket 12-5
ELECTRICAL SYSTEM 1.
ELECTRICAL SYSTEM 2. Disassembling, inspecting and reassembling electrical system 2.1 Inspection before disassembling starter 2.1.1 Inspecting magnetic switch Perform the inspection as described below. If faulty, replace the magnetic switch with a new one. Switch CAUTION Do not apply current continuously for longer than 10 seconds. (1) Disconnect the connector of M terminal. (2) Pull-in test Connect the starter to the circuit as shown in the illustration.
ELECTRICAL SYSTEM 2.1.2 No load test Switch CAUTION Use as thick a wire as possible and firmly tighten each terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. (1) Connect the starter to the circuit as shown in the illustration. (2) In normal condition, the pinion pops out when the switch is turned ON, and the starter rotates at more than the specified rotation speed.
ELECTRICAL SYSTEM 2.
ELECTRICAL SYSTEM 2.2.1 Removing pinion set SW1 CAUTION The starter generates heat when current is being applied. Remove the pinion within 10 seconds. (1) Connect the starter to the circuit as shown in the illustration. (2) Turn the switches SW1 and SW2 ON to move the pinion out and then turn the SW2 OFF to stop the rotation of the armature and the pinion. (3) Place an appropriate tube on the pinion stopper. Tap the tube with a hammer to drop the pinion stopper to the clutch side.
ELECTRICAL SYSTEM 2.2.2 Removing magnetic switch Disconnect the leads, and remove the magnetic switch. Magnet switch 2.2.3 Removing rear bracket Remove the through bolts and screws of the brush holder, and then remove the rear bracket. 2.2.4 Removing brush holder and brush assembly Apply a socket (of the same diameter as the commutator) to the commutator of the armature. Remove the brush holder and brush assembly by sliding on the socket. 2.2.
ELECTRICAL SYSTEM 2.3 Inspecting and repairing starter 2.3.1 Inspecting brushes for wear Measure the length of the brushes. If the measured value is less than the limit, replace both the brush holder assembly and the brush assembly with new ones. Item Brush length Standard Limit 18 mm [0.71 in.] 11 mm [0.43 in.] Measure the length of the brush. Replace if the length is equal to or less than the limit. Inspecting brushes for wear 2.3.
ELECTRICAL SYSTEM 2.3.5 Measuring commutator outside diameter Measure the commutator outside diameter. If the measured value is less than the limit, replace the armature with a new one. Item Nominal Limit Commutator outside diameter ø32 mm [1.26 in.] 31.4 mm [1.236 in.] O dia utsid m e et er Measuring commutator outside diameter 2.3.6 Measuring undercut depth Measure the depth of undercutting between the commutator segments.
ELECTRICAL SYSTEM (3) Check continuity between segments in various combinations. If poor or no continuity is found, replace the armature with a new one. Inspecting continuity between segment 2.3.8 Inspecting field coil (1) Check for no continuity between the end of the coil (brush) and the yoke. (2) Check continuity between both ends of the coil. (3) Check that the pole piece and the coil is not loosen. (4) If it is defective, replace the yoke with a new one. Inspecting field coil 2.3.
ELECTRICAL SYSTEM 2.3.13 Inspecting magnetic switch Inspect the magnetic switch for following items. Replace the magnetic switch if it is defective. (1) Open circuit of coil Check continuity between terminal S and terminal M, also check continuity between terminal S and ground. if continuity does not exist, the coil has an open circuit. (2) Adhesion of contactor Check for no continuity between terminal B and terminal M. If continuity is found, the contactor is welded closed.
ELECTRICAL SYSTEM 2.4 Reassembling starter 10.8 ± 1 N·m {1.1 ± 0.1 kgf·m} [8 ± 0.7 lbf·ft] Apply grease Apply grease Apply grease Reassembling starter 2.4.1 Installing gear shaft (1) Install the lever to the overrunning clutch. (2) Fit the internal gear into the gear shaft. (3) Put the gear shaft into the overrunning clutch.
ELECTRICAL SYSTEM 2.5 Disassembling and inspecting alternator 3 2 Rotation 1 6 Rotation Crack, damage 8 7 Crack, damage 5 Short or open circuit 4 Coil open circuit, ground Disassembling and inspecting alternator Disassembling sequence 1 Pulley (with fan) 4 Coil 7 Regulator assembly 2 Front bracket assembly 5 Stator coil 8 Rectifier assembly 3 Rotor assembly 6 Rear bracket 2.5.
ELECTRICAL SYSTEM 2.5.2 Removing field coil CAUTION When removing the field coil, be sure to observe the removal order of screws. Otherwise, the outlet lines of the field coil will be damaged. If all the screws are removed, the coil will fall with its own weight. Be careful not to drop the coil. When removing the field coil, the outlet side of the coil may be caught with the stator. Do not pull the coil forcibly. Screw㧮 Screw㧭 Removing field coil (1) Unscrew the screw A. (2) Unscrew the screw B.
ELECTRICAL SYSTEM 2.5.5 Removing front bearing Remove the screw, and then remove the bearing retainer and front bearing from the front bracket. Front bracket Front bearing Removing front bearing 2.5.6 Removing stator CAUTION Unsoldering must be finished as quickly as possible. Extended heating will damage the diodes. Stator Lead wire Rectifier Unsolder the joint of the stator and remove the stator from the rectifier. Removing stator 2.5.
ELECTRICAL SYSTEM 2.6 Inspecting and repairing alternator 2.6.1 Inspecting stator (1) Checking continuity between lead wires. Check continuity between a pair of lead wires. Also check for no continuity between a pair of lead wires and other pairs of lead wires. If defective, replace the stator. Inspecting continuity between lead wires (2) Checking insulation between lead wire and core. Check for no continuity between each lead wire and the stator core. If continuity is found, replace the stator.
ELECTRICAL SYSTEM 2.6.3 Measuring field coil Measure resistance between the terminals of the field coil. If the measured value deviates from the standard value, replace the field coil with a new one.
ELECTRICAL SYSTEM 2.7 Reassembling alternator 147 ± 15 N·m {15 ± 1.5 kgf·m} [108.4 ± 11.1 lbf·ft] Reassembling alternator 2.7.1 Installing rectifier assembly and regulator assembly Install the rectifier assembly and regulator assembly on the rear bracket.
ELECTRICAL SYSTEM 2.7.2 Installing stator CAUTION Soldering must be finished as quickly as possible. Extended heating will damage the diodes. Stator Lead wire Rectifier Install the stator and solder the leads of the stator to the rectifier. Installing stator 2.7.3 Installing front bearing Drive the front bearing into the front bracket and secure the bearing retainer with a screw. Front bracket Front bearing Installing front bearing 2.7.
ELECTRICAL SYSTEM 2.7.6 Assembling stator and front bracket Assemble the front bracket, stator and rear bracket, and secure them with through bolts. Stator Front bracket Rear bracket Installing stator and front bracket 2.8 Inspecting glow plug 2.8.1 Continuity test of glow plug As shown in the illustration, check the continuity between the terminal and body. If there is no continuity or if the resistance is high, replace the glow plug. Item Standard 1.0 Ω Resistance value 2.8.
ELECTRICAL SYSTEM 2.9 Inspecting magnetic valve (stop solenoid) 2.9.1 Continuity test of magnetic valve (stop solenoid) Inspect the continuity between the terminal and body as shown in the illustration. If there is no continuity or if the resistance is lower than the standard value, replace the magnetic valve assembly with new one. Item Standard Resistance value 37 to 41 Ω (Ambient temperature: 23 ± 5°C [73.4 ± 9°F]) Continuity test of magnetic valve 2.9.
ELECTRICAL SYSTEM 3. Installing electrical system 3.1 Installing glow plug 1.25 ± 0.25 N·m {0.13 ± 0.03 kgf·m} [0.94 ± 0.2 lbf·ft] 17.5 ± 2.5 N·m {1.75 ± 0.25 kgf·m} [12.7 ± 1.
ELECTRICAL SYSTEM 3.
ELECTRICAL SYSTEM S6S-Y3T62HF Installing alternator 12-28
ELECTRICAL SYSTEM 3.
ADJUSTMENT AND OPERATION 1. Adjusting engine............................13-2 1.1 Inspecting and adjusting valve clearance13-2 1.1.1 Inspecting valve clearance .......................13-2 1.1.2 Adjusting valve clearance ........................13-2 1.2 Draining fuel system .............................. 13-3 1.2.1 Draining fuel filter .....................................13-3 1.3 Bleeding fuel system.............................. 13-3 1.3.1 Bleeding fuel filter.....................................13-3 1.
ADJUSTMENT AND OPERATION 1. Adjusting engine 1.1 Inspecting and adjusting valve clearance Inspect and adjust the valve clearance when the engine is cold. Item Valve clearance (when engine is cold) 1.1.1 Standard Inlet 0.25 mm [0.0098 in.
ADJUSTMENT AND OPERATION 1.2 Draining fuel system WARNING (a) When draining the fuel filter, fuel flows out with the water. Wipe up any spilled fuel thoroughly. Spilled fuel could cause a fire. (b) Tighten the drain plug securely after draining water otherwise fuel may leak out, and it could lead to a fire. When water stayed in the bottom of the fuel filter exceeds the specified level, the water may enter into the fuel system. Bleed the fuel filter of water in the following procedures. 1.2.
ADJUSTMENT AND OPERATION 1.4 Inspecting and adjusting fuel injection timing 1.4.1 Adjusting fuel injection timing When the fuel injection pump is replaced, adjust the fuel injection timing after the replacement. To adjust it, bring No. 1 cylinder piston to top dead center on compression stroke. Make sure that the marks on the flange plate and the fuel injection pump body are aligned. Gear case cover (1) Remove the gear case cover.
ADJUSTMENT AND OPERATION (4) Put a mark B on the flange plate where aligned with the mark A of the fuel injection pump. A B Alignment mark of fuel injection pump CAUTION When removing the flange plate from the fuel injection pump assembly, be sure to put a mark on the flange plate before removal to ensure proper reassembly. Flange plate Front plate Fuel injection pump Bracket (5) Unscrew the flange plate retaining bolt and remove the fuel injection pump from the front plate.
ADJUSTMENT AND OPERATION (8) Install the flange plate and the fuel injection pump gear to the fuel injection pump. (9) Align the mark A of the fuel injection pump with the mark B which was marked above procedure (4) and tighten the nut. Then install the retaining bolt to the nut.
ADJUSTMENT AND OPERATION 1.5 Inspecting V-belt and adjusting V-belt tension CAUTION (a) If defects such as cuts or surface separations are found during inspection, replace the V-belt. (b) Keep oil and grease away from the V-belt, since they may cause the V-belt to slip and shorten the service life. (c) Excessive V-belt tension can cause rapid wear of the alternator bearing and shorten the service life of the Vbelt. Adjust the belt tension accurately by following the procedures below. 1.
ADJUSTMENT AND OPERATION 2. Break-in operation After the engine is overhauled, install the engine to the dynamometer, and run the engine for break-in operation and inspection. 2.1 Starting up (1) Before starting the engine, check the levels of coolant, engine oil and fuel. Also check the inlet and exhaust systems. Bleed air from the fuel and cooling systems. (2) Stop the fuel supply, and crank the engine with the starter for about 10 seconds to lubricate the engine.
ADJUSTMENT AND OPERATION 3. Performance test (JIS standard) The following describes the procedures specified in "Earth moving machinery - Engines - Part 1: Test code of net power (JIS D0006-1)" and "Earth moving machinery Engines - Part 2: Standard format of specifications and testing methods of diesel engines (JIS D0006-2)." Other test items may be required in some applications. All test results should be evaluated comprehensively in order to determine the engine performance. 3.
ADJUSTMENT AND OPERATION 3.4.2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value. If the applicable range of the correction formula is exceeded, indicate the corrected values and record the test conditions on the test record.
