Service manual

TABLE OF CONTENTS
INTRODUCTION
Serial Number .......................................................... 2
Siphon Break
TESTING FOR OVERHAUL ........................................... 3
Disassembly
Assembly
ENGINE TROUBLESHOOTING (Charts) ................... A-7
ENGINE DISASSEMBLY, INSPECTION
AND ASSEMBLY
DISASSEMBLY PROCEDURES ..................................... 8
CYLINDER HEAD REMOVAL ........................................ 9
CYLINDER HEAD ....................................................... 10
Cylinder Head Inspection
Valve Guide Replacement
Valve Seat Repair
Installing the Cylinder Head
Bolt Tightening Sequence
VALVE AND VALVE SPRING INSPECTION ................. 11
Valve Removal
Valve Inspection
VALVE INSTALLATIONNALVE CLEARANCE ............... 12
Torquing the Cylinder Head Bolts
VALVE CLEARANCE ................................................... 12
VALVE ADJUSTMENT/INJECTION TIMING ................ 13
Timing Adjustment
GEAR CASE/GOVERNOR ............................................ 14
Front Oil Seal Replacement
Governor Shaft/Disassembly Inspection
Installing the Governor Shaft
TIMING GEAR/CAMSHAFT ........................................ 15
Removing the Timing Gears
Timing Gear Inspection
Valve Camshaft Removal
Injection Pump Camshaft Removal
CAMSHAFT/PISTONS
AND CONNECTING RODS .......................................... 16
Inspecting the Camshaft
Installing the Camshaft/Gears
Piston and Connecting Rod Disassembly
PISTON AND CONNECTING ROD ......................... 17-18
Inspection
Piston Ring End Gap
Piston Ring Side Clearance
Installation
Installing the Piston Rings
Installing the Piston and Connecting Rod
CRANKSHAFT ............................................................ 19
Removal/Inspection
Rear Oil Seal Replacement
Inspecting the Oil Clearance
Installing the Crankshaft
CYLINDER BLOCK ..................................................... 20
Inspection
Bore Dimensions
Cylinder Reboring
ENGINE ASSEMBLY .............................................. 21-22
TORQUE SPECIFICATIONS ........................................ 23
GOVERNOR SYSTEM ........................................... 24-25
Disassembly/Inspection
Installation
EXHAUST MANIFOLD/HEAT EXCHANGER ................. 26
FUEL INJECTION PUMP ............................................ 27
FUEL INJECTORS ................................................. 28-29
GLOW PLUGS ........ .- ................................................... 30
Fuel Lift Pump
Inlet Fuel Filter
TACHOMETER ............................................................ 31
ENGINE ADJUSTMENTS ....................................... 32-34
Measuring Compression
Belt Adjustment
Testing Oil Pressure
Adjusting Idle Speed
Fuel Run/Shut-Off Solenoid
RAW WATER PUMPS .......................................... 35-36
ATLERNATOR TESTING ........................................ 37-38
STARTER MOTOR TESTING ................................. 39-42
TRANSMISSION ...................................................... .43
ENGINE SPECIFICATIONS ......................................... .44
WIRING DIAGRAMS ............................................ .45-46
SERVICE DATA/STANDARDS LIMITS .................. .47-48
STANDARD HARDWARE TORQUES .......................... .49
REMOTE OIL FILTER ................................................. 50
METRIC CONVERSION DATA ............................... 51
Engines & Generators
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