97821-02031_shop Manual 6d1(for Industrial Use)_sep.2004.pdf

6 D 1 (for industrial use)

PUb.No.97821-02031 , SEPTEMBER 2004

Shop Manual diesel engine

FUSO

6D1 diesel engine

Shop Manual (for industrial use)

GROUP INDEX HOW TO READ THIS MANUAL GENERAL ...................... _ ENGINE ........................ . LUBRICATION ...................

1fII

FUEL AND ENGINE CONTROL ... _

FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi 601 series diesel engine, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in orderto perform correct service with no wastage. For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models 6014 6014-T 6015-T 6016 6016-E 6016-T 6016-TE 6016-TL 6016-TLE

© 2003 Mitsubishi FUSO Truck & Bus Corporation Printed in Japan

ELECTRONICALLY CONTROLLED FUEL SYSTEM

m-:II ... ~

COOLING ....................... INTAKE AND EXHAUST ..........

IEI l1li

CLUTCH ....................... . ELECTRICAL SYSTEM ........... _ SPECIAL EQUIPMENT .......... .

HOW TO READ THIS MANUAL HOW THIS MANUAL IS COMPILED ........................

ii

GENERAL EXPLANATION OF THIS MANUAL . . . . . . . . . . . . . . .

iii

TERMS AND UNITS ......................................

vii

HOW TO READ THIS MANUAL How This Manual Is Compiled • This manual is compiled by classifying various systems into certain groups. • Each group contains specifications; troubleshooting; maintenance service standards; fluid and sealant; I.Q special tools; and service procedure.

0

tightening torque; ~ lubricant,

• Page enumeration is independent by every group where firs page is always 1. Group No.

II

Group denomination

Contents

00

General

General specifications, engine No. and name plate, precautions for maintenance operations, table of standard tightening torques

11

Engine

Engine body

12

Lubrication

Lubrication system

13

Fuel and engine control

Fuel system

14

Cooling

Cooling system

15

Intake and exhaust

Intake and exhaust system, turbocharger, intercooler

21

Clutch

Clutch proper, bearing case

54

Electrical system

Alternator, starter, preheating system, engine start system, automatic stop system

61

Special equiprnent

Air compressor, pressure governor

General Explanation of This Manual • Specifications Particulars relative to maintenance service are made. • Structure and operation (1) Regarding conventional equipment, descriptions are made in brief. (2) Regarding new equipment, descriptions of system and operating condition are made in detail. • Troubleshooting Symptoms of troubles and possible causes are described comparatively. • Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle.

• Service procedure In principle, an explanation is given at the spread title page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation.

Regarding the design of this manual CLUTCH BODY p,.. .ure Plate and Lever A.sembly

,-

• DI_Hmbty'

Mquence

:~"1 a

nv.ade oistlapoo.

13,14

SIIdIngRllf_ot"'-'llPO-

~

Pressure spring cap RebJmspnng Releaseleverplsle Clutch cover

Slicingaurteceeolltllea' Slklngaurf.oeeolllupf:

4 ~::::~:;-;-:_'---,--E=~~=~:==:_'----I7-::.:c:::;:.::]

Special tool.

11

Bushing Support lever Raleaselever Bushing

Unit"mm

Tool name and shape

Location

12 Release lever pin 13 $upportieverpm 14 15 16 17

1 10,16 12,17

[NLGI No. 2(LI soap)]

7 Prel (DGTv,--

8 9 10 11

Quantity

PoInhlolappilcatloo

location

2 Washer 3 Washer

--5 ~ ,

2 Pressureplale&leverassemtHy

lrp21-12

--

" "."

3 Clutch disc •. Flywheel

A: Positioning pin (a12 places)

Part No.

18 .... 11 ....

13~

14 .... ,6 .... k~:

11b. .

~9.2012n

(~'5-· """""

,,>5

7 ---16 .... 5 ..... 4 .... 3 .... 2 .... '

-.

Unit mm

Slandardvalue {Basic diameter in { ])

Melntenanceitem 1,10.

limit

Cl&ilrAACClbetweMlBlrapboltandslrappiat.

750N (78.7kgf)

5.0 04 difference

R,...."

...,...

--~ Adjus1

0.5 or Ie8s

o nghtenlng torque Locallon

1. 1a. 1b.

2. 3.

4. 5. 6.

Parla 10 br

,

Strap bolt (seeuril"lg 8h"I

4

8oI1(MIOUIinglockplak

3

Tlllhtening torque

ReIeue ...... plldehelghl.djulI!ITIenl

"""

dutch release

Service atandard.

~lfllIlltIdmatalallonolciutchcover

?

0: Non-r8usable part

Repair

MH061OS1

Application

Remarks

39 to 59 {4 to 61

~~m ~:

19 01280

• service procedure [I] [!I ctMrance betwMn strap bolt and lItnIp p'" II the measurement exceeds the limit, replace the detective part

A: Strap plate

[l]

I.......n.tion of PfMIW1I apring

"pr9Mure plale 18 has been reground, Inser! adjusllng washer A corresponding 10 the amount of regrind in !he space betWe«t ItIe pressure plale and pf8S8UJlt spring 7. Typeandno.ofwuhere

1 mmorrnorel01eMlhan2mm 2mmormorelo .... lhan3mm

Onal.2-mm Twol.2·mmor0f\&2.3-mm

.•

~----'_-=':.:::."7:.:::. .• =(O.6c:c"0::::' .•J_--'--'=---'

Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. Names of parts show an example of the disassembly (removal) sequence. When the assembly (installation) sequence differs from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown. Service standards are shown collectively, classified by location. Tightening torques are shown collectively, classified by location. Points of lubricant, fluid and sealant application are shown collectively, classified by location. Special tools to be used are shown collectively, classified by location. When it is considered hard to understand the service procedure, just by the foregoing description, a supplementary description of the service procedure is given.

iii

HOW TO READ THIS MANUAL 1. Illustration for disassembly and assembly or removal and installation

This shows the key No. of the part. In the text, this No. is referred to uniformly throughout.

This shows that the appropriate service procedure is described in the text.

CLUTCH BODY Pressure Plate and L ver Assembly •

sembly sequence

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _O,,-,1::.:.27..:..J6

This shows an example of the disassembly (removal) sequence.

Strap bolt Washer Washer Boft Lockplate Support nut Pressure sp~ ___________

This shows that the service procedure is described in another section.

mGrOO

COpOO-OO

Pressure spring cap Return spring Release lever plate Clutch cover Release lever pin Support lever pin Bushing Support lever Release lever Bushing

: shows reference page within the same group.

co GrOO

shows reference group within the same book.

2 Pressure plate & lever assembly mp21-12 3 Clutch disc

*. Flywheel A: . ioning pin (at 2 places) .,: Non-re ble part • Assembly sequence 16-> 17 -> 12-> 10->9->8-> 7 ->6->5->4->3-> 14-> 15-> 13----.T

Repair kit: clutch release lever kit

Meaning of symbols 0: shows that the tightening torque is specified. ~: shows that application of lubricant, fluid or sealant is required. 0: shows that the part should not be reused.

No service procedure is referred to in this section, but the item can be an objective of various procedures. This is shown when the assembly (installation) sequence is not the reverse of the disassembly (removal) sequence.

This shows that a repair kit is available.

iv

2. Service standards table Only the relevant service standards are shown.

Service standards

Unit:mm Maintenance item

Location

Clearance between strap bolt and strap plate

1,11

Pressure spring

7

Installed load (Installed length 49.1) Tilt

Standard value

Limit

Remedy

0.01 toO.16

0.3

Replace

835 N {85 kgf}

710 N {72.3 kgf}

Replace

2.9 or less

5.0

Replace

This shows the key No. of the relevant part.

3. Tightening torque table This shows specified tightening torque .

o

•

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened

1

Strap bolts (Strap bolt mounting)

4

Bolt (Lock plate mounting)

Tightening torque

Remarks

39 to 59 {4 to 6}

-

5.9 to 7.8 {0.6 to O.B}

Wet

This shows the key No. of the relevant part.

This shows that the item is to be tightened wet.

4. Lubricant, fluid and sealant table Only the relevant lubricant, fluid and sealant are shown. This shows the application pOint. ~

Lubricant, fluid and sealant

Location

1 10,16

Points of application

r

Kinds

Quantity

Thread area of bolt

LOCTITE 272

As required

Friction surfaces of release lever plate and release lever

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

This shows the key No. of the relevant part.

This shows the specified brand.

v

HOW TO READ THIS MANUAL 5. Special tools table Purpose of special tools is shown.

Only the relevant special tools are shown.

+

I.Q Special tools Location

Unit:mm

Part No.

Tool name and shape

Application

11

Clutch installer

MH061051

Removal and installation of clutch cover

16

Master plate

MH062291

Adjust release lever heights

01278

This shows the key No. of the relevant part.

Quote this number when placing an order for the part.

6. Service procedure This indicates a special service tool.

This shows the key No. of the relevant part.

~

[!!] •

• •

Removal and installation of clutch cover

Depress pressure spring 7 using [g clutch installer, then remove the following parts: Strap bolt 1, washer 2, washer 3, bolt 4, lock plate 5, support nut 6 Loosen the clutch installer gradually, then remove clutch cover 11 when the pressure spring is fully released. For installation, follow the removal sequence in reverse.

The key No. referred to in the text is always the same as the key No. shown in the illustration.

vi

Servicing procedures of disassembly (removal), assembly (installation), inspection, adjustment, etc. are shown collectively.

Terms and Units The terms and units in this manual are defined as follows. • This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER&,

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING&'

Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION&' - - - Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or a better understanding.

• Front and rear The terms "front" is the fan side and "rear" the flywheels side of the engine. • Left and right The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine. • Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [ 1is the basic diameter. (2) Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. • Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque.

Vll

HOW TO READ THIS MANUAL • Unit

Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Systeme International d'Unites Example: 390 N'm {40 kgf·m}

-r-

L

Metric unit

L S I unit

SI unit {metric unit}

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N·m {kgf·m}

9.80665 N· m {1 kgf· m}

kPa {kgf/cm2}

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH 2O}

9.80665 Pa {1 mmH 2O}

Volume

dm 3 {l}

1 dm 3 {1 l}

Power

kW iPS}

0.7355kW {1 PS}

Heat quantity

J {kcal}

4186.05 J {1 kcal}

W {kcal/h}

1.16279 W {1 kcal/h}

°

-

Temperature

°C

-

Electric current

A

-

Voltage

V

-

Resistance

Q

-

Electric power

W

-

Foot-pound unit

Conversion rate

Unit Force Moment of force Positive pressure Pressure

Vacuum pressure

Heat flow Angle

SI unit

Unit Force

N (Newton)

Ibf

Moment of force

N·m

ft.lbs

Pressure

kPa (kilopascal)

psi

Volume

l

gal.

cm 3

oz

cm 3

cu.in.

Power

kW (kilowatt)

PS

Temperature

°C

of

Mass quantity of matter

kg

Ib oz

Dimension

viii

9 m mm

ft. in.

= 0.2248 Ibf 1 N· m = 0.7375 fUbs 1 kPa = 0.145 psi 1 kPa = 0.2953 in. Hg 1 l = 0.2642 gal. (U.S.) 1 l =0.220 gal. (Imp.) 1 cm 3 = 0.033814 oz (U.S.) 1 cm 3 = 0.035195 oz (Imp.) 1 cm 3 = 0.061023 cu.in. 1 kW = 1.3596 PS tOC = (1.8tOC + 32)OF 1 kg = 2.2046 Ib 1 9 = 0.035274 oz 1 m = 3.2808 ft. 1 mm = 0.03937 in. 1N

00

GROUP 00 GENERAL GENERAL SPECIFICATIONS ..............................

00-2

ENGINE NUMBER AND NAME PLATE. . . . . . . . . . . . . . . . . . . . . .

00-3

PRECAUTIONS FOR MAINTENANCE OPERATION ..........

00-4

TABLE OF STANDARD TIGHTENING TORQUES ............

00-12

00-1

GENERAL SPECIFICATIONS Specifications

Item 6014

Engine model

6014 -T

6015 -T

601616016 -E

6016160161601616016 -T -TE -TL -TLE

6-cylinder in-line, water-cooled 4-cycle diesel

Type

Oirect injection type

Combustion chamber type

Overhead valve (OHV) type

Valve mechanism 110 x 115

Bore x Stroke mm

113 x 115

6557

Total displacement cc

118 x 115

6919

Compression ratio

17.5

16

Empty mass kg*

500

540

7545 17.5

I

19

500

I

16 550

I

17.5

560

* Empty mass as measured according to Mitsubishi Motors Corporation standard.

Engine Outputs Classified By Application

~

6014

Middle-speed specification

Application

Intermittent rated output kW (HP)

6014-T High-speed specification

6016-T Middle-speed specification

High-speed specification 101 (136)/1500 121 (163)/1800

59 (79)/1500 70 (94)/1800

83 (111)/1500 98 (132)/1800

79 (106)/1500 95 (127)/1800

71 (95)/1500 85 (114)/1800

106 (142)/1500

77 (103)/2000 82 (110)/2200

106 (143)/2000 111 (150)/2200

103 (139)/2000

93 (125)/2000 101 (135)/2200

131 (176)/2000 140 (188)/2200

87 (117)/2500 92 (123)/2800 Continuous rated output kW (HP)

6016

111 (150)/2200 120 (161 )/2500 126 (168)/2800

123 (165)/1800

111 (149)/2500 120 (161)/2800

151 (203)/2800

53 (72)/1500 64 (86)/1800

75 (101)/1500

72 (96)/1500

65 (87)/1500

96 (129)/1500

92 (123)/1500

89 (120)/1800

86 (115)/1800

77 (103)/1800

111 (149)/1800

110 (148)/1800

70 (93)/2000 74 (99)/2200

96 (129)/2000 101 (136)/2200

94 (126)/2000 101 (136)/2500

84 (113)/2000 93 (125)/2200

119 (160)/2000 127 (170)/2200

118 (158)/2000 125 (168)/2200

109 (146)/2500 114 (153)/2800

101 (135)/2500 110 (147)/2800

79 (106)/2500 83 (111)/2800

NOTE 1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.

00-2

131 (175)/2000 139 (186)/2200 147 (197)/2500

133 (178)/2500 137 (184)/2800

00

ENGINE NUMBER AND NAME PLATE

The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its own number. This number is required for incidental inspection of the engine. Please do not fail to mention this number to the dealers when ordering spare parts.

Engine Number Engine number 1 is punch-marked on the left of the crankcase.

1

Example: 6016-000000

1

Engine model

LEngine number

Name Plate The name plate is attached to the portion shown in the illustration, and indicate the following items.

Name plate

18779

1 Engine model

1

t-

.... 1

2 Total displacement 1

JIr

TOTAL CYL VOL. 6557cc (400cu. in) OUT PUT 0 / rp MITSUBISHI MOTORS CORPORATION TOKYO JAPAN

c::::J

c==J

-

2

3

3 Maximum output 4 Valve clearance 5 Firing order

6 Fuel injection timing

VALVE CLEARANCE (COLD) INLET a EXHAUST O.4mm(O.016 in)-p-FIRING ORDER 1-5-3-6-2-~1 FUEL INJECTION TIMING °BTDC~5

4

6

18780

00-3

PRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the customer's demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure. Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual.

18770

Perform maintenance work at a level area. Prepare the following. • Prepare general and special tools necessary for the maintenance work.

WARNING'&' - - - - - - - - - - - - - Do not attempt to use tools other than special tools where use of special tools is specified in this manual. This will avoid injury or damage.

Pay special attention to safety when removing or installing heavy items such as engines, transmissions.

o

x

When lifting up heavy items using cables, pay special attention to the following points: • Check the mass of the item to be lifted and use a cable capable of lifting that mass.

14194

• If you do not have the specified lifting hanger, secure the item using cable taking the point-of-balance of the item into consideration.

14195

• You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls.

00-4

00 Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to accidentally bump switches or levers.

00012

Check for oil leakage before cleaning the area having the fault otherwise you might miss detecting the leakage. Prepare replacement part(s) beforehand.

00014

"-

"

"

~

.........

;...

/'

~~~~ij~~~OO~ [fOO?ElID ./

--

--

"

/

Replace oil seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

/

00015

['>C)g~0 ,,\

f

,,0 ~

On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

",/'

00016

00-5

PRECAUTIONS FOR MAINTENANCE OPERATION Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where performance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust.

CAUTION,&.-------------• Take care to avoid mixing up numerous parts, similar parts, left and right, etc. • Keep new parts for replacement and original (removed) parts separate.

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oil, grease, etc. for lubricant, remove the excess immediately after application with a piece of waste, etc.

CAUTION,&.-------------------------When the specified lubricant, fluid and sealant is not available, you may use an equivalent.

00018

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries to prevent them from short-circuiting and burning-out.

CAUTION'&' - - - - - - - - - - - - - - - - - - - - - - - - - Be sure to turn starter and lighting switches, etc. off before disconnecting or connecting battery terminals, because the semiconductors can be damaged.

00-6

00 Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit.

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.

When washing the vehicle, cover the electric system parts and instruments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00023

When using an electric welder, such electronic parts that are directly connected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit. Parts that have switches might be subject to the same danger if the switches are left on. Therefore, do not fail to observe the following. • Connect the negative terminal of the welder as near as possible to the area that is to be welded. • Disconnect the negative terminals of batteries.

To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt. Do not apply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always fed the battery voltage.

14185

00-7

PRECAUTIONS FOR MAINTENANCE OPERATION When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.

00027

Measurement Procedures Using Connectors

A~

Connect the test harness and connector A between these parts 02587

Test with connectors engaged (continuity through circuit obtained) <Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connector.

Insert test probe C from the harness side of the connector. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.

C

02588

Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

00-8

00 Using male pins Touch the pins directly using test probes.

CAUTION&-------------Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit.

02590

Connector Inspection Procedures Visual inspection Check for loose connection and poor engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

Check for a decrease in contact pressure between the male and female terminals.

02593

Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles.

00-9

PRECAUTIONS FOR MAINTENANCE OPERATION Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the terminals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness gently.

02594

Inspection Procedures for Blown Fuses Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present.

A

The major causes of a short circuit are as follows: • Harness stuck onto the vehicle body. • Harness sheath damaged by friction or heat. • Water in connectors or circuits. • Mistakes (accidental short circuits) A: Battery B: Fuse C : Loaded switch 0: Load E: Short circuit

o

02596

Precautions for Handling Alternator When servicing the alternator, pay attention to the following: • Do not connect the alternator with battery polarities reversed. If the alternator is connected with reversed polarities, a large current flow from the battery to the alternator occurs, and the diode or regulator might be damaged.

04746

00-10

00 • While the engine is running, do not remove the battery terminals. If the battery terminals are removed at that time, a surge voltage is generated and the diode or regulator might be weakened.

• Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.

02371

• Do not splash water over the alternator. If water is directly splashed over the alternator, individual components will be short-circuited and might be destroyed.

05165

• Do not short-circuit terminal B and terminal L while running the alternator. If the terminals are short-circuited while the alternator is running, the diode trio might be destroyed.

04749

• Disconnect the battery terminals before quick-charging the battery. Quick-charging without disconnecting the battery terminals might damage the diode or regulator.

00-11

TABLE OF STANDARD TIGHTENING TORQUES • Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise specified. • Threads and contact seats shall be dry. • Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply.

Hex-head Bolt and Stud Bolt Strength classification

~ sentation

Diameter symbol

Unit: N . m {kgf· m}

7T

4T

@) 0 @ (Stud)

8T

e

®8 0 ® @ (Stud)

-

4 to 6 {OA to 0.6}

4 to 6 {OA to 0.6}

-

M8

9 to 14 {0.9 to 1A}

M10

02154

(Stud)

-

5 to 7 {0.5 to 0.7}

-

7 to 11 {0.7to1.1}

-

8 to 12 {0.8 to 1.2}

-

-

17 to 26 {1.7 to 2.6}

-

20 to 29 {2.0 to 3.0}

-

19 to 28 {1.9 to 2.8}

18 to 26 {1.8 to 2.7}

36 to 52 {3.5 to 5.5}

33 to 49 {3.3 to 5.0}

45 to 60 {4.5 to 6.0}

41 to 59 {4.3 to 6.9}

M12

35 to 50 {3A to 5.0}

31 to 46 {3.1 to 4.7}

70 to 95 {7.0 to 9.5}

65 to 85 {6.5 to 8.5}

85 to 110 {8.5 to 11}

75 to 100 {7.5 to 10}

M14

60 to 85 {6.0 to 8.5}

55 to 75 {5.5 to 7.5}

120 to 160 {12to16}

110 to 140 {11 to 14}

130 to 180 {13to18}

120 to 160 {12 to 17}

M16

90 to 130 {9.5 to 13}

90 to 120 {9.0 to 12}

180 to 240 {18 to 24}

160 to 220 {16 to 22}

200 to 270 {20 to 27}

190 to 260 {19 to 26}

M18

140 to 190 {14to19}

120 to 160 {12 to 16}

260 to 340 {25 to 35}

220 to 290 {22 to 30}

290 to 390 {30 to 40}

260 to 340 {26 to 35}

M20

190 to 260 {19 to 26}

170 to 230 {17 to 23}

350 to 470 {36 to 48}

320 to 420 {32 to 43}

410 to 550 {41 to 56}

370 to 490 {37 to 50}

M22

260 to 340 {26 to 35}

230 to 300 {23 to 31}

470 to 640 {48 to 65}

430 to 570 {43 to 58}

550 to 740 {56 to 75}

490 to 670 {50 to 68}

M24

340 to 450 {34 to 46}

290 to 390 {29 to 40}

630 to 840 {63 to 86}

540 to 730 {55 to 74}

730 to 980 {74 to 100}

630 to 840 {64 to 86}

M5

2 to 3 {0.2 to 0.3}

M6

Hex-head Flange Bolt Strength classification

Unit: N·m {kgf·m}

4T

~0 sentation

Diameter symbol

7T

8T

~

~

~

~

0

02154

M6

4 to 6 {OA to 0.6}

-

8 to 12 {0.8 to 1.2}

-

9 to 14 {0.9 to 1A}

-

M8

10 to 15 {1.0 to 1.5}

-

19 to 28 {1.9 to 2.8}

-

22 to 32 {2.2 to 3.3}

-

M10

21 to 30 {2.1 to 3.1}

20 to 28 {1.9 to 2.9}

39 to 58 {3.9 to 6.0}

37 to 53 {3.6 to 5A}

50 to 65 {5.0 to 6.5}

45 to 65 {4.5 to 6.5}

M12

38 to 54 {3.8 to 5.5}

35 to 51 {3A to 5.2}

80 to 110 {8.0 to 11}

70 to 95 {7.0 to 9.5}

90 to 120 {9.0 to 12}

85 to 110 {8.5to11}

00-12

00 Hex-head Nut

Unit: N· m { kgf· m}

Strength classification Representation

Diameter symbol

6T

4T

@

@

©

ED]

(ED 02155

Standard screw

Coarse screw

Standard screw

Coarse screw

M5

2 to 3 {0.2 to 0.3}

-

4 to 6 {OA to 0.6}

-

M6

4 to 6 {OA to 0.6}

-

7 to 11 {0.7 to 1.1}

-

M8

9 to 14 0.9 to 1A}

-

17 to 26 {1.7 to 2.6}

-

M10

19 to 28 {1.9 to 2.8}

18 to 26 {1.8 to 2.7}

36 to 52 {3.5 to 5.5}

33 to 49 {3.3 to 5.0}

M12

35 to 50 {3A to 5.0}

31 to 46 {3.1 to 4.7}

70 to 95 {7.0 to 9.5}

65 to 85 {6.5 to 8.5}

M14

60 to 85 {6.0 to 8.5}

55 to 75 {5.5 to 7.5}

120 to 160 {12 to 16}

110 to 140 {11 to 14}

M16

90 to 130 {9.5 to 13}

90 to 120 {9.0 to 12}

180 to 240 {18 to 24}

160 to 220 {16 to 22}

M18

140 to 190 {14to19}

120 to 160 {12 to 16}

260 to 340 {25 to 35}

220 to 290 {22 to 30}

M20

190 to 260 {19 to 26}

170 to 230 {17 to 23}

350 to 470 {36 to 48}

320 to 420 {32 to 43}

M22

260 to 340 {26 to 35}

230 to 300 {23 to 31}

470 to 640 {48 to 65}

430 to 570 {43 to 58}

M24

340 to 450 {34 to 46}

290 to 390 {29 to 40}

630 to 840 {63 to 86}

540 to 730 {55 to 74}

Hex-head Flange Nut Strength classification Representation

Diameter symbol

Unit: N· m {kgf· m} 4T

(@) Standard screw

02155

Coarse screw

M6

4 to 6 {OA to 0.6}

-

M8

10 to 15 {1.0to1.5}

-

M10

21 to 30 {2.1 to 3.1}

20 to 28 {1.9 to 2.9}

M12

38 to 54 {3.8 to 5.5}

35 to 51 {3A to 5.2}

00-13

TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flare nut for general purpose Pipe diameter Tightening torque

Unit: N· m {kgf· m}

<1>4.76 mm

<1>6.35 mm

8mm

10mm

<1>12 mm

15mm

17 {1.7}

25 {2.6}

39 {4.0}

59 {6.0}

88 {9.0}

98 {1 O.O}

Tightening torque for air piping nylon tube for general purpose {DIN type} 6 x 1 mm

Standard diameter Tightening torque

20+ 6 -0

{ 2.0

~g.6 }

10 x 1.25 mm 29+ 10 -0

{ 3.0

~~.o }

12 x 1.5 mm 49+ 10 -0

{ 5.0

~~.O }

Tightening torque for air piping nylon tube for general purpose {SAE type} 1/4 in.

Standard diameter Tightening torque

00-14

13+4 -0

{ 1.3

3/8 in.

~g.4 }

29+ 5 -0

{ 3.0

Unit: N· m {kgf' m} 15 x 1.5 mm 54+ 5 -0

49+5 -0

{ 5.0

~~.o }

Unit: N· m {kgf· m} 5/8 in.

1/2 in.

~g.5 }

{ 5.5

~g.5 }

64+ 5 -0

{ 6.5

~g.5 }

11

GROUP 11 ENGINE SPECIFICATIONS ........................................

11-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5. 6. 7.

Cylinder Head and Crankcase ................................... Valve Mechanism............................................... Connecting Rods.......... .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons ........................................................ Timing Gears .................................................. Flywheel .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel PTO ..................................................

TROUBLESHOOTING. . . . . . . . .. . . . . . . .. . . .. . . . . . . .. . . . . . . .

11-3 11-4 11-4 11-5 11-5 11-6 11-6

11-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Inspecting and Adjusting Valve Clearances ......................

11-8 11-10

CYLINDER HEAD AND VALVE MECHANiSM................

11-12

PISTONS, CONNECTING RODS, AND CYLINDER LINERS ...

11-28

FLYWHEEL PTO .........................................

11-44

FLYWHEEL ..............................................

11-48

TIMING GEARS ..........................................

11-54

CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-64

CRANKSHAFT AND CRANKCASE.........................

11-72

11-1

SPECIFICATIONS Specifications

Item 6014

Engine model

6D15-T

6D14-T

6016

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

Total displacement Compression ratio

11-2

6D16-T 6D16-TE 6D16-TL

6D16-TLE

6-cylinder, in-line, water-cooled, 4-cycle diesel

Type

Cylinder bore x stroke

6D16-E

mm

<»110 x 115

<»113 x 115

<»118 x 115

6557

6919

7545

cc 17.5

16.0

17.5

19

16.0

17.5

STRUCTURE AND OPERATION

11

1. Cylinder Head and Crankcase <Engines with wet type cylinder liners: 6014, 14-T, 15-T>

Connecting plate Glow plug Cylinder liner O-ring Crankcase Water jacket Piston 8 Injection nozzle 9 Cylinder head

1 2 3 4 5 6 7

A: Cylinder liner size mark: A, B, C • The cylinder liners 3 are a removable wet type liners. They are press-fitted into the top of the crankcase 5 and the bottom of the water jacket 6. • The O-rings 4 are provided to prevent the ingress of coolant. • The cylinder liners 3 and pistons 7 have size marks. The liner and piston that are paired should be of the same size mark. A

3

01924

<Engines with dry type cylinder liner: 6015-T, 16, 16-E, 16-T, 16-TE, 16-TL, 1 2 3 4 1 5 6 7 8

16-TLE> Connecting plate Glow plug Cylinder liner Crankcase Water jacket Piston Injection nozzle Cylinder head

A: Cylinder liner size mark Outer diameter mark: 1, 2, 3 Inner diameter mark: A, B

7

A

3

• The cylinder liners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fitted into the crankcase 4. • The cylinder liners 3, crankcase 4, and pistons 6 have size marks. They should be combined as specified according to the size marks. CD P.11-28

01925

11-3

STRUCTURE AND OPERATION 2. Valve Mechanism 10

9

/

11

, ---15

1,2

16

4

2 3 01926

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16

Exhaust valve Inlet valve Camshaft Tappet Push rod Rocker shaft Rocker shaft spring Rocker Rocker shaft bracket Valve cap Valve cotter Upper retainer Outer valve spring Inner valve spring Valve stem seal 'Jalve guide

• The valve stem seals 15 are fitted onto the valves 1 , 2 to control the amount of lubricant flowing onto the sliding surfaces of the valves 1, 2 and valve guides 16. • The valve springs 13, 14 are unevenly pitched to prevent abnormal vibration at high speeds. To prevent the inner and outer springs from meshing with each other, the springs are wound in opposite directions. • To facilitate removal and reinstallation of the camshaft from the rear end of the crankcase, the diameter of each bushing is smaller toward the front of the engine.

3. Connecting Rods <6014, 15-T (A-type), 16,16E> 1

1 2 3 4 5

<6014-T, 15-T (B-type), 16-T, 16-TE, 16-TL, 16-TLE> 1

2

3

B

A

3

4 13622

11-4

Connecting Connecting Connecting Connecting Connecting

rod rod rod rod rod

bushing bearing cap bolt

A: Alignment mark B: Weight mark stamp (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z: <except 6D16-TLE» (A, B, C, D, E, F: <6D16-TLE»

11 4. Pistons B

A: Part number B: "T" mark <6014-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE> C: Size mark (A, B, C: <6014, 14-T, 15-T» (A, B: <6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE» 0: Weight mark L\: Front mark

c

~o o

"~"

16936

5. Timing Gears 1 2 3 4 5 6

Camshaft gear No.2 idler gear No. 1 idler gear Oil pump gear Crankshaft gear Air compressor drive gear or injection pump drive gear 7 No. 1 idler gear 8 PTO idler gear <models with flywheel PTO> 9 PTO idler gear <models with flywheel PTO>

<Without flywheel PTO>

Each gear is stamped with a timing gear alignment mark ("1", "2", "3", or "4") to facilitate reassembly.

16937

<With flywheel PTO>

16938

11-5

STRUCTURE AND OPERATION 6. Flywheel I 111111111111111111111

1 Flywheel 2 Pilot bearing 3 Ring gear

'I"

A: Angle scale, cylinder number

3 2 A I hlllllllllllllllllll'I'

01934

7. Flywheel PTO 1 2 3 4

1

5

6 7 8 9

Flange PTO shaft PTO idler shaft Flywheel housing Crankshaft gear No. 1 idler gear PTO idler gear PTO idler gear PTO gear

The flywheel PTO is fitted onto the top of the flywheel housing 4 and is driven by the crankshaft gear 5.

4

01935

11-6

11

TROUBLESHOOTING Symptoms

Q)

::J

a.

"5 0

'Q)

Incorrect/defective fuel Incorrect valve clearance Defective cylinder head gasket Worn valve/valve seat, and carbon deposits Weakened valve spring Worn/damaged piston ring(s) Worn/damaged piston ring groove(s) Incorrect injection timing Defective injection pump Defective cooling system Defective injection nozzle(s) Air trapped in fuel system Clogged air cleaner Clogged muffler Defective turbocharger Incorrectly fitted pipe(s)/hose(s) Injection pump, alternator, or other auxiliary device(s) defective/incorrectly fitted Loose/damaged V-belt Incorrectly fitted crankshaft pulley Defective air cleaner or muffler Defective valve spring(s) Defective rocker shaft and bracket Incorrect lubrication of rocker shaft bracket Incorrect backlash in timing gears Incorrect lubrication of timing gear peripheries and idler shafts Worn connecting rod small end bushing and piston pin Worn/damaged crankshaft pin and connecting rod big end bearing Worn/damaged crankshaft journal and main bearing Excessive end play in crankshaft and camshaft Worn tappet(s) and camshaft

c "0> c Q)

a.

'-

$:

Possible causes

Q)

$:

0 --l

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Remarks

C

Cii

0

Incorrect oil viscosity

en

"0

E

0

c

.!)


OJ Gr 12 OJ Gr 13 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

OJ Gr 13

mGr 13 OJ Gr 14 OJ Gr 13 OJ Gr 13 OJ Gr 15 III Gr 15 OJ Gr 15 OJ Gr 13 OJ Gr 13, 54 rJ]Gr 14

OJ Gr 15

11-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure Service standards Maintenance item

Location

-

Each cylinder (at 200 rpm)

Compression pressure

Standard value

Limit

Remedy

Except 6D16-E

2550 kPa {26 kgf/cm2}

1960 kPa {20 kgf/cm2}

Inspect

6D16-E

2940 kPa {30 kgf/cm2} 390 kPa {4 kgf/cm 2}

Inspect

Cylinder-to-cylinder pressure difference

-

I:Q Special tools

Unit: mm

Location

Part No.

Tool name and shape

Application

16W x 18 thread Compression Gauge Adapter

MH061461

Centre distance 46

Measuring compression pressure

01942

Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take measurements regularly and keep track of changes; an overview of pressure variations can be useful in fault diagnosis. During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly as piston rings, valve seats, and other parts fit snugly in position. The pressure will then normalize as parts wear. • Before inspections, check that the engine oil, starter, and battery are normal. • Warm up the engine until the coolant temperature reaches 75 to 85°C. • Turn off all lights and auxiliary devices. • To prevent injection of fuel while cranking the engine by the starter, perform the following steps. • Set the stop lever of the injection pump governor to the stop position. <Mechanical governor> • Remove fuse 1 shown in the diagram below. Forthe terminal arrangement of the engine ECU, refer to Gr. 13E. <Electronic governor> Starter SW ~Inal

B ACC M B1 B2 Sl

OFF

-0 -0-

ACC ON

1

START

q

/

7

/

Engine ECU

--r

--,

STARTER SW(S) STARTER SW(M)-1

ECU main power relay

T

.- "Y"r"'\ - ,

Battery r----: re lay :~ 9I Battery

~!~ 1

1

!

T

I__ :!J

T

!,

,---C3 CS

STARTER SW(M)-2

C7 MAIN RELAY-1 OS MAIN RELAY-2 013 ECU POWER(+VB)-1 01 ECU POWER(+VB)-2 02

®47396 L -_________________________________________________________________________________

~

11-8

11 • Remove the injection nozzle A. CO Gr 13A

CAUTION&-------------Cover the mounting holes and injection pipes to prevent the entry of dust and dirt.

01938

• Cover the injection nozzle mounting hole B with a cloth C. Then, turn the engine over with the starter and check that no foreign matter adheres to the cloth.

C

WARNING& - - - - - - - - - - - - - If any cylinder is cracked, coolant, engine oil, and fuel will enter the cylinder through the crack. When the engine is turned over, these substances will spray out of the nozzle mounting hole B at a high temperature. For safety, move away from the nozzle mounting hole before turning over the engine.

01939

'-------------------'

• Fit the ~ Compression Gauge Adapter onto an injection nozzle mounting hole B together with a nozzle gasket. Then, connect the compression gauge 1. • Turn the engine over and measure the compression pressure. • Measure the compression pressure in every cylinder and determine the pressure differences between cylinders. • If any compression pressure or cylinder-to-cylinder pressure difference exceeds the specified limit, pour a little engine oil into the cylinder via the injection nozzle mounting hole B then take the measurement again. • If the compression pressure increases, there may be wear or damage on piston rings and inner surfaces of cylinders. • If the compression pressure does not increase, valves may be seized or incorrectly seated, or the cylinder head gasket may be defective.

11-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspecting and Adjusting Valve Clearances Service standards

o

Standard value

Maintenance item

Location

-

Unit: mm

Valve clearance (when cold)

Limit

0.4

Tightening torques Tightening torque

Rocker arm adjusting screw lock nut

2,6

Adjust Unit: N . m {kgf· m}

Parts to be tightened

Location

Remedy

-

Remarks

34 {3.5}

-

Valve clearances should be checked and adjusted when the engine is cold.

<Without flywheel PTO>

[Inspection] • Bring piston No.1 or piston NO.6 to the top-dead-centre (TDG) position of its compression stroke. To do this, crank the engine until the "1.6" mark inscribed on the flywheel is aligned with the pOinter A in the flywheel housing inspection window. (If the engine has a flywheel PTO, align the pointer A with the "0" mark inscribed on the torsional damper.)

NOTE Pistons whose push rods are not pushing up their rockers are at top-dead-centre (TOe) of their compression strokes.

A

Ol-

I

til""

Ol- 0 !

III I" I

I

• When piston No.1 or piston No.6 is at the TDG position of its compression stroke, measure the clearance B of every valve marked "0" in the following table. Piston No. Valve arrangement

2

1

4

3

5

6

In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

No.1 piston at TOG of compression stroke

O 0

0

x

x

0

0

x

x

0

x

x

No.6 piston at TOG of compression stroke

x

x

0

0

x

x

0

0

x

0

0

x

NOTE To measure the clearance, insert a feeler gauge 1. The gauge should be able to move in the gap, albeit not loosely. Accurate measurements cannot be taken if the gauge moves loosely in the gap.

11-10

11 • If any measurement is out of specification, make adjustments as follows: [Adjustment] • To adjust the valve clearance B, loosen the lock nut 2 and turn the adjusting screw 3 until the feeler gauge 1 moves more stiffly in the gap. • After adjusting the clearance, tighten the lock nut 2. At this time, use a screwdriver C to stop the adjusting screw 3 from turning. Next, insert the feeler gauge 1 once more to confirm that the clearance B is correct.

11621

11-11

CYLINDER HEAD AND VALVE MECHANISM

04134

• Disassembly sequence

1 2 3 4 5 6 7

Joint Oil filler cap Bolt Plate Rubber Rocker cover gasket Rocker cover

8 Cylinder head bolt 9 Rocker and bracket assembly CO P.11-16 10 Cylinder head and valve assembly CO P.11-20 11 Cylinder head gasket

• Assembly sequence

Follow the disassembly sequence in reverse.

11-12

12 Push rod 13 Tappet

*: Crankcase CO P.11-72 ~ : Locating

pin *3 : Non-reusable part

11 Service standards

Unit: mm

12 13,*

o

Standard value (Basic diameter in [ ])

Maintenance item

Location

Push rod runout

-

Tappet-to-crankcase clearance

Remedy

004

Replace Replace tappet

6D14, 14-T,15-T, 16, 16-E

[31] 0.06 to 0.10

0.2

6D16-T, 16-TE, 16-TL, 16-TLE

[31] 0.03 to 0.07

0.1

Tightening torques

Location

Limit

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

1

Joint

3

Rocker cover bolt

8

Cylinder head bolt (installation of rocker and bracket assembly and cylinder head and valve assembly)

Remarks

29 {3.0}

-

-

3.9 {OA}

78 {8} + 180

M14 bolt

M10 bolt

0

•

Wet

•

Can be reused up to 3 times

-

17 {1.75} + 34 {3.5}

Ij Lubricant Location

Points of application

Specified lubricant

Quantity

2

Rubber seal of oil filler cap

Engine oil

As required

8

Threads of cylinder head bolts

Engine oil

As required

12 13

Both ends of push rods

Engine oil

As required

Outer surfaces of tappets

Engine oil

As required

~ Special tools Location

Tool name and shape

Part No.

Application

~

~~ ~t=Y 10

Socket Wrench

MH063388

Tightening cylinder head bolts (M14 bolt only)

-~

~j

'--

01984

• Service procedure

IIQI Cylinder head and valve assembly [Removal] • Before loosening the cylinder head bolts 8, loosen the adjusting screw C on every rocker A that is compressing its valve spring B.

13021

11-13

CYLINDER HEAD AND VALVE MECHANISM (~)

®

(5)

@)

(3)

en

• Loosen and remove the cylinder head bolts 8 in the sequence shown. Each cylinder head bolt should be loosened a little at a time.

@

@l

01945

[Installation]

CAUTION,& 8

Before fitting any cylinder head bolt 8, check the punch marks A on its head. Do not use the bolt if there are more than two punch marks. The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method. Any bolt that already has three punch marks must be replaced.

®21229

@

@

@

ega;

(3ID

~~

• Tighten the cylinder head bolts 8 to the specified torque (M14 bolts: 78 N'm {8 kgf'm}; M10 bolts: 17 N'm {1.75 kgf·m}) in the sequence shown. Then, turn the bolts further in accordance with the following procedure.

* : Tighten together with rocker and bracket assembly

CD to c?~ : M14 bolt (wet) @

@

@

@ to @ : M 10 bolt 01945

<M14 Bolts> • Before fitting the I&J Socket Wrench over a cylinder head bolt, turn the holder D counter-clockwise to tension the built-in spring.

F

E: Socket F:Rod G: Rod (extension)

~G

~

01991

• Set the socket such that the built-in spring force forces the rod G against the rocker shaft bracket, an injection pipe, or another nearby part. • On the holder D, select the inscribed line H that is easiest to see. • Using the selected line as a reference, turn the socket E 180° clockwise. (One gradation on the scale J represents 5°.)

CAUTION,&--------------------------Since the M14 cylinder head bolts 8 utilize the plastic region tightening method, they must not be tightened further after this procedure.

12825

11-14

11

~D

@ll

@

v

v

'-

0

~

0

0

0 0

0 0

0

0 0

0 0

0 0

0 0

QgJ

QOl

0 0

0 0

C2.~

0

0 0

<M10 Bolts> • After fitting the M14 cylinder head bolts 8, tighten the M1 0 bolts to the spencified torque (34 N . m {3.5 kgf· m}) in the sequence shown.

0 0

01945

[TI]

Cylinder head gasket

[Removal]

CAUTION&-------------When removing the cylinder head gasket 11, be careful not to scratch the cylinder head and valve assembly 10 and the crankcase *. [Fitting] • Fit the cylinder head gasket 11 onto the crankcase

* as shown.

11

13582

~ Push rod runout If any measurement exceeds the specified limit, replace the defective part(s).

01948

13

~

G Tappet-to-crankcase clearance

If any measurement exceeds the specified limit, replace the defective part(s).

~---------------------------

11-15

CYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly • Disassembly sequence

1 Rocker assembly 2 Rocker bushing 3 Lock nut 4 Adjusting screw 5 Rocker 6 No.6 rocker shaft bracket 7 Set screw 8 No.5 rocker shaft bracket 9 No.4 rocker shaft bracket 10 No.3 rocker shaft bracket 11 No.2 rocker shaft bracket 12 No. 1 rocker shaft bracket 13 Rocker shaft spring 14 Rocker shaft

1

I

J 11

1

L-~

13

• Assembly sequence

6

Reverse the order of disassembly.

13022

Service standards

Unit: mm

Location

2,14

o

Maintenance item Rocker bushing-to-rocker shaft clearance

Standard value (Basic diameter in [ ])

Limit

Remedy

[24] 0.01 to 0.08

0.12

Replace

Tightening torques

Location

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Remarks

3

Adjusting screw lock nut

34 {3.S}

-

7

Rocker shaft set screw

3.9 {OA}

-

~ Lubricant Location

2

Points of application

Specified lubricant

Rocker bushing inner surface

Engine oil

As required

~ Special tools Location

2

Unit: mm Tool name and shape

Part No.

Rocker Bushing Puller

MH061777

01951

11-16

Quantity

Application

Removing and installing rocker bushings

11 • Service procedure ~

[HI

Rocker bushing and rocker shaft

[I nspection] If any clearance exceeds the specified limit, replace the defective part(s).

Rocker bushing [Removal]

2

12994

[Installation] • Align the oil hole A in the rocker bushing 2 with the oil hole B in the rocker 5. • Position the notch C and seam 0 on the rocker bushing 2 as shown. • Install the rocker bushing 2 into the rocker 5 from the chamfered side

F.

A

o B

12995

[]] [!J to [§] [HI 9,10,

12~B

6~B A

AE

Installing rocker shaft brackets and rocker shaft

Rocker shaft brackets Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions. A:Oil hole B: Threaded hole (for M8 rocker cover bolt) C: Threaded hole (for M6 set screw) 0: No threaded hole

13023

11-17

CYLINDER HEAD AND VALVE MECHANISM Rocker shaft Align the oil hole G in the No.6 rocker shaft bracket 6 with the oil hole H in the rocker shaft 14.

13024

11-18

11

MEMO

11-19

CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Valve Mechanism <Without glow plug>

20300

<With glow plug>

7 01955

• Disassembly sequence 1 Valve cap 2 Valve cotter 3 Upper retainer 4 Outer valve spring 5 Inner valve spring 6 Valve stem seal 7 Exhaust valve 8 Inlet valve

Injection nozzle IT) Gr 13 Dust seal Nozzle tip gasket Nut <With glow plug> Connecting plate <With glow plug> 14 Glow plug <With glow plug> IT) Gr54 15 Exhaust valve guide 9 10 11 12 13

16 17 18 19 20

Inlet valve guide Exhaust valve seat Inlet valve seat Stud Cylinder head

0: Non-reusable part

CAUTION~----------------------------------------------------The injection nozzles 9 and glow plugs 14 project from the bottom surface of cylinder head 20. Take care not to damage them . • Assembly sequence

Follow the disassembly sequence in reverse.

NOTE Any valve stem seal 6 removed from an exhaust valve 7 or inlet valve 8 must be replaced.

11-20

11 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

6014, 14-T, 15-T, 16, 16-E

67.0

64.0

Replace

6016-T,16-TE, 16-TL,16-TLE

68.3

65.3

6014, 14-T, 15-T, 16, 16-E

330 N {33.5 kgf}

290 N {29.7 kgf}

6016-T,16-TE, 16-TL,16-TLE

390 N {40.0 kgf}

350 N {35.5 kgf}

Maintenance item

Location Outer valve spring

4

Free length

Installed load (at 47.8 installed length)

-

Squareness Inner valve spring

5

Exhaust valve

7

Inlet valve

8

Free length

Replace Replace

55.1

52.1

6016-T,16-TE, 16-TL,16-TLE

65.1

61.5

92 N {9.4 kgf}

78 N {8.0 kgf}

155 N {15.8 kgf}

130 N {13.4 kgf}

Installed load (at 40.5 installed length)

6014, 14-T, 15-T, 16, 16-E

Squareness

6014, 14-T, 15-T, 16, 16-E

-

2.0

6016-T,16-TE, 16-TL,16-TLE

-

2.5

Stem outside diameter

<1>

8.93 to 8.94

<1>

Replace

Replace

Replace

8.85

1.3to 1.7

2.0

Inspect every location

Valve margin

1.5

1.2

Reface or replace

Seat angle

45°

-

Correct

8.85

Replace

Sinkage from cylinder head bottom surface

Stem outside diameter Sinkage from cylinder head bottom surface

<1>

8.96 to 8.97

<1>

Except 6016-E

1.1 to 1.5

1.8

6016-E

1.3 to 1.7

2.0

1.5

1.2

Valve margin Seat angle

45° ± 15'

Inspect every location Reface or replace

-

Correct

7,15

Exhaust valve stem-to-valve guide clearance

[9] 0.07 to 0.10

0.2

Replace

8, 16

Inlet valve stem-to-valve guide clearance

[9] 0.04 to 0.06

0.15

Replace

Exhaust valve seat width

1.8 to 2.2

2.8

Correct or replace

Inlet valve seat width

1.8 to 2.2

2.8

Correct or replace

Bottom surface distortion

0.08 or less

0.2

Correct or replace

Height from top to bottom surface

94.9 to 95.1

94.5

Replace

17

18 20

o

2.5

6014, 14-T, 15-T, 16, 16-E

6016-T,16-TE, 16-TL,16-TLE

Replace

Cylinder head

Tightening torques

Location

Parts to be tightened

14

Glow plug <With glow plug>

19

Exhaust manifold mounting stud

Unit: N· m {kgf· m}

Tightening torque

Remarks

15 to 20 {1.5 to 2.0}

-

29 {3}

-

11-21

CYLINDER HEAD AND VALVE MECHANISM Ii

Lubricant Points of application

Location

Quantity

1

Rocker contact surface on valve cap top

Engine oil

As required

6

Lip of valve stem seal

Engine oil

As required

Valve stem

Engine oil

As required

7,8

I:Q

Specified lubricant

Special tools

Unit: mm Tool name and shape

Location

Part No.

Application

A

2

A: MH061668 (with 42 valve lifter seat)

A: Valve Lifter B: Valve Lifter Hook

Removing and installing valve cotters

B: MH061679 <1>42

6

Valve Stem Seal Installer

B



MH061293

Installing valve stem seals

30091-07500 (inlet, exhaust)

Lapping valves and valve seats

MH061 066 (inlet, exhaust)

Removing valve guides

MH061998

Installing inlet and exhaust valve guides

01957

7,8

Valve Lapper

01958

Valve Guide Remover

15,16

<1>28 Valve Guide Installer



15r--n---l=

18

01960

11-22

11 Tool name and shape

Location

Part No.

A: Caulking Tool Body

A: MH061067 B: MH061695 <6014, 14-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE> (Inlet)

B: Installer Ring

~ 17,18

C dimension

MH061695



49

MH061696



42

MH061693



51

MH061694



44

Application

~

t=~"F~-

<1>9

C B

A 01961

MH061696 <6014, 14-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE> (Exhasut)

Installing valve seats

MH061693 <6016, 16-E> (Inlet) MH061694 <6016, 16-E> (Exhaust)

• Service procedures ~ Valve cotters [Removal] To remove the valve cotter 2, use the ~ Valve Lifter to evenly compress the valve springs 4, 5. [Installation) To install valve cotters, follow the removal instructions in reverse.

CAUTION~--------------------------Do not compress the valve springs 4, 5 more than is necessary. If the valve springs are compressed excessively, the upper retainer 3 can touch the valve stem seal 6 and be damaged.

[!] WInstalling outer and inner valve springs Fit the outer and inner valve springs 4, 5 onto the cylinder head 20 with their painted ends downward. A: Painted end

11641

WInstalling valve stem seals • Apply engine oil to the lip A of the valve stem seal 6. • Install the valve stem seal 6 using the ~ Valve Stem Seal Installer. Strike the Valve Stem Installer until it sits snugly on the cylinder head

20.

01964

11-23

CYLINDER HEAD AND VALVE MECHANISM [ZJ [!]

Valve

[Inspection]

(1) Valve stem outside diameter Replace the valve 7,8 if its stem's outside diameter is below specification or severely worn.

CAUTION.&------------Whenever a valve 7,8 is replaced, be sure to lap the valve and valve seat 17,18. P.11-25.

m

01965

(2) Valve seat angle and valve margin Reface or replace the valve 7, 8 if the valve seat angle or valve margin exceeds the specified limits.

7,8 A: Valve seat angle B: Valve margin

B

02264

[Rectification]

NOTE • Keep grinding to a minimum. • If the valve margin is below specification after grinding, replace the valve 7, 8. • After grinding, be sure to lap the valve and 7,8 valve seat 17,18. P.11-25

m

[ZJ [!] ~ B]I

Valves and valve guides

[Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

Valve guides [Removal]

01972

11-24

11 [Installation] Install the valve guide 15, 16 using the ~ Valve Guide Installer. Strike the Valve Guide Installer until it sits snugly on the cylinder head 20.

CAUTION~---------------------------

18mm

• The valve guides 15, 16 must be pressed in to the specified depth. Be sure to use the ~ Valve Guide Installer for this operation. • Exhaust valve guides 15 are longer than inlet valve guides 16. Be sure to install the correct type of guide in each location.

15, 16 02220

[1] W5ZI ~

Valves and valve seats

[I nspection] • Apply an even coat of minium to the valve seat 17, 18 surface A that makes contact with the valve 7,8. • Using the ~ Valve Lapper, strike the valve 7, 8 against the valve seat 17, 18 once. Do not rotate the valve during this operation.

NOTE c.:>

c.:>

=

=

}/'---'~/j~

01968

000

~~------~yr------~)

o

Carry out these inspections after inspecting the valves and valve guides. • If the minium deposited on the valve 7,8 indicates a poor contact pattern, rectify the contact pattern as follows: Corrective action

Contact Minor defect

Lapping

Serious defect

Reface or replace valve and valve seat

01969

[Refacing] Lap the valve in accordance with the following procedure: • Apply a thin, even coat of lapping compound to the surface A of the valve 7,8 that makes contact with the valve seat 17, 18.

-7,8

---- B

CAUTION~--------------------------Ensure that no compound adheres to the stem B of the valve 7,

'A

8.

01970

NOTE • Start with intermediate-mesh compound (120 to 150 mesh) and finish with fine-mesh compound (200 mesh or more). • The addition of a small amount of engine oil makes lapping compound easier to apply.

11-25

CYLINDER HEAD AND VALVE MECHANISM

--\...'

=

• Using the r.g Valve Lapper, lightly strike the valve 7,8 against the valve seat 17, 18 while turning it little by little. • Wash away the compound with gas oil or a similar fluid. • Apply engine oil to the contact surfaces of the valve seat 17,18 and rub it in so that the contact surfaces are lubricated and mate together snugly. • Inspect the contact pattern of the valve 7,8 and valve seat 17, 18 once more. • If the contact pattern is still defective, replace the valve seat 17, 18.

=

";

~

01971

[!Z] ~

Valve seats

[Inspection]

7,8 17,18

(1) Valve seat width If the measurement exceeds the specified limit, rectify or replace the valve seat 17,18. A : Valve seat width

01975 ~----------------------------~

NOTE Whenever a valve seat 17, 18 is rectified or replaced, be sure to lap the valve seat and valve 7, 8. [0 P.11-2S (2) Valve sinkage from cylinder head bottom surface If any measurement exceeds the specified limit, rectify or replace the defective part(s).

7,8 17,18

B: Valve sinkage

B

02265

[Rectification] • Grind the valve seat 17, 18 using a valve seat cutter or valve seat grinder. • After grinding, put some sandpaper of around #400 grade between the cutter and valve seat and grind the valve seat lightly. • Use a 15° or 17° cutter to achieve the specified valve seat width A. C: Valve seat angle 01977

~----------------------~----~

CAUTION~---------------Ensure that grinding does not cause the valve sinkage B to exceed the specified limit. • After rectification, lap the valve 7,8 and valve seat 17, 18. [0 P.11-25

11-26

11 [Removal] Valve seats 17, 18 are installed by expansion fitting. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature.

17, 18

D: Material to remove

D

0.5 to 1.0 mm

01973

[I nstallation] • Check that the valve seat hole diameters E, F in the cylinder head 20 conform with the values shown below. Unit: mm

~ 20

E

F

01976

6014,14-T, 15-T,16-T, 16-TE,16-TL, 16-TLE

6016

6016-E

Inlet valve seat hole (E)

q> 49+ ~.O25

q> 51 + ~O3

q> 53 + ~.O3

Exhaust valve seat hole (F)

q> 42+ ~O25

q> 44 + ~O25

q> 46+ ~.O25

• Cool the valve seat 17,18 by immersing it in liquid nitrogen. • Install the valve seat 17,18 in the cylinder head 20 using the ~a Caulking Tool Body and ~b Installer Ring. • After installing the valve seat 17,18, lap the valve seat and valve 7,8.

mP.11-25

01974

~ Inspecting cylinder head • Measure the extent of distortion in the cylinder head's bottom surface. • If the degree of distortion exceeds the specified limit, rectify the distortion with a surface grinder.

CAUTION&.-------------Ensure that grinding does not cause the cylinder head's top surface-to-bottom surface distance to fall below the specified limit. 01978

11-27

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • Pre-disassembly inspection P.11-30

• Removal sequence 1 2 3 4 5

Bolt Lower connecting rod bearing Connecting rod cap Upper connecting rod bearing Piston and connecting rod assembly IT] P.11-36 6 Cylinder liner 7 a-ring <6014, 14-T, 15-T>

L

*a: Oil pan IT] Gr 12 *b: Crankshaft IT] P.11-72

• Installation sequence Reverse the order of removal. *a

16914

Service standards

2,4,*b

6

Remedy Inspect each location

0.85 to 1.06

-

Connecting rod end play

0.15toO.45

0.6

Replace

Except 6016-TLE

[65] 0.04 to 0.09

0.2

Replace

6016-TLE

[70] 0.04 to 0.09

Except 6016-TLE

-

Less than 69.5

6016-TLE

-

Less than 74.5

Connecting rod bearing

Oil clearance

Piston and connecting rod assembly-tocylinder liner clearance Cylinder liner

6014,14-T

[110] 0.137 to 0.159

-

Replace

6015-T

[113] 0.166 to 0.138

-

Replace

6016,16-E

[118) 0.075 to 0.105

-

Replace

6016-T, 16-TE, 16-TL, 16-TLE

[118] 0.136 to 0.165

-

Replace

0.03 to 0.10

-

Replace

Flange projection Inside diameter

6014,14-T

<1>

110 to 110.035

<1>

110.25

Replace or grind to oversize

6015-T

<1>

113 to 113.035

<1>

113.25

Replace

118 to 118.03

<1>

118.25

Replace

6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE Cylindricity

11-28

Limit

Piston projection

Span when free

5,6

Standard value (Basic diameter in [ ])

Maintenance item

Location

-

Unit: mm

<1>

6014, 14-T, 15-T

0.02 or less

-

Replace or grind to oversize

6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE

0.03 or less

-

Replace or grind to oversize

11

o

Tightening torques

Location

1 ~

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Bolt (connecting rod installation)

29 {3} + 90° ± 5°

Remarks Wet

CD P.11-31

Lubricant

Location

1

2,4

6

Points of application

Specified lubricant

Bolt threads

Engine oil

As required

Connecting rod bearing inside suriace

Engine oil

As required

Cylinder liner outside suriace

Engine oil

As required

~ Special tools

Unit: mm

Location

5

Quantity

Tool name and shape

Part No.

Socket Wrench

MH061560

Application

Installing piston and connecting rod assembly

01984

Piston Guide

~ 6014,14-T

A dimension <1>

<6014,14-T> 30091-08200 <6015-T> MH061327

110 r--------------¥

6015-T

5

<1>

113

A

Installing piston and 01980 1 - - - - - - - - - - - - - - - - - - - - - - - - - - + - - - - - - - - - - - - - 1 connecting rod assembly <6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> A: MH061760 B: MH061658

A: Piston Guide Clamp B: Piston Guide Lever

Cylinder Liner Extractor

~

6

6014,14-T

<1>

109.5

6015-T

<1>

112.5

6016,16-E, 16-T,16-TE, 16-TL,16-TLE

<6014,14-T>

C dimension

<1>

A: MH061719 <6015-T> B: MH062003

B

Removing cylinder liners

<6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> B: MH061761

117.5

Cylinder Liner Installer

~ 6015-T 6016,16-E, 16-T,16-TE, 16-TL,16-TLE

A dimension <1>

112.5

<1>

117.5

<6015-T> MH062002 <6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> MH061771

A

Installing cylinder liners (dry type)

01983

11-29

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • Service procedure • Pre-disassembly inspection (1) Piston projection from crankcase top surface

NOTE The piston projections affect engine performance and must therefore be checked.

WARNING,&:-------------

01985

With 6016, 16-E, 16-T, 16-TE, 16-TL and 16-TLE engines, the cylinder liners may rise out of position when the crankcase is turned over or the crankshaft is turned. Hold their flanges down using bolts and washers A.

• Measure the projection of each piston at two paints and calculate the average of the two values. A: Front of engine • If the average value is out of specification, check the clearances between all relevant parts.

01986

(2) Connecting rod end play • Measure the end play of every connecting rod. • If any measurement exceeds the specified limit, replace the defective part(s).

01987

(3) Cylinder liner flange projection If any measurement is out of specification, replace the defective part(s). B : Flange projection

CAUTION&-------------If the cylinder liner 6 flange projection is insufficient, bearing pressure on the cylinder head gasket will be too low in the region of the bore, possibly causing gas to leak.

B

01988

11-30

11 2

A

rn I1l

Connecting rod bearings

[Installation] Install the connecting rod bearings 2, 4 by fitting the lugs A into their spective grooves.

B

~e­

CAUTION&-------------The upper connecting rod bearing has an oil hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts.

[I nspection1

CAUTION&-------------• Do not attempt to manually expand a connecting rod bearing 2, 4 if its span is insufficient. • Upper and lower connecting rod bearings 2, 4 must be replaced as a set. (1) Span when free If the span is less than the specified requirement, replace the upper and lower connecting rod bearings 2,4 as a set. (2) Connecting rod bearing-to-crankshaft pin clearance If the connecting rod bearing-to-crankshaft pin clearance exceeds the specified limit, replace the defective part(s).

01996

01997

~ Installing piston and connecting rod assembly

CAUTION&---------------• Ensure that the piston ring gaps A remain in their correct positions. CD P.11-41 • Take care not to damage the piston crown B (the area that forms part of the combustion chamber). • Ensure that the connecting rod does not touch the oil jet C. 11650

11-31

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • With the piston's "A" front mark facing the front of the engine, install the piston and connecting rod assembly in accordance with the following procedure.

"fj,."

0: Front of engine

L? o

03384

<6014, 14-T, 15-T>

02009

<6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> • Fit the [ga Piston Guide Clamp over the piston skirt. Using the bolt E of the [gb Piston Guide Lever, adjust the clamp's inside diameter such that it matches the piston's outside diameter. • Once the [ga Piston Guide Clamp is adjusted properly, remove it from the piston and smear engine oil over the following items: • Outside of piston • Inside of the [ga Piston Guide Clamp • Cylinder liner 11651

F: ~a Piston Guide Clamp tightening direction

02011

• With the piston installed, align the mating marks F on the connecting rod and connecting rod cap 3 and tighten the bolts to the specified torque. Then, tighten the bolts 1 further in accordance with the following procedure.

3

01990

11-32

11 • Before fitting the r.g Socket Wrench over a bolt, turn the holder G counter-clockwise to tension the built-in spring. H: Socket J:Rod K: Rod (extension)

tK ~

01991

• Set the socket wrench such that the built-in spring force forces the rod K against the crankshaft. • On the holder G, select the inscribed line L that is easiest to see. • Using the selected line as a reference, turn the socket H 90° ± 5° clockwise. (One gradation on the scale M represents 5°.)

K

NOTE After fitting the connecting rod caps 3, inspect the following items: • Connecting rod end play ( P.11-30) • Piston projections P.11-30)

(m

L

m

11652

~

[!]

Piston-and-connecting rod assembly and cylinder liners

[Inspection] <6014, 14-T, 15-T> • If the cylinder section inside diameter of the cylinder liner 6 exceeds the specified limit, remove the cylinder liner from the crankcase and rebore it to oversize. Also replace the piston and piston rings with ones suitable for the oversized cylinder liner inside diameter.

E E LO

mi-____~~~--~ Q)

CAUTION~---------------------------

(5

E -,--------,-7-7-7--3:ct-------l

Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diameter.

(5 E -'------_"-'¥:1l.-____--'-' E o

LO

01999

75.1

mm C

03375

A: Measuring direction of cylinder liner bore (crankshaft axis direction) B: Measuring direction of cylinder liner bore (perpendicular to crankshaft axis) C: Measuring position of piston diameter (perpendicular to piston pin hole axis) • Even if the cylinder section inside diameter of the cylinder liner 6 is within the specified limit, the piston and piston rings must be replaced if the piston-to-cylinder liner clearance is out of specification. [Use of oversize pistons] • Oversizes available: 0.50 mm, 0.75 mm, 1.00 mm (three sizes in total) • To determine the required oversize, measure the inside diameter of every cylinder and find the cylinder of the largest inside diameter. Select an oversize most suitable for the diameter. • Measure the outside diameter C of the oversize piston to be used. • Bore all the cylinder liners to achieve the specified nominal piston-tocylinder clearance. Diameter after boring (tolerance ± 0.005 mm) = Oversize piston diameter C (measurement) + Piston-to-cylinder clearance (nominal range central value) - 0.02 mm (honing margin)

11-33

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • After boring, hone-finish the cylinder liner to the final diameter (tolerance ± 0.005 mm). Final diameter (tolerance ± 0.005 mm) = Oversize piston diameter C (measurement) + Piston-to-cylinder clearance (nominal range central value)

CAUTION~--------------------------• Honed surface roughness: 2 to 4 f-lm • Honing cross-hatching angle: 15 to 25° (half angle) • Squareness of cylinder bore: 0.05 mm • Check the piston-to-cylinder clearance. Cylinder liners [Removal]

NOTE If any cylinder liner 6 must be reused after removal, make an alignment mark with paint and use this mark to reinstall the cylinder liner in its original position.

02000

[I nstallation]

6

Apply soap suds G to the cylinder liner 6. Taking care not to twist the 0rings 7, insert the cylinder liner into the crankcase.

CAUTION ~ --------------------------• Size marks H are provided on the cylinder liner 6 and piston. When the cylinder liner is replaced, the new one must bear the same size mark as the piston.

02001

J: Cylinder liner size mark K: Piston size mark • After installation, check that the O-rings 7 are not twisted.

J

H

K

A-------A

B

C

11-34

B

C

02002

11 <6016, 16-E, 16-TLE> 76.1 mm <6015-T, 16-T,16-TE, 16-TL> 75.1 mm

o

o

<6D15-T, 16, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> If any clearance is out of specification, replace the defective part(s). 0: Outside diameter measurement position E: Direction of crankshaft axis F: Perpendicular to crankshaft axis

NOTE The cylinder liners are of a thin design and cannot be bored to oversize dimensions. To prevent deformation of the cylinder liners, do not remove them except for replacement.

185 mm or more

03375

75 mm or more mm or more

110

02003

Cylinder liners [Removal]

NOTE If any cylinder liner 6 must be reused after removal, make an alignment mark with paint and use this mark to reinstall the cylinder liner in its original position.

02004

A

• Apply engine oil to the outside surface of the cylinder liner 6. • Insert the cylinder liner into the crankcase and press it into position using the l&J Cylinder Liner Installer. Push down evenly on the entire upper surface of the Cylinder Liner Installer.

~2A

CAUTION~---------------------------

3~3A 02005

• Size marks L are provided on the cylinder liner 6, piston, and crankcase (6 places). When the cylinder liner is replaced, select the proper one according to the size marks on the crankcase and the piston, as shown in the illustration.

M

N

P

1~1A ------1B

2~2B

--------3B

M : Crankcase size mark N: Cylinder liner size mark P: Piston size mark

02006

• The cylinder liners are of a thin design. Handle them with care, and do not subject them to hammer blows or other severe shocks.

02007

11-35

PISTONS, CONNECTING RODS, AND CYLINDER LINERS Piston and Connecting Rod Assembly • Disassembly sequence 1 Snap ring

2 Piston pin

3 Connecting rod bushing 4 Connecting rod 51st compression ring 6 2nd compression ring 7 Oil ring 8 Piston

4r0,

• Assembly sequence Reverse the order of disassembly.

02012

Service standards Maintenance item

Location

2,3 2,8

4 5 to 7

Unit: mm Limit

Remedy

0.1

Replace

0.05

Replace

0.05

Correct or replace Replace

Piston pin-to-connecting rod small end bushing clearnace

Except 6016-TLE

[38] 0.02 to 0.05

6016-TLE

[42] 0.02 to 0.05

Piston pin-to-piston clearance

Except 6016-TLE

[38] 0.004 to 0.02

6016-TLE

[42] 0.004 to 0.02

Connecting rod bend and torsion Piston ring end gap

1st compression ring

2nd compression ring

Oil ring

11-36

Standard value (Basic diameter in [ ])

-

6014,14-T, 15-T (8 type)

0.3 to 0.45

1.5

6015-T (A type)

0.3 to 0.5

1.5

6016, 16-T, 16-TL

0.35 to 0.55

1.5

6016-E, 16-TE, 16-TLE

0.35 to 0.5

1.5

6014

0.3 to 0.5

1.5

6014-T,15-T

0.3 to 0.45

1.5

6016, 16-T, 16-TL

0.35 to 0.55

1.5

6016-E,16-TE

0.35 to 0.5

1.5

6016-TLE

0.45 to 0.6

1.5

6014, 14-T, 15-T

0.3 to 0.5

1.5

6016, 16-E, 16-T, 16-TE,16-TL, 16-TLE

0.35 to 0.55

1.5

Replace

Replace

11

5 to 8

Standard value (Basic diameter in [ ])

Limit

Remedy

6014

0.09 to 0.13

0.2

Replace

6014-T, 15-T (B type)

0.05 to 0.10

0.15

Replace

6015-T (A type)

0.10 to 0.15

0.2

6016

0.11 to 0.15

0.2

6016-E

0.13 to 0.17

0.2

6016-T,16-TL, 16-TLE

0.13 to 0.18

0.2

6014, 15-T (A type), 16, 16-E

0.05 to 0.08

0.15

6014-T, 15-T (B type), 16-T,16-TE, 16-TL,16-TLE

0.07 to 0.10

0.15

0.03 to 0.06

0.15

Maintenance item

Location Piston ring-topiston ring groove clearance

1st compression ring

2nd compression ring

Oil ring

Replace

Replace

*6015-T (B type): wedge-shaped connecting rod small end

~ Lubricant Location

Points of application

Specified lubricant

Quantity

2

Piston pin outer surface

Engine oil

As required

3

Connecting rod bushing outer surface

Engine oil

As required

4

Bushing installation surface of connecting rod

Engine oil

As required

~ Special tools Location

Tool name and shape

Part No.

<6014, 15-T (A type), 16,16-E> MH061778

Connecting Rod Bushing Puller

3

I - - - - - - - - - - - - - - - - - - - - + - - - - - - - j Removing and installing connecting rod

bushings <6014-T, 15-T (B type), 16-T,16-TE, 16-TL> MH062023

Connecting Rod Bushing Puller Kit

02015



5 to 7

Application

100 to



<6016-TLE> MH062556

120

Piston Ring Tool

30091-07100

Removing and installing piston rings

02013

11-37

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • Service procedure

rn W

Piston and connecting rod

If the clearance exceeds the specified limit, replace the defective part(s).

02017

Connecting rod bushing

<6014, 15-T (A-type), 16, 16-E> [Removal] Apply the r;g Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) such that the bushing is pressed out of the connecting rod 4.

. 4

3

13616

[I nstallation] • Align oil hole A in the connecting rod bushing 3 with oil hole B in the connecting rod 4. • Apply the r;g Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 kN (5,000 kg f) such that the bushing is pressed into the connecting rod 4 from the chamfered side C.

4

NOTE 13617

11-38

After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play.

11 <6D14-T, 15-T (B-type), 16-T, 16-TE, 16-TL, 16-TLE> Replace the connecting rod bushing 3 using the ~ Connecting Rod Bushing Puller Kit. This consists of the following parts:

02019

0: Base E: Bracket F: Puller G: Collar H: Plate J: Collar K: Nut [Removal] • Remove the bearing (if fitted) from the big end of the connecting rod

4. H

• Mount the connecting rod 4 on the base 0 and lock it in position with the bracket E and plate H. • Position the puller F and collar G as shown in the illustration. Then, slowly apply pressure of approximately 49 kN (5,000 kg f) until the connecting rod bushing 3 is pressed out.

02020

~,F

[I nstallation] • Apply engine oil to the small end of the connecting rod 4 and to the outer surface of the connecting rod bushing 3 . • Fit the collar J over the puller F, position the connecting rod bushing 3 and collar G as shown in the illustration, and lock this arrangement together with the nut K. • Align the oil holes L in the small end of the connecting rod bushing 3 and connecting rod 4. Then, use a press to slowly apply pressure of approximately 49 kN (5,000 kgf) until the bushing is pressed into place. • After press-fitting the connecting rod bushing 3, ream it to achieve the specified nominal clearance between the bushing and piston pin 2.

.

G3 [~G~~ -----

11507

NOTE After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play.

~

m[!]

Piston pin, connecting rod, and piston

[Removal] • Tap out the piston pin 2 using a rod and hammer. • If the piston pin 2 is difficult to remove, heat the piston 8 in hot water or using a piston heater.

02022

11-39

PISTONS, CONNECTING RODS, AND CYLINDER LINERS

"6.'*,

[I nstallation] • Apply engine oil to the piston pin 2. With the connecting rod 4 and piston 8 aligned as illustrated, insert the piston pin to hold these components together.

A

2

1~~

0

~

8

A : Weight mark B: Weight mark (A, S, C, D, E, F, G, H, I, V, W, X, V, Z) C: Alignment mark for connecting rod cap Front mark

4

C B

02023

6.:

• If the piston pin 2 is difficult to insert, heat the piston 4 in hot water or using a piston heater.

CAUTION~--------------------------• No piston should differ from any other piston by a weight of more than log. • The connecting rods must all have the same weight mark. • After inserting the piston pin 2, check that it turns smoothly and without play.

rn [!] 8

Piston pin-to-piston clearance

If the clearance exceeds the specified limit, replace the defective part(s).

[!]

C

A

Connecting rod bend and twist

• Fit the connecting rod bushing 3 and piston 2 in their respective positions of the connecting rod 4. • Measure the extent of bending A and twisting B in the connecting rod

D

4. • If either measurement exceeds the specified limit, replace the connecting rod 4 or rectify it. C: Connecting rod 4 aligner (measurement device)

NOTE • Before mounting the connecting rod 4 on the connecting rod aligner C, install the upper and lower connecting rod bearings in their respective positions. • Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. P.11-29

B

100mmr~

m

C 02040

11-40

11 []] to [!]

Piston rings and piston

Piston rings [Removal]

8

~~

5,6

C

02028

[I nstallation] • Fit the oil ring 7 onto the piston 8 with its side rail gaps A and the expander spring gap B in the positions illustrated. • Fit the compression rings 5, 6 onto the piston such that the manufacturer's marks C near the gaps face upward. • Align the compression ring gaps 0, E as illustrated.

0: 1st compression ring gap E: 2nd compression ring gap b.: Front mark [I nspection] (1) Piston ring end gap • Using the crown of a piston 8, push the piston ring 5, 6 or 7 horizontally into a cylinder liner F for measurement. • Taking care not to move the piston ring 5, 6 or 7, measure the end gap. Replace all the rings of a piston if any gap exceeds the specified limit.

8

NOTE 5 to 7

F

02027

• To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them into the cylinder liner F using a piston 8. • Push the piston ring 5, 6 or 7 down to the bottom of cylinder liner F; the bottom should be less worn than the top. • Piston rings 5, 6 or 7 must be replaced as a set. Never replace piston rings individually.

11-41

PISTONS, CONNECTING RODS, AND CYLINDER LINERS (2) Piston ring-to-piston ring groove clearance • If any measurement exceeds the specified limit, replace the defective part(s). • Measure the 1st compression ring 5 clearance with a thickness gauge H while pressing the ring against the piston 8 with a straight edge G.

NOTE

H

02025

02026

11-42

• Remove any carbon deposits from the ring groove of the piston 8 and measure the clearance around the piston's entire periphery. • Piston rings 5, 6, 7 must be replaced as a set. Never replace piston rings individually.

11

MEMO

11-43

FLYWHEEL PTO

5 16919

• Pre-disassembly inspection

mP.11-45 • Disassembly sequence

1 2 3 4 5 6 7 8 9

Flywheel PTO head assembly Shim Seal cap Nut Cover Ball bearing Cotter PTO idler shaft PTO idler gear A

• Assembly sequence

Reverse the order of disassembly.

11-44

mP.11-46

10 11 12 13 14 15

Spacer PTO idler gear B Spacer Snap ring Ball bearing Snap ring

~ : Locating

pin

*: Flywheel housing

mP.11-48

11 Service standards Gear backlash

Between PTO idler gear A and No.1 idler gear

Between PTO gear and idler gear B

Total PTO gear backlash

o

Standard value

Limit

Remedy

6016, 16-E

0.08 to 0.20

0.35

Reference value

6016-T, 16-TE

0.12 to 0.26

0.35

6016, 16-E

0.08 to 0.20

0.35

6016-T, 16-TE

0.12toO.26

0.35

Maintenance item

Location

-

Unit: mm

0.18 to 0.35

Tightening torques

Location

4

-

Reference value

Rectify or replace Unit: N· m {kgf' m}

Parts to be tightened

Tightening torque 125 {12.8}

PTO idler shaft mounting nut

Remarks -

• Service procedure • Pre-disassembly inspection Gear backlash • Measurement of the backlash between PTO idler gear A and No.1 idler gear and of the total backlash should be carried out at the <\> 100 pitch circle on the PTO flange A. If backlash is out of specification, adjust it using a shim 2. Shims are available in the following sizes: 0.1 mm, 0.2 mm, and 0.3 mm. 02045

• Measurement of the backlash between the PTO gear and PTO idler gear B should be carried out at the <\>100 pitch circle on the PTO flange. Hold the PTO idler shaft B steady while taking measurements. If the backlash is out of specification, adjust it using a shim 2. Shims are available in the following sizes: 0.1 mm, 0.2 mm, and 0.3 mm.

11-45

FLYWHEEL PTO Flywheel PTO Head Assembly

1

16921

• Disassembly sequence 11 12 13 14

Seal cap Ball bearing Cotter PTO shaft 10 PTO gear

6 7 8 9

1 Split pin 2 Nut 3 Flange 4 Oil seal 5 Rear cover

Spacer Snap ring Ball bearing Cover

• Assembly sequence

Opposite of disassembly sequence.

Service standards

Unit: mm

Location

-

o

Maintenance item PTO shaft end play

o to 0.8

Tightening torques

Location

2

rG

Standard value

Parts to be tightened Flange mounting nut

Limit

Remedy

-

Replace

Unit: N· m {kgf· m} Tightening torque

Remarks

125 {12.8}

-

Lubricant

Location

Points of application

Specified lubricant

Quantity

3

Flange splines

Wheel bearing grease [NLGI NO.2 (Li soap)]

As required

4

Oil seal lip

Wheel bearing grease [NLGI NO.2 (Li soap)]

As required

9

PTO shaft splines

Wheel bearing grease [NLGI NO.2 (Li soap)]

As required

11-46

//

11 • Service procedure • Pre-disassembly inspection PTO shaft end play

If the measurement exceeds the specified limit, replace the defective part(s).

13618

[]] Removing PTO shaft

A: Plastic mallet

16922

11-47

FLYWHEEL 6 <Without flywheel PTO>

*

3 2 1

0

rG

16923

• Disassembly sequence

1 2 3 4 5 6 7 8 9

Spacer Bolt Washer plate Flywheel assembly Pilot bearing Ring gear Flywheel Rear oil seal Rear oil seal retainer <models with flywheel PTO>

• Assembly sequence

Reverse the order of disassembly.

11-48

10 11 12 13 14

O-ring <models with flywheel PTO> Plug Bolt <models with flywheel PTO> Flywheel housing Thrust plate <models with flywheel PTO>

* :Crankshaft OJ P.11-72 ~ : Locating

pin

0: Non-reusable part

11 Service standards

Unit: mm

4

13

o

Flywheel assembly

Limit

Remedy

Friction surface distortion

0.05 or less

0.2

Correct or replace

Height of friction surface

20

19

Replace

Friction surface runout (when fitted)

-

0.2

Correct or replace

-

0.2

Inspect or replace

Eccentricity of joint

Tightening torques 2

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

~

Standard value

Maintenance item

Location

98 {10} + 150

0

Flywheel mounting bolt

Remarks •

Wet

•

Can be reused up to 3 times OJ P.11-50

-

88 {9}

11

Plug

12

Bolt <models with flywheel PTO>

34 {3.5}

Lubricant and/or sealant Points of application

Location 2

Specified lubricant and/or sealant

Bolt threads

Quantity

Engine oil

As required

Rear oil seal lip

Engine oil

As required

Flywheel mounting surface of rear oil seal <models without flywheel PTO>

Threebond 1207C

As required

10

O-ring

Engine oil

As required

13

Engine mounting surface of flywheel housing

Threebond 1207C

As required

8

~ Special tools Location

Tool name and shape

Part No.

Socket Wrench

4

Application

MH062354

01984 1 - - - - - - - - - - - - - - - - - - - - + - - - - - - - 1 Fitting flywheel

Magnetic Base

MH062356

00471

11-49

FLYWHEEL • Service procedure

[!]

Flywheel assembly

[Removal] To remove the flywheel assembly 4, screw the mounting bolts 2 into the removal holes A.

[I nstallation]

CAUTION.&-------------2

Before installing the bolt 2, check the number of punch marks K on its head. (If there are two or less, the bolt is reusable.) The number of punch marks corresponds with the number of times a bolt has been tightened by the plastic region tightening method. If there are three (which means that the bolt has been tightened 3 times), replace the bolt. ®36164

B:-~-

o

t ~

• Tighten the bolts 2 to their specified torque, then tighten them further in accordance with the following procedure: • Turn the holder B of the ~ Socket Wrench counter-clockwise to tension the built-in spring. E

c: Socket D: Rod E: Rod (extension) 01991

• Set the socket wrench such that the built-in spring forces the rod E against the ~b Magnetic Base. • On the holder B, select the inscribed line F that is easiest to see. • Using the selected line as a reference, turn the socket 150 0 clockwise. (One gradation on the scale G represents 5°.)

3 ~a

CAUTION.&-------------Since the bolts 2 utilize the plastic region tightening method, they must not be tightened further after this procedure. ~b 14312

11-50

11 [Inspection]

(1) Runout • Tighten the bolts 2 to their specified torque. • If runout exceeds the specified limit, check that the bolts 2 are tightened correctly and inspect the crankshaft* mounting surface. Then, rectify or replace the flywheel assembly 4 as required.

02055

(2) Height of friction surface If the measurement is below the specified value, rectify or replace the flywheel assembly 4. H : Height of friction surface

03349

(3) Distortion of friction surface If distortion exceeds the specified limit, rectify or replace the flywheel assembly 4.

NOTE If any abnormality is evident on the ring gear 6, replace the ring gear before making inspections.

H

H

tUn l

~ &$111

[Rectification] Grind the friction surface such that its height H remains greater than the specified minimum. The friction surface must remain parallel with surface J with a tolerance of 0.1 mm.

J 03351

[]] Ring gear [I nspection] Inspect the ring gear 6 for damage and abnormal wear. If any defect is evident, the ring gear must be replaced.

11-51

FLYWHEEL [Removal] • Heat the ring gear 6 evenly with an acetylene torch or the like.

7

CAUTION~--------------------------­ Be careful not to get burned.

• Remove the ring gear 6 from the flywheel 7 by tapping around its entire periphery.

6

02057

[Installation] • Using a piston heater or the like, heat the ring gear 6 to approximately 1 for 3 minutes.

6

aaoe

CAUTION~--------------------------Be careful not to get burned.

• Fit the ring gear 6 with the non-chamfered side of its teeth toward the flywheel 7. 03353

A: Chamfered side of ring gear []] Fitting rear oil seal

<Models without flywheel PTO> • Apply an even, unbroken bead of sealant A to the rear oil seal 8 in the position illustrated B. • Fit the rear oil seal 9 onto the flywheel housing 12 within 3 minutes of applying the sealant A.

CAUTION~--------------------------• Ensure that the sealant application position B on the oil seal 8 is clean before applying sealant. • When fitting the rear oil seal 8, hold it firmly in position to prevent spreading the sealant. • After fitting the rear oil seal 8, wait at least 30 minutes before starting the engine. • Applya new bead of sealant A whenever the mounting bolts of the rear oil seal 8 have been loosened.

• Apply engine oil to the lip of the rear oil seal 8. • Fit the rear oil seal 8 onto the flywheel housing 13 in the direction illustrated.

02059

11-52

11 <Models with flywheel PTO> • Fit the rear oil seal 8 into the rear oil seal retainer 9 in the direction illustrated by pushing its periphery evenly until the end A becomes flush with the end surface of the rear oil seal retainer 9 all around.

A

9

8 ®47289

~ Flywheel housing

<j>2mm

[Installation] • Apply an even, unbroken bead of sealant A to the crankcase mounting surface of the flywheel housing 13. • Fit the flywheel housing 13 onto the crankcase within 3 minutes of applying the sealant A.

CAUTION~--------------------------11704

• Ensure that the sealant application position on the flywheel housing 13 is clean before applying sealant. • When fitting the flywheel housing 13, hold it firmly in position to prevent spreading the sealant. • After fitting the flywheel housing 13, wait at least an hour before starting the engine. • Apply a new bead of sealant A whenever the mountiing bolts of the flywheel housing 13 have been loosened. [I nspection] • Rotate the crankshaft and check the extent of eccentricity at the joint A of the flywheel housing 13. • If eccentricity exceeds the specified limit, carry out reassembly. • If eccentricity still exceeds the specified limit after reassembly, replace the defective part(s).

A

02062

11-53

TIMING GEARS <Without Flywheel PTO>

*b

e Pre-disassembl . P.11-56 Y Inspection

OJ

e Disassembl y sequence 1 Bolt ~ No. 1 idler shaft No.1 idler 4 No.1 idl gear bushing 5 Nut er gear

10 Thrust washer 11 No.2 idler 12 No.2 'dl gear bushing 13 I er gear No.2 idler shaft

6 O-ring

*a'D' . rive gear *b : Camshaft g *c : Crankshaft ear OJ P.11-64 gear OJ P.11-72

7 Collar

8 O-ring 9 Bolt eAssembl R y sequence everse th e order of d'Isassembly.

11-54

0: Non-reusabl e part CAUTION'&: Since the N'o.1ldlerg . 4 ported by th ear is sup th ese parts e No . 1 I'd ler shaft 2must be ' . a single unit. removed as

11 Service standards Standard value (Basic diameter in [ ])

Limit

Remedy

Between No.1 idler gear and crankshaft gear

0.08 to 0.15

0.35

Replace

Between No.1 idler gear and No.2 idler gear

0.07 to 0.15

0.35

Replace

Between No.1 idler gear and drive gear

0.07 to 0.15

0.35

Replace

Between No.2 idler gear and camshaft gear

0.08 to 0.16

0.35

Replace

[37] 0.01 to 0.05

0.2

Replace

0.05 to 0.15

0.3

Replace

[32] 0.01 to 0.05

0.2

Replace

Maintenance item

Location

-

Unit: mm

Gear backlash

2,3

No.1 idler shaft-to-gear bushing clearance

4,12

Idler gear end play

11,13

No.2 idler gear bushing-to-shaft clearance

o

Tightening torques Parts to be tightened

Location

~

Unit: N· m {kgf· m} Tightening torque 88 {9}

1

No.1 idler gear mounting bolt

5

Collar mounting nut

82 {8.4}

9

No.2 idler gear mounting bolt

95 {9.7}

Remarks

-

Lubricant Points of application

Location

6,8

O-ring

Specified lubricant Engine oil

Quantity As required

11-55

TIMING GEARS ~ Special tools

Unit: mm

Location

2, 4

Part No.

Tool name and shape

MH061326

Gear Puller

Application

Removing No.1 idler shaft and gear

02065 Idler Gear Bushing Puller

3,11

A

B

No.1 idler gear bushing

<1>37

<1>40

No.2 idler gear bushing

<1>32

--------

MH062601 MH061779

Removing and fitting idler gear bushings

<1>35

02066

13

Idler Shaft Puller

MH062405

M8

Removing No.2 idler gear shaft

x 1.5 02067

• Service procedure • Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more pOints. If any measurement exceeds the specified limit, replace the defective part(s).

02284

(2) Idler gear end play If the measurement exceeds the specified value, replace the defective part(s).

02069

11-56

11 [I] W No.1

idler shaft and No.1 idler gear bushing

[Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

EB 02576

No.1 idler gear bushing [Removal] A: Press

02577

[I nstallation] • Using the ~ Idler Gear Bushing Puller, press the No.1 idler gear bushing 3 into the No.1 idler gear 4 from the side of the gear whose internal diameter is chamfered B.

.(}A ~

A: Press

3 B

4

• After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 3. 02578

[I] WRemoving No.1

idler shaft and No.1 idler gear

Loosen the bolt 1 by approximately 15 mm, then remove the No.1 idler shaft 2 and No.1 idler gear 4 as a single unit.

02070

W~ Installing No.1 and No.2 idler gears

12

Fit the No. 1 and No.2 idler gears 4, 12 such that their alignment marks ("1", "2", "3", "4") are aligned with those on the gears with which they mate.

*a: Drive gear *b : Camshaft gear

*c: Crankshaft gear *c

02074

11-57

TIMING GEARS [!!] ~

No.2 idler gear bushing and No.2 idler shaft

[Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

No.2 idler gear bushing [Removal) A: Press

02580

[I nstallation]


• Using the l&J Idler Gear Bushing Puller, press the No.2 idler gear bushing 11 into the No.2 idler gear 12 from the side of the gear whose internal diameter is chamfered B. A: Press

12 • After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 11. 02581

~ Removing No.2 idler shaft

02075

11-58

11

MEMO

11-59

TIMING GEARS <With Flywheel PTO>

*b

•

Disassembly sequence

1 2 3 4 5 •

Bolt O-ring No. 1 idler gear bushing No.1 idler gear No. 1 idler shaft

*a: Drive gear

6 Thrust washer 7 No.2 idler gear bushing 8 No.2 idler gear 9 No.2 idler shaft

*b : Camshaft gear OJ P.11-64

*c: Crankshaft gear OJ P.11-72 *d : Th rust plate OJ P.11-48 Non-reusable part

o:

Assembly sequence

Reverse the order of disassembly.

Service standards Location

-

3,5 4 7,9

8

11-60

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

Between No. 1 idler gear and crankshaft gear

0.07 to 0.20

0.35

Replace

Between No.1 idler gear and No.2 idler gear

0.10 to 0.22

0.35

Replace

Between No. 1 idler gear and drive gear

0.10 to 0.20

0.35

Replace

Between No.2 idler gear and camshaft gear

0.12 to 0.26

0.35

Replace

[401 0.03 to 0.07

0.2

Replace

0.1 to 0.6

1.0

Replace

[321 0.01 to 0.05

0.2

Replace

0.05 to 0.20

0.4

Replace

Maintenance item Gear backlash

No.1 idler shaft-to-gear bushing clearance No.1 idler gear end play No.2 idler gear bushing-to-shaft clearance No.2 idler gear end play

11

o

Tightening torques Parts to be tightened

Location

1 ~

No. 1 idler gear mounting bolt

Tightening torque

Remarks

135 to 165 {14 to 17}

-

Lubricant 2

Specified lubricant

Points of application

Location

r.g

Unit: N . m {kgf· m}

Engine oil

O-ring

Quantity As required

Special tools

Unit: mm Part No.

Tool name and shape

Location

Application

Idler Gear Bushing Puller

A 3, 7

No.1 idler gear bushing



No.2 idler gear bushing



40

B

MH061228

44

MH061779 32



Removing and fitting idler gear bushings

35

• Service procedure • Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more pOints. If any measurement exceeds the specified limit, replace the defective part(s).

02068

(2) No.2 idler gear end play If the end play measurement exceeds the specified value, replace the defective part(s).

02077

11-61

TIMING GEARS

[]] WNo.1 idler gear bushing and No.1 idler shaft [I nspection]

If the clearance exceeds the specified limit, replace the defective part(s).

EB 02582

No.1 idler gear bushing

ZJ.A

[Removal] The No.1 idler gear bushing 3 consists of two parts. Press out both parts together.

A: Press

3

3

02583

[Installation] • Using the r.g Idler Gear Bushing Puller, press each part of the No. 1 idler gear bushing 3 into the No.1 idler gear 4 from its respective side of the gear.

{}A

4 A: Press

• After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 3.

3

02584

[!]

No.1 idler gear end play

Measure the dimensions shown in the illustration and determine the end play D using the formula shown below. If the end play exceeds the specified limit, replace the defective part(s).

D = 72.15 mm - (A + B + C)

[!] [!]

Installing No.1 and No.2 idler gears

Fit the No.1 and No.2 idler gears 4, 8 such that their alignment marks ("1", "2", "3", "4") are aligned with those on the gears with which they mate.

*a: Drive gear *b : Camshaft gear

*c: Crankshaft gear

11-62

11 [I] ~

No.2 idler gear bushing and No.2 idler shaft

[I nspection]

If the clearance exceeds the specified limit, replace the defective part(s).

No.2 idler gear bushing [Removal] A: Press

02580

[Press fitting] • Using the r.g Idler Gear Bushing Puller, press the No.2 idler gear bushing 7 into the No.2 idler gear 2 from the side of the gear whose internal diameter is chamfered B.

.() A

A: Press • After installation, measure the clearance again. If the measurement is below the nominal value range, ream the No.2 idler gear bushing 7. 02581

11-63

CAMSHAFT <With electric speed sensor>

---_~H!t~

2~6rb -@\\W ~'l}

~t

~

<With mechanical tachometer drive>

~~~~/ 3

.:.

18061

• Pre-disassembly inspection

CD

P.11-66

• Disassembly sequence 1 Engine speed sensor <models with electric speed sensor> 2 Adapter <models with electric speed sensor> Tachometer drive case <models with mechanical tachometer> 3 O-ring

4 Pulse rotor <models with electric speed sensor> Tachometer drive coupling <models with mechanical tachometer> 5 Side cover 6 Camshaft assembly 7 Bolt 8 Camshaft gear 9 Thrust plate

NOTE • Do not remove the engine speed sensor 1 unless defects are evident. • Do not remove the camshaft gear 8 unless defects are evident. • Assembly sequence Reverse the order of disassembly.

11-64

10 11 12 13 14 15

Key Camshaft No.4 camshaft No.3 camshaft No.2 camshaft No. 1 camshaft

bushing bushing bushing bushing

* :Crankcase CD P.11-72 .:. : Non-reusable part

11 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Location

Remedy

1

Resistance of engine speed sensor (at 25°C)

2.3 ± 0.2 kQ

-

Replace

6

Camshaft assembly end play

0.05 to 0.22

0.4

Inspect each part

11

Camshaft

Except 6D16-E

6.901

6.40

Lobe height: 49.011 Base circle diameter: 42.110

6D16-E

7.42

6.93

Lobe height: 50.33 Base circle diameter: 42.91

7.680

7.18

Lobe height: 49.307 Base circle diameter: 41.627

0.02 or less

0.04

Replace

0.25

Replace

Cam lift

Inlet

Exhaust

Bend

11, 12 to 15

o

Limit

Camshaft journal-tocamshaft bushing clearance

No.1 journal

[57.75] 0.05 to 0.10

No.2 journal

[58.00] 0.05 to 0.10

No.3 journal

[58.25] 0.13 to 0.18

No.4 journal

[58.50] 0.05 to 0.10

Tightening torques

Location

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

29 ± 5.9 {3.0 ± 0.6}

-

Pulse rotor <models with electric speed sensor>

98 {1 O}

-

Camshaft gear mounting bolt

175 {18}

-

1

Engine speed sensor <models with electric speed sensor>

4 7

~~

~

Lubricant and/or sealant Points of application

Location

Specified lubricant and/or sealant

Quantity

1

Engine speed sensor threads <models with electric speed sensor>

Threebond 11 04J

As required

5

Crankcase mounting surface of side cover

Threebond 1207C

As required

11

Camshaft journals

Engine oil

As required

Inside surfaces of camshaft bushings

Engine oil

As required

12 to 15

11-65

CAMSHAFT ~ Special tools

Unit: mm Tool name and shape

Location

Part No.

~

V--

Plug

M10

Application

MF665007

Blanking plug for use when removing camshaft gear

MH061326

Removing camshaft gear

MH062025

Removing and installing camshaft bushings

x 1.25 02082

8

Gear Puller

02065 Camshaft Bushing Installer and Extractor

12 to 15

I~

A, C dimension

B dimension

No.1

<\> 62.00

<\> 57.75

No.2

<\>62.25

<\> 58.00

No.3

<\>62.50

<\>58.25

No.4

<\>62.75

<\>58.50

• Service procedure • Pre-disassembly inspection Camshaft end play

6

If the end play measurement exceeds the specified limit, replace the defective part(s).

02084

[!]

Inspecting engine speed sensor

<Models with electric speed sensor> • Measure the electrical resistance between terminals (1) and (2). • If the measurement is out of specification, replace the speed sensor 1. Gr 11

m

CAUTION~--------------------------­ Check the tightening torque of the engine speed sensor 1. If the sensor is insufficiently tightened, it may not produce signals. 03674

11-66

11

rcpd

[]J

<6014, 6014-T, 6015-T>

-=,~5mm

Fitting side cover

• Apply an even, unbroken bead of sealant A to the side cover 5. • Fit the side cover 5 onto the crankcase within 3 minutes of applying the sealant A.

CAUTION.&-------------5

• Ensure that the sealant application surface of the side cover 5 is clean before applying sealant. • When fitting the side cover 5, hold it firmly in position to prevent spreading the sealant. • After fitting the side cover 5, wait at least an hour before starting the engine. • Apply a new bead of sealant A whenever the mounting bolts of the side cover 5 have been loosened.

<6016, 16-E, 6016-T, 16-TE, 6016-TL, 16-TLE> A

18062

5

[I] Camshaft assembly

6

[Removal] • When removing the camshaft assembly 6, take off the side cover 5 and support the camshaft by hand. • Remove the bolts A from the camshaft gear holes, then slowly remove the camshaft assembly 6.

CAUTION.&----------------------------02086

9 11

Take care not to damage the camshaft bushings 12 to 15 when removing the camshaft assembly 6.

[Installation] • Before installing the camshaft assembly 6, measure the end play between the thrust plate 9 and camshaft 11. • If the measurement exceeds the specified limit, replace the defective part(s). • With the alignment marks lined up on the camshaft gear 8 and No.2 idler gear, fit the camshaft assembly. CD P.11-54

02092

[!]

8

Camshaft gear

[Removal]

CAUTION.&------------------The camshaft gear 8 must be removed with the appropriate special tools. 00 not tap off the camshaft gear since this would damage it.

02088 ~----------------------------~

[,ga: Gear Puller [,gb: Plug

11-67

CAMSHAFT [I nstallation] • Fitthe camshaft gear 8 onto the camshaft 11 in the direction illustrated. • Do not forget to fit the key 10.

"4"

~

8

:::------

10

11714

[!] Inspecting camshaft (1) Cam lift

11

o <::;::::J

IIA~llgB Bmm

C

Bmm

A

A 02090

L--_ _ _ _ _ _ _ _ _ _ _ _ _ _----'

If any base circle-to-Iobe height difference is less than the required value, replace the camshaft 11.

NOTE Since the cams are tapered, they must be measured at the position A shown in the diagram. B : Lobe height C: Base circle diameter 0: Front of engine

(2) Camshaft bend Support the camshaft 11 at its No.1 journal E and No.4 journal F, then take measurements at the No.2 journal G and No.3 journal H. If either measurement exceeds the specified limit, replace the camshaft.

NOTE Turn the camshaft 11 through one revolution. One-half of the dial indicator reading represents the camshaft's bend.

04108

[!] to ~

Camshaft and camshaft bushings

[I nspection] If any clearance exceeds the specified limit, replace the defective part(s).

NOTE Measure the camshaft bushings 12 to 15 with the camshaft installed in the crankcase*. 11 02093

11-68

11 Camshaft bushings Removal and installation of camshaft bushings should be carried out using the I£J Camshaft Bushing Installer and Extractor. Each guide of the tool is stamped with an identification mark ("1", "2", "3", "4") in the position shown. Use correct adapter and/or guide piece to remove and install a bushing according to the table below.

"1", "2" "3", "4" 13020

Bushing No. (from front of engine)

Identification mark

No.1

1

No.2

2

No.3

3

No.4

4


I£J Camshaft Bushing Installer and Extractor>

A: Rod B: Camshaft bushing adapter C: Guide piece 0: Nut

12 to 15

[Removal] Remove the No.4 and No.3 camshaft bushings 12, 13 from the rear of the engine. Remove the No.2 and No.1 camshaft bushings 14, 15 from the front of the engine.

I£J: Camshaft Bushing Installer and Extractor

02094

[I nstallation] • Identify the No.1 to No.4 camshaft bushings 12 to 15 from their identification marks ("1", "2", "3", "4") in accordance with the table below. If any bushing's identification mark is unclear, identify the bushing from its internal diameter E.

"1", "2" "3", "4"

12 to 15 11741

Bushing No. (from front of engine)

Identification mark

Internal diameter (mm)

NO.1

1

cp 57.75

No.2

2

cp 58.00

No.3

3

cp 58.25

No.4

4

cp 58.50

11-69

CAMSHAFT • Install the bushings 12 to 15 by using all components of the lQ Camshaft Bushing Installer and Extractor (rod A, camshaft bushing adapter B, guide piece C and nut 0). • Install the camshaft bushings 12 to 15 in the following order: No.3, No. 4, No.2 and NO.1.

NOTE Install the No.3 and No.4 camshaft bushings 12, 13 from the rear of the engine. Install the No.1 and No.2 camshaft bushings 14, 15 from the front of the engine.

c

06225

• Ensure that the oil holes F in the No.1 and No.4 camshaft bushings 15,12 are aligned with the oil holes G in the crankcase. With the No. 4 camshaft bushing, ensure also that the longer oil hole H is toward the rear of the engine.

J: Bushing clinch joint

lQ: Camshaft Bushing Installer and Extractor

04109

11-70

11

MEMO

11-71

CRANKSHAFT AND CRANKCASE

~~"'

,

l

.~

1

~O

0

~\ f)

18070

• Pre-disassembly inspection

CD

P'11-75

• Disassembly sequence

1 2 3 4 5 6 7 8 9

Bolt Crankshaft pulley Bolt Torsional damper Front cover assembly Front oil seal Front cover Bolt Lower main bearing

10 11 12 13 14

Main bearing cap Thrust plate Crankshaft assembly Front oil seal slinger Rear oil seal slinger <models without flywheel PTO> Sleeve <models with flywheel PTO> 15 Crankshaft gear

16 Crankshaft 17 Upper main bearing 18 Crankcase f): Non-reusable part

NOTE Do not remove front oil seal slinger 13, rear oil seal slinger (or sleeve) 14 and crankshaft 15 unless faulty. • Assembly sequence

Reverse the order of disassembly.

11-72

11 Service standards

Unit: mm

9, 17

Standard value (Basic diameter in [ ])

Limit

Remedy

Except 6D15-T (with dry cylinder liners)

[84] 0.05 to 0.10

0.15

Replace

6015-T (with dry cylinder liners)

[80] 0.05 to 0.10

Less than 85.5

Replace

Maintenance item

Location Main bearing

Oil clearance

-

Span when free

16

Crankshaft

End play

0.10toO.25

0.4

Replace

Bend

0.05 or less

0.1

Correct or replace

Roundness

0.01 or less

0.03

Correct or replace

Cylindricity

0.006 or less

Pin and journal

18

o

Distortion of crankcase top surface

Tightening torques

Location

~

0.07 or less

Correct or replace

-

0.2

Replace

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

1

Crankshaft pulley mounting bolt

185 {19}

-

3

Torsional damper mounting bolt

67 {8}

-

8

Main bearing cap mounting bolt

67 {8} + 90°

•

Wet

•

Can be reused up to 3 times CD P.11-76

Lubricant and/or sealant Points of application

Location

Specified lubricant and/or sealant

Quantity

5

Crankcase mounting surface of front cover assembly

Threebond 1207C

As required

6

Front oil seal lip

Engine oil

As required

8

Bolt threads

Engine oil

As required

Main bearing inside surfaces

Engine oil

As required

Apply inner surface of sleeve <with flywheel PTO>

Engine oil

As required

9,17 14

11-73

CRANKSHAFT AND CRANKCASE ~ Special tools Location

Unit: mm Tool name and shape

Part No.

Main Bearing Cap Extractor

Application

MH061189

Removing main bearing caps

MH061560

Fitting main bearing caps

MH062710

Installing front oil seal

MH061470

Installing rear oil seal slinger <without flywheel PTO>

MH062037

Installing rear oil seal sleeve <with flywheel PTO>

MH061326

Removing crankshaft gear

02097

10

Socket Wrench

01984

13

Front Oil Seal Slinger Installer

100 13625

Rear Oil Seal Slinger Installer

105.4 02051

14

Sleeve Installer

$110

15

®47290

Gear Puller

02065

11-74

11 • Service procedure • Pre-disassembly inspection Crankshaft assembly end play If the measurement exceeds the specified limit, replace the defective part(s).

02098

[1] Torsional damper CAUTION&--------------

14933

Leakage of silicon oil from the caulked seam A can cause the viscous-type torsional damper to stop functioning. Note the following points: • Check that the caulked seam is free of gouges and other damage. • Do not submit the torsional damper to shock by striking it with a hammer or dropping it. • Do not roll the torsional damper or stack it with other units.

[[] Installing front cover assembly • Apply an even, unbroken bead of sealant A to the mating surface of the front cover assembly 5 to be mounted to the crankcase 20. • Fit the front cover assembly 5 onto the crankcase 20 within 3 minutes of applying the sealant A.

CAUTION&--------------• Ensure that the sealant application surface of the front cover assembly 5 is clean before applying sealant. • When fitting the front cover assembly 5, hold it firmly in position to prevent spreading the sealant. • After fitting the front cover assembly 5, wait at least an hour before starting the engine. • Apply a new bead of sealant A whenever the mounting bolt of the front cover assembly 5 have been loosened.

~

[i]

Main bearings

[I nstallation1 Install the main bearings 9, 17 such that their lugs A fit into the corresponding grooves.

CAUTION&--------------The upper main bearing 17 has an oil hole B. The lower main bearing 9 has no oil hole. Take care not to confuse the upper and lower parts.

11-75

CRANKSHAFT AND CRANKCASE [Inspection)

CAUTION.&.-------------• Do not attempt to manually expand either bearing 9, 17 if its span is insufficient. • Upper and lower bearings 9, 17 must be replaced as a set. (1) Span when free If either bearing's span when free exceeds the specified limit, the bearings 9, 17 must be replaced.

(2) Main bearing-to-crankshaft clearance • Fit the upper main bearing 17 into the crankcase 18 and the lower main bearing 9 into the main bearing cap 10. Then, tighten the bolts 8 to their specified torque. • Measure the internal diameters of the main bearings 9, 17 and the outside diameter A of the crankshaft journal. If the clearance exceeds the specified limit, replace the defective part(s).

18

9

10

16 A

02104

[!QI

Main bearing caps

[Removal]

10 02100

[Installation] • Starting at the front of the engine B, fit the main bearing caps 10 in the order of the numbers A embossed on them and such that the numbers are in the pOSitions illustrated. • The bolts 8 can be reused only three times. Before fitting the bolts, make a punch mark on the head of each bolt to indicate times of reuse.

o

CAUTION.&.--------------------------If any bolt already has three punch marks, it must not be reused any more; replace it with a new one. 02103

11-76

11 • Tighten the bolts 8 to the specified torque. Then, turn the bolts further in accordance with the following procedure: • Turn the holder C of the ~ Socket Wrench counter-clockwise to tension the built-in spring.

EjyF ~

0: Socket E: Rod F: Rod (extension) 01991

• Set the socket wrench such that the built-in spring force forces the rod F against the crankshaft assembly 12. • On the holder C, select the inscribed line G that is easiest to see. • Using the selected line as a reference, turn the socket 0 90° clockwise. (One gradation on the scale H represents 5°.)

CAUTION&.-------------Since the bolts utilize the plastic region tightening method, they must not be tightened further after this procedure. 12829

[TIl

Installing thrust plates

Fit a thrust plate 11 on each side of the main bearing caps 10 and at the rear end of the crankcase 18 such that the oil grooves A are on the outside. B: Locating pin

NOTE 11731

If oversize thrust plates 11 are used, they must be fitted on both sides of the bearing caps 10. Ensure that the bearing cap rear thrust plates and the rearmost thrust plate in the crankcase 18 are the same size. Note, however, that the front and rear thrust plates on each bearing cap may be of different sizes.

~ Installing front oil seal slinger

13

B

Using the ~ Front Oil Seal Slinger Installer, drive the front oil seal slinger 13 onto the crankshaft 16 until the tool's end face A is pressed firmly against the guide B.

'---\- t A

16 11969

11-77

CRANKSHAFT AND CRANKCASE A

~ Rear oil seal slinger and sleeve

14

[Installation] <Models without flywheel PTO> Using the r.g Rear Oil Seal Slinger Installer, drive the rear oil seal slinger 14 onto the crankshaft 16 until it is pressed firmly against the end face A of the crankshaft gear 15.

16 02063

<Models with flywheel PTO> If the outer surface of the sleeve 14 is scratched or grooved, replace the sleeve as follows. [Removal] Use a chisel to cut the sleeve 14, then remove the sleeve from the crankshaft gear 15.

CAUTION~--------------------------Be careful not to damage the crankshaft gear 15.

C

®47291

[Installation] With the sleeve 14 set as shown (pay attention to the direction), turn the bolt A of the r.g Sleeve Installer as far as it goes. Do not tighten the bolt firmly. B: White paint C: Apply engine oil

B]]

15

Crankshaft gear

<Models without flywheel PTO> [Removal]

CAUTION~--------------------------Do not tap off the crankshaft gear 15 since this could damage it.

r.g: Gear Puller 02110

15

02111

11-78

[I nstallation 1 • Using a piston heater or the like, heat the crankshaft gear 15 to a temperature of approximately 1aaoG. • Align the locating pin A on the crankshaft 16 with the notch B in the crankshaft gear 15. Then, drive the gear into position by striking its end face with a plastic mallet.

11 <Models with flywheel PTO> [Removal] Screw the flywheel mounting bolts 0 evenly into the threaded removal holes C in the crankshaft 16. Alternatively, remove the crankshaft gear using the rg Gear Puller.

15

CAUTION&-------------DO not tap off the crankshaft gear since this could damage it.

02112

B

[Installation] • Using a piston heater or the like, heat the crankshaft gear 15 to a temperature of approximately 100DC. • Align the locating pin A on the crankshaft 16 with the dowel pin B on the crankshaft gear 15. Then, drive the gear into position by striking its end face with a plastic mallet.

15

02113

~ Crankshaft B

A

[I nspection] (1) Roundness and cylindricity of crankshaft journal and pin If either measurement exceeds the specified limit, replace the crankshaft 16 or grind it to undersize. A: Roundness B: Cylindricity 21871

(2) Bend • Support the crankshaft 16 at its No.1 journal A and NO.7 journal B. Measure the extent of bending in the crankshaft at the centre of the NO.4 journal C. • If the measurement exceeds the specified limit, replace the crankshaft.

NOTE 04110

H

With the dial indicator applied to the centre journal, turn the crankshaft 16 through one revolution. One-half of the dial indicator reading represents the extent of bending. [Rectification]

G

NOTE

E

If the crankshaft 16 is rectified by grinding, the main bearings 9, 17 must be replaced with undersized ones. F • Grind such that the centre-to-centre distance F between the journal 0 and pin E does not change. F'. 575 +0.025 . -0.075 mm 16

02107

11-79

CRANKSHAFT AND CRANKCASE • Grind such that the journal width G and pin width H do not change. G:37 mm H:42 +g2

mm

• Finish the corner fillet smoothly and to the specified radius J.

J: R4±O.2 mm • Carry out a magnetic inspection to check for cracks caused by grinding. Also, check that the Shore hardness of the surface has not dropped below Hs 75.

-

Unit: mm

Crankshaft undersize dimensions

Finished journal diameter

Finished pin diameter

-----

Degree of undersize 0.25

0.50

0.75

1.00

Except 6D15-T (with dry cylinder liners)

83.685 to 83.705

83.435 to 83.455

83.185 to 83.205

82.935 to 82.955

6D15-T (with dry cylinder liners)

79.685 to 79.705

79.435 to 79.455

79.185 to 79.205

78.935 to 78.955

Except 6D16-TLE

64.67 to 64.69

64.42 to 64.44

64.17 to 64.19

63.92 to 63.94

6D16-TLE

69.67 to 69.69

69.42 to 69.44

69.17 to 69.19

68.92 to 68.94

Roundness

0.01 or less

Cylindricity

0.006 or less

K

16

• When grinding K, turn the crankshaft 16 counter-clockwise as viewed from its front end. The grinder L should rotate in the same direction. • When finishing N the crankshaft 16 with sandpaper or a whetstone M, rotate the crankshaft clockwise.

N

02108

~ Distortion of crankcase top surface If distortion exceeds the specified limit, correct it with a surface grinder. A: Measurement positions

CAUTION.&-------------When grinding the crankcase 18, take care that the piston projections stay within specification.

11-80

12

GROUP 12 LUBRICATION SPECIFICATIONS ........................................

12-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5. 6.

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump ...................................................... Oil Filter ....................................................... Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure Switch, Regulator Valve..................... Lubrication of Related Parts ....................................

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-3 12-4 12-4 12-6 12-7 12-7

12-12

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement .......................................... 2. Engine Oil Replacement........................................ 3. Oil Pressure Measurement......................................

12-13 12-17 12-18

OIL PAN, OIL JET, AND OIL LEVEL SENSOR ...............

12-20

OIL PUMP AND OIL STRAINER. . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-22

OIL FILTER <Spin-on Type> ................................................ .

12-26 12-28

OIL COOLER <Except 6016-TLE> ............................................. <6016-TLE> ....................................................

REGULATOR VALVE .....................................

12-30 12-32

12-34

12-1

SPECIFICATIONS Item Mode of lubrication

Specifications Oil pump type

Oil filter type

Spin-on paper-filter type or replaceable-element type

Oil cooler type

Shell and plate type (multi-plate type)

Engine oil

Turbocharged engine: API CD or above Non-turbocharged engine: API CC or above

Oil quantity dm 3 {L}

Oil pan

Oil filter

12-2

General power applications

Approx. 9.5 {9.5}

Construction machinery applications

Approx. 16 {16}

Spin-on type: A, B type

2.1 {2.1}

Spin-on type: C type, Replaceable-element type

2.3 {2.3}

12

STRUCTURE AND OPERATION 1. Lubrication System (Oil Flow) 1

2

29

16887

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Engine oil pressure gauge unit Main oil gallery Bypass valve Oil cooler Engine oil bypass alarm switch Full-flow filter element Bypass filter element Check valve (built into oil filter) Bypass check valve (built into oil filter) Relief valve (built into oil pump) Oil pump Oil strainer Regulator valve Crankshaft main bearing Connecting rod bearing

16 Connecting rod bushing 17 Check valve for oil jet 18 Piston 19 Injection pump 20 Injection pump drive (or air compressor) 21 Timing gears 22 Camshaft bushing 23 Rocker bushing 24 Push rod 25 Tappet

26 Idler gear shaft No. 1 27 Idler gear shaft No.2 28 Turbocharger <6014-T, 15-T, 16-T, 16-TL, 16-TLE> 29 Oil pan

12-3

STRUCTURE AND OPERATION 2. Oil Pump 1 2 3 4

Crankshaft gear Oil pump gear Oil pump Oil strainer 5 Relief valve

B

5~

2

A: To oil filter B: From oil pan C: To oil pan

C

Oil pump 3 is a gear type. It is driven by rotation of the crankshaft via crankshaft gear 1 and oil pump gear 2. Relief valve 5 is fitted to the oil pump. When the oil pump discharge pressure exceeds a specified level, the relief valve returns some of the engine oil to the oil pan, thus protecting the lubrication system from excessive oil pressure.

3 A

t 01476

3. Oil Filter <Spin-on type (A, B type» 1 2 3 4 5

1

Full-flow filter element Bypass filter element Engine oil bypass alarm switch Check valve Bypass check valve

A: To oil cooler B: From oil pump C:To oil pan

3

~ 4

12-4

~

®47027

This oil filter is a spin-on paper-filter type incorporating full-flow filter element 1 and bypass filter element 2. Engine oil bypass alarm switch 3 is fitted to the oil filter bracket. If clogging causes the pressure difference before and after the element to exceed a specified level, a valve inside the switch opens to allow oil to flow directly to the oil cooler. Check valve 4 is fitted to the inlet to prevent a reverse flow of oil out of the filter when the engine is stationary. In conjunction with this, bypass check valve 5 opens only when oil pressure in the bypass arrangement exceeds a specified level. As a result, the oil level in the filter is kept constant and oil reaches all parts of the lubrication system quickly when the engine is started.

12 <Spin-on type (C type»

1 Engine oil bypass alarm switch 2 Bypass filter element 3 Full-flow filter element

A B C

A: To oil pan B: To oil cooler C: From oil pump This oil filter is a paper-filter type incorporating full-flow filter element 3 and bypass filter element 2.

®34244

Engine oil bypass alarm switch

• If the oil filter element becomes clogged, the flow of engine oil is restricted, causing engine parts to seize. To prevent this, engine oil bypass alarm switch 1 is fitted to the spin-on filter. • When the oil filter element becomes clogged, engine oil bypass alarm switch 1 is activated. As a result, engine oil is allowed to flow directly to the oil cooler, bypassing full-flow filter element 3. When the engine oil bypass alarm switch is activated, a warning lamp illuminates to notify the operator of the clogged oil filter element.



1 2 3 4

Full-flow filter element Bypass filter element Engine oil bypass alarm switch Check valve

A: From oil pump B: To oil cooler C:To oil pan This oil filter is a replaceable-element type incorporating fullflow filter element 1 and bypass filter element 2. Engine oil bypass alarm switch 3 is fitted to the oil filter bracket. If clogging causes the pressure difference before and after the element to exceed a specified level, a valve inside the switch opens to allow oil to flow directly to the oil cooler. Check valve 4 is fitted to the inlet to prevent a reverse flow of oil out of the filter when the engine is stationary. This ensures that the oil level in the filter remains constant such that oil reaches all parts of the lubrication system quickly when the engine is started.

4

~

04342

12-5

STRUCTURE AND OPERATION 4. Oil Cooler <Except 6016-TLE>

<6016-TLE>

3 01478

1 Oil cooler cover 2 Oil cooler element 3 Bypass valve

®34273

A: To main oil gallery B: From oil filter

• Bypass valve

<Except 6016-TLE>

Bypass valve 3 is fitted to the oil cooler. When engine oil is cool and its viscosity is high, or when the oil cooler element becomes clogged and restricts the flow of engine oil, this valve opens. As a result, engine oil is allowed to flow directly to the main oil gallery, bypassing the oil cooler. A: To main oil gallery B: From oil filter 01479

<6016-TLE>

A

,

v

®34275

12-6

12 5. Engine Oil Pressure Switch, Regulator Valve 1 Crankcase 2 Engine oil pressure switch 3 Regulator valve

<Except 6D16-TLE>

B

l

A: To oil pan B: Main oil gallery

l

• Engine oil pressure switch

16888

<6D16-TLE>

If the pressure of engine oil to the main oil gallery drops below a specified level, an electrical contact incorporated in engine oil pressure switch 2 closes. This causes a relevant warning lamp on the meter cluster to illuminate, notifying the operator of the excessive pressure drop.

• Regulator valve If the oil pressure in the main oil gallery exceeds a specified level, regulator valve 3 opens to allow some of the engine oil to return to the oil pan, thereby regulating the oil pressure to specification.

1

®44719

6. Lubrication of Related Parts Engine oil fed to the main oil gallery lubricates the following related parts:

• Main Bearing and Connecting Rod Bearing 1 2 3 4

Connecting rod bushing Connecting rod bearing Crankshaft Main bearing

A:Oiljet B: Connecting rod oil passage C: Main oil gallery Oil supplied via the oil passage in crankshaft 3 flows through connecting rod oil passage B to lubricate the connecting rod's small end. The oil then sprays out of oil jet A at the top of the connecting rod to cool the piston.

12-7

STRUCTURE AND OPERATION • Timing gear and camshaft

1 2 3 4 5 6 7 8

2

3

4 5

1::I1"r'\~~-_

Camshaft bushing No.4 Camshaft Idler gear No.2 Idler gear bushing Idler shaft No.2 Idler gear No.1 Idler gear bushing Idler gear shaft No. 1

A: To rocker bushing B: From main oil gallery

6 7

Engine oil flows through the inside of camshaft 2 and lubricates each camshaft bushing.

--=~~JiL~~- 8

01482

If a flywheel power take-off (PTO) is fitted, oil flows through an oil passage in the flywheel housing and sprays out of the oil jet to lubricate PTO idler gear B 12.

<With flywheel PTO>

9

..-tLb!-H----

9 10 11 12 13

11

10

PTO idler gear A Idler No.1 PTO idler shaft PTO idler gear B Oil jet

12

7 13

16889

12-8

~/

12 • Valve mechanism

1

2

3

1 2 3 4 5 6 7 8 9 10

Rocker shaft bracket Rocker Rocker shaft Rocker bushing Crankcase Cylinder head Cylinder head bolt Push rod Tappet Camshaft

A: From camshaft bushing No.4 B: Oil reservoir C: To oil pan 01484

After lubricating rocker 2, the camshaft bushings, and other components, oil enters oil reservoir B to lubricate the cams.

10

01485

• Check valve and oil jet 1 Piston 2 Oil jet 3 Check valve A: Main oil gallery

01487

An oil jet 2 is fitted in the lower part of the main oil gallery A for each piston. These oil jets cool the pistons 1 by injecting oil into them. Each oil jet is fitted with a check valve that opens and closes at specified oil pressure levels. At low engine speeds, these check valves 3 close to maintain the required volume of oil in the lubrication system and prevent reductions in oil pressure.

12-9

STRUCTURE AND OPERATION • Turbocharger <6D14-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE>

1

1 2 3 4

2

Bearing housing Snap ring Piston ring Bearing

A: From main oil gallery B: To oil pan Via an oil pipe, engine oil is delivered from the main oil gallery to the bearing housing 1 to lubricate the inside of the bearing housing. At each end of the turbine wheel shaft, piston ring 3 acts as an oil seal.

4

2

01488

• Injection pump

3

1 Injection pump 2 Governor 3 Air compressor (or injection pump drive) A: From main oil gallery B:To oil pan

01489

L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _

Engine oil that has lubricated injection pump 1 and governor 2 returns to the oil pan via the timer case, air compressor 3 (or injection pump drive), and timing gear train. • Air compressor 1 2 3 4 5

Piston Connecting rod Crankshaft Connecting rod bushing Crankcase

A: From main oil gallery B:To oil pan Engine oil from the main oil gallery splashes onto connecting rod 2 and lubricates connecting rod bushing 4. Piston 1 and the connecting rod's small end are lubricated by oil that is splashed onto them by the rotation of the crankshaft 3.

11107

12-10

12 • Vacuum pump Some of the oil used to lubricate the camshaft bushings is fed to the vacuum pump housing via a flexible hose. After lubricating the vacuum pump vanes, this oil leaves via an outlet at the bottom of the housing and returns to the oil pan.

01491

12-11

TROUBLESHOOTING Symptoms

Q) OJ

ctl

..:.::

ctl ~

§. c 0

:;:::;

a..

E

t ctl

U5

-

Q) ....

0

OJ

ctl

.c

"~

a..

Q)

Q)

....

ill

Oil cooler element installed poorly Gasket defective a-ring defective Oil cooler element clogged Oil cooler element damaged Fatigue in bypass valve spring Oil pump malfunctioning Interference between oil pump gear and oil pump case or cover Oil pump

c

c .c .... "6l Q) c >

Possible causes

Oil cooler

::::l

en en Q)

"0

Oil strainer clogged

....

"0 ~ 0

"0 Q)

> en Q)

"00 ()

><

-l

ill

0 0 0 0 0 0 0

0 0 0 0 0

0 0 0 0

0 0

0 0

0 0 0

0

0

Fatigue in relief valve spring

0

Oil filter fitted poorly Element clogged Oil filter

0

()

0

0

Oil pipe poorly fitted

Remarks

::::l

en c

Fatigue in check valve and bypass check valve springs

0

a-ring defective

0 0 0 0 0

mGr 11 mGr 11 mGr 11

Oil working its way up into combustion chamber(s)

0

QJ Gr 11

Oil working its way down into combustion chamber(s)

0

mGr 11

Front cover assembly timing gear case Flywheel housing

Front oil seal defective Front cover assembly fitted poorly Rear oil seal defective Gasket fitted poorly

0

Fatigue in regulator valve spring

0

Piston cooling oil jet(s) defective

Oil viscosity too high

0

Deterioration in oil

0 0

Fuel mixed with oil

0

Unsuitable oil quality

12-12

[LlGr11

12

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement <Spin-on type>

o

Tightening torques

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location 1

Oil filter drain valve

2

Oil filter drain plug

Remarks

29 ± 4.9 {3 ± 0.5}

-

7.8 ± 2.0 {0.8 ± 0.2}

-

~ Special tools Location

4

Unit: mm Part No.

Tool name and shape

Oil Filter Wrench

MH061537

Application

Oil filter removal

01503

WARNING& - - - - - - - - - - - - - -



• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

4 1

CAUTION&--------------

3

®47028

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

<8 type>

For type A or type B oil filter, loosen drain plug 1 or oil filter drain plug 2 and air plug 3 in that order, then drain the oil out of filter 4.

3 4 ®47029

4

®11108

12-13

ON-VEHICLE INSPECTION AND ADJUSTMENT

[Removal]

I£l

I£l: Oil Filter Wrench

®47030



\I ®47031



®11109

12-14

12

~A

4tJ 5-~

1-_~ ®47032

[I nstaliation1 • Clean the surface on oil filter head 5 that makes contact with oil filter 4. • Apply a film of engine oil to gasket area A of filter 4. • Screw oil filter 4 into oil filter head 5 until gasket area A touches the oil filter head. • From this position, tighten filter 3 by a further 11/8 to 1 3/ 8 of a turn. • Fit oil filter drain valve 1 or oil filter drain plug 2. • Start the engine and check that no oil leaks from gasket area A. • Check the engine oil level and add oil if necessary.



5

®47033



12-15

ON-VEHICLE INSPECTION AND ADJUSTMENT

o

Tightening torques

Location

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

1

Oil filter drain valve

29 ± 4.9 {3.0 ± O.5}

-

4

Center bolt

54 ± 4.9 {5.5 ± O.5}

-

WARNINGL1. - - - - - - - - - - - - - • Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

3

CAuTIONL1.-------------1

16768

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective. With a downward-facing oil filter, loosen drain valve plug 1 and air plug 2 in that order, then drain the oil out of filter 3. [Removal] 4 Center bolt 5 O-ring 6 Filter case 7 O-ring 8 Set spring 9 Element 10 Filter bracket

16769

[Installation] Wash all components other than the element in cleaning solvent, then fit the filter in the opposite order from that in which it was removed.

CAUTIONL1.-------------------------• If O-ring 7 is twisted when fitted, it may be severed. • Element 9 cannot be washed and reused.

12-16

12 2. Engine Oil Replacement

o

Tightening torques

Location

Unit: N . m {kgf· m} Tightening torque

Parts to be tightened

2

Oil pan drain plug

3

4

Remarks

69 {7}

-

Oil filter drain valve

29 ± 4.9 {3 ± 0.5}

-

Oil filter drain plug

7.8 ± 2.0 {0.8 ± 0.2}

-

~ Lubricants Location

-

Points of application Oil pan dm 3 {L}

General power applications

Kinds

Quantity

Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

Approx. 9.5 {9.5}

Construction machinery applications

-

Oil filter dm 3 {L}

Spin-on type: A, B type

Approx. 16 {16} Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

Spin-on type: C type Replaceable-element type

Approx. 2.1 {2.1} Approx. 2.3 {2.3}

WARNING'&' - - - - - - - - - - - - - - - -

<Spin-on type: A type> 1

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION.&.-------------------------5

2

®16770

<Spin-on type: B type> 1

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective. [Draining] • Warm up the engine, then remove oil filler cap 1. • Remove oil pan drain plug 2, oil filter drain valve 3 or oil filter drain plug 4, and air plug 5. Then, drain the engine oil.

®47034

2 <Spin-on type: C type>

[Filling] Tighten oil pan drain plug 2 and oil filter drain valve 3 or oil filter drain plug 4 to their specified torques, then pour the specified quantity of engine oil into the engine.

1

4

2

®47096

1

!~~J 35

2

®16772

12-17

ON-VEHICLE INSPECTION AND ADJUSTMENT 3. Oil Pressure Measurement <Except 6016-TLE> Service standards

-

o

Oil pressure (at oil temperature 70 to 90°C)

Limit

Remedy

At no-load minimum speed

0.1 MPa {1.0 kgf/cm2} or higher

Up to 0.1 MPa {1.0 kgf/cm 2}

Adjust

At no-load maximum speed

0.2 to 0.6 MPa {2.0 to 6.1 kgf/cm2}

Up to 0.2 MPa {2.0 kgf/cm2}

Tightening torque 1

Unit: N· m {kgf· m}

Parts to be tightened

Location

rG

Standard value

Maintenance item

Location

Engine oil pressure gauge unit

Tightening torque

Remarks

15 to 22 {1.5 to 2.2}

Check with engine cold

Sealant

Location

1

Points of application

Specified sealant

Wrap around thread of engine oil pressure gauge unit

Teflon tape

Quantity

3 1/2 turns

• Remove engine oil pressure gauge unit 1.

1

16773

• Fit adapter 3 onto the engine oil pressure gauge unit mounting, then fit the oil pressure gauge onto the adapter. • Warm up the engine until the oil temperature reaches 70 to gooe. • Measure the oil pressure at no-load minimum speed and at no-load maximum speed. If the measured values are below the specified standard values, overhaul the lubrication system. • After taking measurements, fit oil pressure gauge unit 1 and tighten it to the specified torque. PT1/8

12-18

NOTE 16774

Oil pressure gauge unit 1 must be fitted with the engine cold.

12 <6D16-TLE> Service standards

-

o

Standard value

Limit

Remedy

At no-load minimum speed

0.1 MPa {1.0 kgf/cm2} or higher

Up to 0.1 MPa {1.0 kgf/cm 2}

Adjust

At no-load maximum speed

0.2 to 0.6 MPa {2.0 to 6.1 kgf/cm 2}

Up to 0.2 MPa {2.0 kgf/cm2}

Adjust

Maintenance item

Location Oil pressure (at oil temperature 70 to 90°G)

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened Engine oil pressure switch

1

Tightening torque

Remarks

15 to 22 {1.5 to 2.2}

Tighten with engine cold

~ Sealant Points of application

Location

Specified sealant

Wrap around thread of engine oil pressure switch

1

Teflon tape

Quantity 3 1/2 turns

• Remove engine oil pressure switch 1.

2

1

2: Oil cooler

®11112

• Fit adapter 3 into the opening from which the engine oil pressure switch has been removed. Install an oil pressure gauge onto the adapter. • Run the engine until oil temperature reaches 70 - 90°C. • Measure the oil pressure at both no-load minimum and maximum speeds. If either of the measured values is below the limit pressures, overhaul the lubrication system. • Fit engine oil pressure switch 1 and tighten it to the specified torque.

PT1/8

~ 3

NOTE ®11113

Installation of engine oil pressure switch 1 must be performed while the engine is cold.

12-19

OIL PAN, OIL JET, AND OIL LEVEL SENSOR • Disassembly sequence 1 Drain plug

2 Oil pan

3 Engine oil temperature sensor 4 Check valve 5 Oil jet

*:

Crankcase assembly @ : Locating pin 0: Non-reusable part

OJ Gr 11

• Assembly sequence

5~@ 00 4---6

Reverse the order of disassembly.

CAUTION.&.------Do not tighten check valve 4 in excess of the specified torque. Excessive tightness can cause defective operation, resulting in scorching of the engine.

®c~

i'~~wo

01~ 16775

Service standards 3

Standard value

Maintenance item

Location

Resistance of engine oil temperature sensor (between ternimal CIl and body)

50°C

(136 n)

80°C

48±5n

100°C

27.2 ± 2 n

Limit

Remedy

-

Replace

Figures in parentheses are approximate.

o

Tightening torques

Location

rG

Unit: N· m {kgf· m}

Parts to be tightened

1

Drain plug

3

Engine oil temperature sensor

4

Check valve

Tightening torque

Remarks

34 ± 6.9 {3.5 ± O.7}

-

34 {3.5}

-

69 {7}

Sealant

Location

2

12-20

Points of application Crankcase mounting surface of oil pan

Specified sealant THREEBOND 1207C

Quantity As required

12 • Service procedure ~ Fitting oil pan 2

A

~

1.5mm

(~\~\':]] 11115

• Apply sealant A to the mounting surface of oil pan 2 as illustrated. Apply the sealant evenly and without breaks. • Within three minutes of applying sealant A, fit oil pan 2 onto the crankcase*.

CAUTION~--------------------------• Clean the oil pan mounting surface and ensure it is free of oily substances before applying sealant A. • Carefully mount oil pan 2 exactly in the correct position. Ensure that sealant A does not spread to other areas. • After fitting oil pan 2, wait at least one hour before starting the engine. • Reapply sealant A whenever the oil pan mounting bolts have been loosened.

@]

Engine oil temperature sensor

• Place engine oil temperature sensor 3 in a container of engine oil. • Heat the engine oil until it reaches each of the temperatures in the service standards table. • At each of the given temperatures, measure the electrical resistance between the engine oil temperature sensor's terminal (1) and body@. • If the resistance values do not match those in the service standards table, replace the engine oil temperature sensor 3. 03868

12-21

OIL PUMP AND OIL STRAINER

3

01497

• Inspection before disassembly

OJ P.12-23 • Disassembly sequence 1 2 3 4 5 6 7

Oil strainer Oil pipe Oil pump assembly Bolt Cover Driven gear assembly Ring

8 9 10 11 12

Relief valve Relief valve spring Washer Gear and case assembly Shim

*a: Crankcase assembly OJ Gr 11 *b: Crankshaft gear OJ Gr 11 *c: Oil pump gear ~ : Locating pin

0: Non-reusable part

NOTE • Do not remove parts #7 to 10 unless they are defective. • Gear and case assembly 11 is an integrated unit and cannot be disassembled. If any defect is apparent, replace the whole unit. • Do not remove oil strainer 1 and oil pipe 2 from oil pump assembly 3 unless they are defective. Remove those three as a unit. • Assembly sequence Reverse the order of disassembly.

12-22

12 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

Clearance between drive gear shaft and inner diameter of cover

[20] 0.04 to 0.07

0.15

Replace

5,6,11

Clearance between driven gear shaft and inner diameter of case and cover

[20] 0.04 to 0.07

0.15

Replace

6,11

Clearance between case and tooth tips of each gear

0.10 to 0.19

0.2

Replace

Difference between height of each gear and depth of case

0.06 to 0.11

0.15

Location

5,11

8

Relief valve opening pressure

9

Relief valve spring load (installed length = 30)

*b,*c

o

Maintenance item

Maintenance item

Backlash between oil pump gear and crankshaft gear

980 to 1175 kPa {1 0 to 12 kgf/cm 2 }

-

Replace

84 N {8.6 kgf}

-

Replace

Without PTa

0.08 to 0.18

With PTa

0.10 to 0.22

Tightening torque 4

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

Adjust with shims

0.35

Remarks

25 ± 4.9 {2.5 ± 0.5}

Oil pump cover mounting bolt

-

• Service procedure • Inspection before disassembly

c

Measure the backlash between oil pump gear *c and crankshaft gear *b. If the amount of backlash exceeds the specified limit, adjust it with shims

12. Shim thickness

Change in amount of backlash

0.1 mm

0.073 mm

0.2 mm

0.146 mm

NOTE Shim 12 must have the same thickness on the left and right sides.

[[] [[] [!] Inspection of cover, driven gear assembly, and gear and case assembly

5

Measure the clearance between each gear shaft and the internal diameters of the cover and case.

EO EO 01499

12-23

OIL PUMP AND OIL STRAINER [§J [TI]

Inspection of driven gear assembly and of gear and case assembly

(1) Differences between gear heights and case depth Replace any component whose measurement is out of specification.

(2) Clearance between gear teeth and case Replace any component whose measurement is out of specification.

12-24

12

MEMO

12-25

OIL FILTER <Spin-on Type>

• Disassembly sequence 1 2 3 4 5 6 7 8 9

*a

Oil filter drain valve Oil filter drain plug Oil filter P.12-13 Engine oil bypass alarm switch O-ring Air plug Oil filter head Spacer O-ring

m

m

*a: Oil cooler P.12-30 *b: Crankcase assembly ., : Non-reusable part

mGr 11

®47035



• Assembly sequence Reverse the order of disassembly.

*a



®47036

*b

7

~2

12-26

~

®34249

12 WARNING~---------------------------------------------------• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION~-----------------------------------------------------­ When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

Service standards Location

Maintenance item

4

Engine oil bypass alarm switch valve opening pressure

o

0.19~O5

MPa {1.9+ o65 kgf/cm2}

Limit

Remedy

-

Tightening torques

Replace

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

rG

Standard value

Remarks

1

Oil filter drain valve

29 ± 4.9 {3.0 ± 0.5}

-

2

Oil filter drain plug

7.B ± 2.0 {O.B ± 0.2}

-

4

Engine oil bypass alarm switch

49 ± 4.9 {5.0 ± 0.5}

-

Lubricant

Location

Points of application

3

Apply thin film to oil filter gasket area

9

Apply to O-rings

Specified lubricant

mP.12-13

Quantity

Engine oil

As required

Engine oil

As required

• Service procedure

[!]

AQ

11312

Inspection of engine oil bypass alarm switch

Carry out the following inspections and replace the engine oil bypass alarm switch 4 if the results are unsatisfactory: • With no air pressure A applied to engine oil bypass alarm switch 4, check that there is no electrical continuity between the terminal Cl! and body (2) of the engine oil bypass alarm switch. • Starting with pressure of 0 kPa {O kgf/cm 2 }, gradually increase the air pressure A on engine oil bypass alarm switch 4. Note the air pressure when electrical continuity appears between the terminal G) and body (2} Verify that this pressure conforms with the specified standard value.

B: Air pressure gauge

12-27

OIL FILTER • Disassembly sequence

o

1 2 3 4 5 6 7 8 9 10 11

~ 4

0 ~3 ~

2

5 6~0

7

*

80

Oil filter drain valve Air plug Center bolt a-ring Filter case a-ring Set spring Element Engine oil bypass alarm switch Filter bracket a-ring

* :Oil cooler OJ P.12-30 0: Non-reusable part • Assembly sequence Reverse the order of disassembly. 16778

WARNING&' --------------------------------------------• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION&.---------------------------------------When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

Service standards Location

Maintenance item

9

Engine oil bypass alarm switch valve opening pressure

o

145

+6°

kPa {1 .5 +~5 kgf/cm2}

Tightening torques

Location

rG

Standard value

Limit

Remedy Replace

-

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

1

Oil filter drain valve

29 ± 4.9 {3.0 ± O.5}

-

3

Center bolt

54 ± 4.9 {5.5 ± O.5}

-

9

Engine oil bypass alarm switch

49 ± 4.9 {5.0 ± O.5}

-

Lubricant Points of application

Location

4,6,11

12-28

Apply to O-rings

Specified lubricant Engine oil

Quantity As required

12 • Service procedure ~ Inspection of engine oil bypass alarm switch

A¢ (2)

11312

Carry out the following inspections and replace the engine oil bypass alarm switch 9 if the results are unsatisfactory: • With no air pressure A applied to engine oil bypass alarm switch 9, check that there is no electrical continuity between the terminalG) and body ® of the engine oil bypass alarm switch. • Starting with pressure of 0 kPa {O kgf/cm 2}, gradually increase the air pressure A on engine oil bypass alarm switch 9. Note the air pressure when electrical continuity appears between the terminal CD and body ®. Verify that this pressure conforms with the specified standard value. B: Air pressure gauge

12-29

OIL COOLER <Except 6D16-TLE> • Disassembly sequence

1 2 3 4 5

6 7 8 9 10 11 12 13 14

90

*

Bypass valve O-ring Oil cooler plug O-ring Nut Oil cooler element O-ring Oil cooler cover Gasket O-ring O-ring Regulator valve CO P.12-34 Engine oil pressure gauge unit Engine oil pressure switch

*: Crankcase assembly CO Gr 11

o :Non-reusable part

8

• Assembly sequence Reverse the order of disassembly.

16779

Service standards Location

o

Maintenance item

1

Oil cooler bypass valve opening pressure

6

Oil cooler element air leakage (air pressure of 980 kPa {10 kgf/cm2} for 15 seconds)

14

Operating pressure of engine oil pressure switch

Standard value

Parts to be tightened

Remedy

-

o cc

-

Replace

49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2}

-

Replace

Tightening torques

Location

Limit

295 ± 20 kPa {3.0 ± 0.2 kg/cm 2}

-

Unit: N· m {kgf· m} Tightening torque

Remarks

1

Bypass valve

20 ± 4.9 {2.0 ± 0.5}

-

3

Oil cooler plug

25 ± 4.9 {2.5 ± 0.5}

-

5

Nut (oil cooler element mounting)

20 ± 4.9 {2.0 ± 0.5}

-

105±9.8{11 ±1}

-

12

Regulator valve

13

Engine oil pressure gauge unit

15 to 22 {1.5 to 2.2}

-

14

Engine oil pressure switch

15 to 22 {1.5 to 2.2}

-

12-30

12 ~

Lubricant and/or sealant

Location

Points of application

Specified lubricant and/or sealant

Quantity

2,4,11

Apply to O-rings

Engine oil

As required

13,14

Wrap around thread of engine oil pressure gauge unit and engine oil pressure switch

Teflon tape

31/2 turns

• Service procedure • Cleaning • Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 6 and oil cooler cover 8 or in the oil cooler's bypass arrangement. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 6 or oil cooler cover 8. IT] Gr 14

WInspection of oil cooler element Plug outlet A of oil cooler element 6 and connect a hose to the oil inlet. Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

A

01505

Arrow mark

13

~ Engine oil pressure gauge unit If the engine oil pressure gauge unit 13 is installed horizontally, it must be fitted with its arrow pointing upward.

16886

~ Inspection of engine oil pressure switch (1)

L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Perform the following checks, and if any fault is found, replace the engine oil pressure switch 14. • Inspection by not applying air pressure Make sure that there is continuity between terminals en and (2) (body). • Inspection by applying air pressure • Gradually apply air pressure A to the switch starting from 0 kPa {O kgf/cm2}. • Measure the degree of air pressure at the moment when continuity is not detected between terminals (1) and (2) (body), and make sure to confirm if the value meets the standard. B: Air pressure gauge

12-31

OIL COOLER <6D16-TLE> • Disassembly sequence 1 Bypass valve plug a-ring Bypass valve spring Bypass valve Engine oil pressure switch Regulator valve OJ P.12-34 a-ring Nut 9 Oil cooler element 10 Gasket 11 Oil cooler plug 12 a-ring 13 Oil cooler plug 14 a-ring 15 Oil cooler cover 16 a-ring 17 Gasket

2 3 4 5 6 7 8

100

*: Crankcase assembly OJ Gr 11

®34270

o :Non-reusable part

• Assembly sequence Reverse the order of disassembly.

Service standards

Unit: mm

3

Standard value

Maintenance item

Location

Bypass valve spring

o

-

-

84 ± 3N {8.6 ± 0.3 kgf}

-

Replace

5

Operating pressure of engine oil pressure switch

49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2}

-

Replace

9

Oil cooler element air leakage (Apply air pressure of 1000 kPa {1 0.2 kgf/cm 2} for 15 seconds.)

o cm 3 {OmL}

-

Replace

Tightening torques

Location

rG

Remedy

104.3 ± 1

Free length Spring load (Installed length)

Limit

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

1

Bypass valve plug

34.3 ± 4.9 {3.5 ± 0.5}

-

5

Engine oil pressure switch

15 to 22 {1.5 to 2.2}

-

6

Regulator valve

98 to 118 {1 0 to 12}

-

8

Nut (for fixing oil cooler element)

20 ± 4.9 {2.0 ± 0.5}

-

11

Oil cooler plug

25 ± 4.9 {2.5 ± 0.5}

-

13

Oil cooler plug

34.5 ± 4.9 {3.5 ± 0.5}

-

Lubricant and/or sealant

Location

5

7,12, 14,16

12-32

Points of application

Specified lubricant and/or sealant

Quantity

Thread of engine oil pressure switch

Teflon tape

Wrap around 3 1/2 turns

a-rings on oil cooler

Engine oil

As required

12 • Service procedure • Cleaning • Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 9 and in the oil cooler's bypass arrangement. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 9 or oil cooler cover 15. CD Gr 14

WInspection of engine oil pressure switch Perform the following checks, and if any fault is found, replace the engine oil pressure switch 5. • Inspection by not applying air pressure Make sure that there is continuity between terminals CD and (2) (body). • Inspection by applying air pressure • Gradually apply air pressure A to the switch starting from 0 kPa {O kgf/cm2}. • Measure the degree of air pressure at the moment when continuity is not detected between terminals (1) and (2) (body), and make sure to confirm if the value meets the standard. B: Air pressure gauge

I]] A

Inspection of oil cooler element

Plug outlet A of oil cooler element 9 and connect a hose to the oil inlet. Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure B via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

12-33

REGULATOR VALVE • Disassembly sequence 1 2 3 4

4

Snap ring Valve Spring Body

• Assembly sequence Reverse the order of disassembly. [Installation]

CO P.12-30, 32

1

2 09189

Service standards Location

Maintenance item

3

Regulator valve spring load (installed length =4B.3 mm)

-

Regulator valve opening pressure

12-34

Standard value (Basic diameter in [ ])

Limit

Remedy

76 to BO N {7.B to B.2 kgf}

-

-

390 ± 29 kPa {4.0 ± 0.3 kgf/cm2}

-

-

113A

I

GROUP 13A FUEL AND ENGINE CONTROL SPECIFICATIONS ........................................

13A-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5. 6. 7.

Fuel System ................................................... Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor ...................................................... Feed Pump .................................................... ~~.. Automatic Timer ................ , .............................. 9. Boost Compensator ......... , ... , .............. " .............. 10.lnjection Pump Drive ................................ "." .. , ... 11.lnjection Nozzle ................. , .............. , " " " " , ......

13A-4 13A-5 13A-5 13A-6 13A-6 13A-9 13A-11 13A-12 13A-14 13A-15 13A-15

TROUBLESHOOTING ..................................... 13A-18 ON-VEHICLE INSPECTION AND ADJUSTMENT 1, Checking and Adjusting Injection Timing .,., ............... ,.,.' 13A-22 2. Checking and Adjusting Minimum and Maximum No-load Speeds . 13A-25 3. Cleaning Fuel Feed Pump Gauze Filter. , .......... , ..... , . , .. . ... 13A-26

FUEL FILTER ............................................ 13A-28 SECONDARY FUEL FILTER ............................... 13A-30 WATER SEPARATOR ..................................... 13A-31 INJECTION PUMP ..... , ... ,.,",., .. ,.................... 13A-32 13A-34

INJECTION PUMP DRIVE ........................................ 13A-40 .................... , .. ,"""',....... 13A-44

INJECTION NOZZLE <1-spring Type> ............... ,',.,",., .......................... 13A-48 <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> .. ".............. 13A-52 <2-spring Type: DENSO> ........... , ....... , " " ' , " " " " , . , ... ,' 13A-62

13A-l

SPECIFICATIONS Injection Pump

~:: Item

Model Governor type

6D14-T

6D14

6D15-T

STD

STD

OPT

STD

OPT

Bosch A

Bosch A

Bosch A

Bosch A

Bosch A

RSV-type all-speed mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanical governor

KE

KE

-

-

Feed pump type

KE

KE

KE

Automatic timer type

SA-type mechanical timer

SA-type mechanical timer

SA-type mechanical timer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

Manufacturer

~ Item

6D16,16-E

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

6D16-T,16-TE

STD

OPT

OPT

STD

OPT

Bosch A

Bosch A

Bosch AD

Bosch AD

Bosch AD

RSV-type all-speed mechanical governor

RFD-type minimummaximum mechanical governor

RSV-type all-speed mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanical governor

Feed pump type

KE

KE

KE

KE

KE

Automatic timer type

SA-type mechanical timer

SA-type mechanical timer

SA-type mechanical timer

SA-type mechanical timer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

Model

Governor type

Manufacturer

-

BOSCH AUTOMOTIVE SYSTEMS

~I

6D16-TL STD

STD

Model

Bosch AD

Bosch MD

Bosch MD

RFD-type minimum-maximum mechanical governor

RSV-type all-speed mechanical governor

RED-IV-type electronic governor

Feed pump type

KE

KE

KE

Automatic timer type

SA-type mechanical timer

SPG mechanical timer

SPG mechanical timer

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

Item

Governor type

Manufacturer

J3A-2

6D16-TLE OPT

113A I Injection Nozzle

~el

6015-T

6016,16-E

Hole-type (1-spring)

Hole-type (1-spring)

5

5

6014-T

6014

Item

Model

Hole-type (1-spring)

No. of holes

Hole-type (1-spring)

Hole-type (2-spring) 5

5

Hole diameter (mm)

0.28

0.29

0.315

Manufacturer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

DENSO

~el

0.29

0.31

0.31

0.29

I

I

BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

6016-T, 16-TE

6016-TL

6016-TLE

Hole-type (1-spring) I Hole-type (2-spring)

Hole-type (1-spring)

Hole-type (1-spring)

5

5

5

Hole diameter (mm)

0.31

0.31

Manufacturer

BOSCH AUTOMOTIVE SYSTEMS

Item

Model No. of holes

0.29

0.275

I BOSCH AUTOMOTIVE SYSTEMS

BOSCH AUTOMOTIVE SYSTEMS

Other Items Item Fuel filter type Secondary fuel filter type Water separator type

Specifications Spin-on type (paper filter) Filter paper type Sediment trap type

13A-3

STRUCTURE AND OPERATION 1. Fuel System For electronic fuel system, refer to Gr. 13E.

8

7

6

12574

1 2 3 4

Injection nozzle Fuel filter Automatic timer Fuel tank

5 6 7 8

Feed pump Injection pump Overflow valve Governor

• Fuel from the fuel tank 4 is drawn up by the feed pump 5 and strained by the fuel filter 2. The feed pump is driven by a cam in the injection pump 6. • After filtration, fuel is fed to the injection pump 6. From there, it is fed under high pressure to the injection nozzles 1. The injection nozzles spray the fuel into the combustion chambers. • If the fuel pressure in the injection pump 6 exceeds a preset level, the overflow valve 7 opens to allow excess fuel to return to the fuel tank 4.

13A-4

j13A j 2. Fuel Filter 2

1 Fuel filter 2 Fuel filter head A: From feed pump B: To injection pump The fuel filter separates any water content out of fuel fed from the injection pump's feed pump, and its element removes any impurities.

01822

3. Secondary Fuel Filter 1 Secondary fuel filter 2 Air plug 3 Cover 4 Case 5 Element 6 Drain plug 7 Center bolt

1 2

A: From feed pump B: To fuel filter

3

When the engine is run on JIS class 1 heavy oil (ASTM No.4; BS class D, B1 and B2), a secondary fuel filter is fitted in the position illustrated. Like the regularfuel filter, this unit separates any water content out of fuel received from the feed pump. It uses a paper element to remove impurities.

7

18223

13A-5

STRUCTURE AND OPERATION 4. Water Separator 1 Water level ring A: Fuel outlet (to feed pump) B: Fuel inlet

18224

'---------------------'

The sediment trap type water separator splits fuel and water centrifugally utilizing the difference in specific gravity between the two fluids. Fuel entering from the inlet connector is squeezed through a passage in the head, resulting in a faster flow with a more powerful axial twist. Water separated from the fuel settles in the case, and the water-free fuel flows to the feed pump via a passage in the center of the head. The water separator is effective in removing not only water but also dirt and other impurities. A red water level ring 1 floats inside the case, enabling the water quantity to be checked at a glance.

5. Injection Pump 1 2 3

4 5 6

__- - - 7

1 Delivery valve holder 2 Delivery valve spring

3 Delivery valve 4 Plunger barrel 5 Control pinion

6 Plunger 7 Control rack 8 Control sleeve 9 Plunger spring 10 Tappet 11 Camshaft

-~~~-8

9 10 11

01823

13A-6

The injection pump feeds fuel to the injection nozzles under high pressure and incorporates a mechanism for increasing and decreasing the fuel flow.

113A

I

• Fuel feed action A: B: C: D: E:

D

E 4

Fuel drawn in Start of pressure feed End of pressure feed Inlet/outlet hole Lead

6

1

o

o

o

11

c

B

A

01824

As the plunger 6 rises and its lead E meets the fuel inlet/outlet hole D, fuel flows through the center of the plunger and is expelled from the inlet/outlet hole. Regardless of how much further the plunger rises, no fuel feed takes place thereafter. The stroke length F of the plunger 6 during which pressure feed takes place is known as the "effective stroke."

F

01825

• Injection volume adjustment mechanism To match changes in engine loading, an adjustment mechanism controls the amount of fuel injected. This mechanism turns the plunger 6 by a given angle, thereby altering the point at which the fuel inlet/outlet hole D meets the lead E. Simply stated, the effective stroke is made longer or shorter. A single control rack 7 is used to rotate every plunger in the engine, so the plungers rotate simultaneously and by the same angle.

E IJ=:=="",-

7

6

01826

13A-7

STRUCTURE AND OPERATION • Delivery valve G: Pressurization starts H: Injection J: Pressurization ends (Starting suction) K: Suction ends L : Suction stroke

L

2---iJ

3-11 G

H

J

K 01827

Fuel highly pressurized by plunger pushes up delivery valve 3 for injection, and when delivery of pressurized fuel ends, delivery valve returns by the force of delivery valve spring to close fuel passage, thus avoiding reverse flow of fuel. Delivery valve lowers further to rest at its seat, and for this stroke L, residual pressure between delivery valve and injection nozzle is for an instant lowered. This return suction makes fuel-cutting at nozzles effective and avoids post-injection dripping .

• Overflow valve When the fuel pressure in the injection pump exceeds a preset level, the steel ball R is pushed up, allowing fuel to flow out from the injection pump and return to the fuel tank. This stabilizes the fuel temperature and temperature distribution in the injection pump and keeps the injection rate constant in each cylinder.

01830

13A-8

113A I 6. Governor

3

4

8

11 18225

1 2 3 4 5

6 7 8 9

Tension lever Guide lever Supporting lever shaft Governor housing Control rack Adjusting lever Swivel lever Camshaft Flyweight

10 11 12 13 14 15 16 17

Stop lever FUll-load stopper bolt Ungleich spring or idling spring Idling subspring Governor spring Control lever Shackle Start spring

J3A-9

STRUCTURE AND OPERATION

7

15

11 18227

1 Stop lever 2 Governor housing 3 Governor spring 4 Control rack 5 Swivel lever 6 Camshaft 7 Speed control lever 8 Flyweight 9 Sliding lever 10 Sleeve 11 Floating lever

13A-l0

Stroke adjusting bolt Idling spring Torque spring Smoke set assembly Damper spring Start spring Floating lever link Tension lever 20 Guide lever 21 Governor cover 12 13 14 15 16 17 18 19

113A I 7. Feed Pump 1 2 3 4 5

Priming pump Inlet check valve Gauze filter Outlet check valve Feed pump housing

A: From fuel tank B: To fuel filter The feed pump is driven by the camshaft in the injection pump. The priming pump 1 enables fuel to be drawn up manually when the injection pump is stationary. It is particularly useful for air bleeding. The gauze filter 3 removes large impurities from fuel drawn up from the fuel tank and thus prevents clogging of the feed pump. It must be washed regularly in gas oil. 14431

• Suction stroke When the injection pump camshaft 6 forces up the push rod 7, fuel in the suction chamber C is compressed and opens the outlet check valve 4. Most of the fuel forced out is drawn into the pressure chamber 0 below the piston.

A

13912

• Pressure feed stroke As the camshaft 6 turns and the cam loses its lift, the piston 9 is pushed down by the piston spring 8. The fuel in the pressure chamber 0 is thus forced out and fed toward the fuel filter. At the same time, the outlet check valve 4 closes and the inlet check valve 2 opens. As a result, fuel is again drawn into the suction chamber C.

13913

• Stoppage When pressure in the pressure chamber 0 exceeds a preset level, the piston spring 8 cannot push back the piston 9. The pump therefore stops operating, preventing pressure in the fuel filter from rising more than necessary.

8

9

13914

J3A-J1

STRUCTURE AND OPERATION 8. Automatic Timer The automatic timer utilizes a mechanical arrangement to adjust the injection timing in accordance with the engine speed. The automatic timer is mounted on the injection pump camshaft using a round nut. Via a driving disk, it is driven by the air compressor crankshaft or pump drive shaft.

<SA-type automatic timer>

18228

1 2 3 4

Timer housing Flyweight Roller Timer spring

7

5 Spring seat

6 Shim 7 Flange 8 Cover • With engine stationary

4

When the engine is stationary, the timer spring 4 overcomes the centrifugal force acting on the flyweight 2. The flyweight roller is therefore held down by the flange 7, and the injection timing arrangement is not advanced .

• With engine running

B

As the engine speed rises, the centrifugal force on the flyweight 2 increases. With the timer housing pin A as the fulcrum, the flyweight roller 3 thus moves outward while pushing the curved surface of the flange 7, causing the flange to compress the timer springs 4. As a result, the roller 3 of the flyweight 2 moves the flange 7 in the rotating directing and the injection timing is advanced.

18230

13A-12

113A I <SPG-type automatic timer> 1 2 3 4 5 6 7 8

Timer housing Eccentric cam (small) Eccentric cam (large) Timer holder Flyweight Timer spring Pilot pin Cover

®47183

• With engine stationary With the engine stationary, flyweight 5 is held against timer holder 4 by the force of timer spring 6.

5

®47184

• With engine running As the engine speed increases, the centrifugal force exerted on flyweight 5 matches the force of timer spring 6. As the engine speed increases further, the centrifugal force overcomes the force of spring, causing the flyweight to move outwards. As the flyweight moves outwards, eccentric cam (small) 2 rotates in the reverse direction of the shaft rotation about pin A of the timer housing. Also, center B of eccentric cam (large) 3 rotates in the reverse direction of the shaft rotation about center C of the timer. The eccentric cam (large) has been fit into timer holder 4. Therefore, the movement of the eccentric cam (large) is transmitted to the timer holder. The maximum retard is achieved when the back of the flyweight bottoms against the inner surface of timer housing 1.

13A-13

STRUCTURE AND OPERATION 9. Boost Compensator

5

A

+

1

1

10 P47186

1 Inlet manifold 2 Turbo charger 3 Turbine 4 Boost compensator spring 5 Boost compensator 6 Hose

7 8 9 10 11 12

Diaphragm Push rod Compensator lever Governor Floating lever Control rod

A: Boost pressure B: Intake air C: Exhaust 0: More fuel E, F: Pivot

• The boost compensator is designed to ensure that a greater amount of fuel is injected as the turbo charger feeds more air into the engine so that the engine output increases accordingly. • As boost pressure A in inlet manifold 1 overcomes the force of boost compensator spring 4 of boost compensator 5, diaphragm 7 and push rod 8 are pushed to the left. • As push rod 8 is pushed to the left, compensator lever 9 moves counterclockwise about pivot F to the position shown by the dotted line. This causes floating lever 11 to move counterclockwise about pivot E, which in turn moves control rod 12 in the direction of 0 (more fuel). As a result, a greater amount of fuel is injected irrespective of the operations of governor 10.

13A-14

\13A

I

10.lnjection Pump Drive 1 Pump drive case 2 Bearing 3 Pump drive gear 4 Pump drive shaft 5 Coupling

A: Timing gear side B: Timer side

A

J+---~5~:iJ~

The injection pump drive is fitted onto the flywheel housing on the left of the engine. It is driven by the engine timing gear at half the engine speed. The pump drive shaft 4 drives the injection pump via the coupling 5 on its timer side.

5

4

01844

11. Injection Nozzle <1-spring type> 1 Nozzle spring 2 Needle valve 3 Nozzle 4 Adjusting screw 5 Nozzle holder

..,. B A: To leak-off pipe B: From injection pump Fuel fed from the injection pump enters the nozzle holder 5. When the fuel pressure in the nozzle holder exceeds a preset pressure, it overcomes the nozzle spring 1, pushes up the needle valve 2, and the fuel is sprayed into the cylinder from the orifice at the end of the nozzle 3. Some of the high-pressure fuel lubricates the needle valve 2 and returns to the fuel tank via the leak-off pipe.

04538

I3A-I5

STRUCTURE AND OPERATION <2-spring type>

9

B

6 18361



~r..---1

~B

9

8 7

3 4

6 5

13A-16

18362

1 Valve opening pressure adjustment shim 2 Prelift adjustment shim 3 1st spring 4 1st push rod 5 Nozzle 6 Needle valve 7 Nozzle holder 8 2nd push rod 9 2nd spring Inside the nozzle, there are two springs 3, 9 and two push rods 4, 8. A prelift clearance is provided between the two push rods. When high-pressure fuel from the injection pump overcomes the 1st spring 3 (this spring determines the valve opening pressure), the needle valve 6 pushes up the 1st push rod 4, thereby opening the valve. When the 1st push rod 4 moves through the prelift clearance and contacts the 2nd push rod 8, the needle valve 6 momentarily stops lifting. As the fuel pressure increases further and overcomes the combined force of the 1st spring 3 and 2nd spring 9, the needle valve 6 lifts again for the main injection.

113A I

MEMO

13A-17

TROUBLESHOOTING Symptoms

"0 Q) Q)

D..

..c "g> ..c

Ol

c

t

- "x

0

-- "x --

ttl

.8

"5

1.::

ttl

1.:: ttl

t5

(5

D.. ::J

t5

0 :t:::

0

Q)

en

c

::J U

.lo:: U

"6>

"3: '5

c

Q)

.lo::

Q)

Q)

:0

C

::E

Q)

Q)

c

c

0

c

C

ttl

"6> "6> "6> en c

Injection pump proper

c

w

Possible causes

w

c

W

c

Sticky control rack

Worn tappet Worn camshaft

0

Poorly adjusted injection timing

Insufficient plunger slide stroke Broken plunger spring

0

Defective sliding action in control rack Tappet worn or not sliding correctly Broken delivery valve spring Poor airtightness due to loose delivery valve holder Defective delivery valve operation f---

0 0 0 0 0 0 0

::E ::J en

D..

en E ::J E ttl

E Q)

c

Ol C

:Q Q)

c

"6> C Q) Q)

:0 ttl

"6> t5 c

W

c

::J

.t:: ttl

c 0 0

en en

D..

0

W

0 0

- - i----

0

Gauze filter clogged

()

Check valve not operating

0 0 0 0

0 0

0 0 0 0 0 0

Delivery valve holder too tight Uneven injection volume to cylinders

0

()

0 0

0

0

0

()

=

ttl

E

..c U

ttl

Q) ....

(5 c

en Q)

"~

en

-- D..

0

en

0

c

0

en "0 "3: Q) Q) Q) c c c "6> "6> "6> c c c

-

- - - - - i---

13A-18

c Q) "6

0 0 0

Plunger spring not seating correctly

Piston worn

Q)

0

Loose control pinion

Defective check valve operation

c

Q) Q)

.... Q)

0

Excessively advanced injection timing

Worn tappet

c

"6>

c

Defective delivery valve seat

Sticky push rod

Q)

::J

Worn plunger

Sticky piston

0

en

"0

0 0 0 0 0

Sticky plunger

Sticky delivery valve

Fuel feed pump

::J D.. ::J

en E ::J E

()

W

W

0 0

ctl

"0 Q)

D..

.... 0 Cii .... Q)

Q)

u u

«

>.

0..

D.. ::J

en

Q) ::J

Q)

>

:;:::;

u

Q) Q)

0

113A Symptoms

I

"'0 Q) Q)

Q.

en

..c

OJ

OJ

c:

..c

t

0

"5 Q. "5

t:

t:

Cll

en

"0 c: .~

Q)

c: .0, c:

w

Possible causes Governor

enCll .8 .....

0

Q)

c:

::l ()

en ::s:. ()

~

c:

0

Q)

"'0

::s:.

Q)

Q)

c: OJ

c:

w

c: .0, c: W

OJ

c:

Q)

:0

0

Q)

c: .0, c: Q)

c

Q)

·u

::J

:E ::l en c:

0

0 0 0

enc:Cll

Insufficient full-load stopper position Weak governor spring Incorrectly adjusted control lever

"5 Q. "5

-

en....Cll

.8 "'0 Q) Q)

Q.

en

OJ

c: ~

E Q) c: E .0,

::l

·x

c:

E

Q)

Cll

Q)

c: .0, c: W

Q)

:0

enc:Cll

::J

Q)

.::= Cll

E ::l E

·x Cll

en

~

..c ()

Cll

Q) .... 0 0 en "0 c:

c:

:t::

E Q.

0

en

..... 0

en Q)

c:

0 ..... en

0 "'0

.~

Q)

Q)

Q)

Q.

c: c: c: .0, .0, .0, c: c: c: W

W

W

Bent links Excessive friction or play in links Loose round nut Poorly adjusted idling set bolt

0 0 0 0 0

Blocked injection orifice Poor airtightness in nozzle

0 0 0

Valve opening pressure too high

0 0 0 0 0

Broken spring Defective sliding action in needle valve Defective valve opening pressure

0 0 0 0

Filter (and/or secondary filter) clogged

Fuel tank empty Fuel pipes blocked and/or fuel leaking from connections Air or water in fuel system Low-quality fuel in use

CD () ()

~

::l Q)

> ..;:::; ()

Q) Q)

0

0 0

0

0 0

0

0 0 0

Leaky fuel tank Incorrect oil viscosity

mGr. 12

Incorrect valve clearance

ell Gr. 11

Defective head gasket

U] Gr. 11

0 0 0

Wear and/or carbon deposits on valve and valve seat

mGr. 11

0

en Gr. 11

0 0 0

0 0

0 0

0

0

0

Cracked fuel pipe

Weakness/deterioration in valve spring

Q)

-

0

Weakness/deterioration in spring

--

.... 0 Cil ....

en CD

0

Valve opening pressure too low

Fuel filter

Q.

0

Stop mechanism damaged

Sticky needle valve

::l

Q)

0 0

Defective sliding action in control lever

Injection nozzles

Cii

"'0

0 0 0 0 0

Weak idling spring

Defective advancing action

>.

0

Flyweights not operating effectively

Automatic timer

0

.8 Ci Q.

0

0 0 0 0

13A-19

TROUBLESHOOTING Symptoms

"0 Q) Q)

0..

en .!:: .!::

:J 0.. :J

t:

t:

co iii

en

0

0

"S ~

0

co C

= .~

Q)

Worn piston and cylinder liner Cooling system malfunctioning Defective starter switch Defective glow relay

13A-20

U

0

Q)

w

~

.0,

U

c

c

'5

~

Q)

Q)

CD Gr. 11 CD Gr. 11 CD Gr. 11 CD Gr. 14 CD Gr. 54 CD Gr. 54

w

0 0 0 0 0 0

c

en

c c .0, c .0, .0, c c c

Possible causes Worn/damaged piston ring(s)

:J

-- - -- - -·x -::c ::c « 0 0

Worn/damaged piston ring groove(s)

E E t ·x co co iii E .... Q) C> C

.Q>

W

Q)

Q)

co

en

c

::J

:J 0..

"0

0

0..

"S Q)

Q) Q)

en

C>

§

:Q

.t::

co c

:s:: "-5i

.!::

u

co Q) ....

0

0..

0

>.

.8 0.

:J

0.. Cii :J E Q) 00 en "0 0 en c en Q) E .0, en cen c0 0.. C 0.. .... Ci5 co Q) 0 0Q) .~ 0 :J E Q) en "0 co Q) .... > Q) Q) Q) Q) Q) +=u co .0, c c .0, c .0, c Ci5 Q) .0,

c

W

.~ C>

c

Q)

c

Q)

. (3

~

en

-

:J

c

iii c

::J

0 0 0

c

W

c

W

c

W

u u

Q)

0

\13A

I

MEMO

13A-21

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Checking and Adjusting Injection Timing <Except 6016-TLE> Service standards Maintenance item

Location

-

o

Standard value

Fuel injection timing (BTDC)

Depends on specifications

Tightening torques

Location

Parts to. be tightened

1

2

Bolt (delivery valve holder lock plate)

Delivery valve holder

-

Remedy Adjust

Unit: N . m {kgf' m}

Union nut (injection pipe mounting)

3

Limit

Tightening torque

Remarks

25 {2.5}

-

7.B to 11 {O.B to 1.1}

-

BOSCH AUTOMOTIVE SYSTEMS

4.4 to 6.0 {0.45 to 0.6}

-

BOSCH AUTOMOTIVE SYSTEMS

3.4 to 4.9 {0.35 to 0.5}

-

DENSO

34 to 39 {3.5 to 4}

-

BOSCH AUTOMOTIVE SYSTEMS

39 to 44 {4 to 4.5}

-

BOSCH AUTOMOTIVE SYSTEMS

49 to 54 {5 to 5.5}

-

DENSO

[I nspection1 • From the injection pump's No.1 cylinder, remove the injection pipe 1, lock plate 2, delivery valve holder 3, stopper 4, delivery valve spring 5, and delivery valve 6. • Fit the delivery valve holder 3.

CAUTION~--------------------------­ Place all parts in gas oil after removal to keep them free of dust.

18934

• Fit an injection pipe 7 onto cylinder No.1. Point the pipe's other end downward such that fuel flowing out can be seen clearly. • Rotate the crankshaft pulley clockwise (as seen from the front of engine) by at least 180° and bring cylinder No.1 to approximately 30° BTDC on its compression stroke.

7

NOTE

18935

If the engine is turned in its reverse direction (when stopping the engine or by cranking), the automatic timer may stay in an advanced condition. This may not be cancelled by a slight forward rotation of the engine. Be sure to crank the engine forward manually by at least 180°.

7 • Feed fuel into the injection pump using the priming pump 8. With fuel flowing out of the injection pipe 7, crank the engine slowly clockwise (as seen from the front of engine).

NOTE Ensure that the stop lever 9 at the side of the governor is not in its STOP position.

18936

13A-22

113A I • When the flow of fuel from the injection pipe 7 diminishes, crank the engine more slowly. When the flow of fuel stops completely, stop cranking the engine.

7

18937

• Check that the pointer 10 on the flywheel housing or torsional damper B indicates the value 1° earlier than the correct fuel injection timing. A: Flywheel

NOTE • The injection timing in this measurement becomes 1° earlier than the correct injection timing due to the inactivation of the delivery valve spring. • The correct injection timing is indicated on the plate attached on the rocker cover. 14814

<With flywheel PTO>

14584

• If the injection timing should be measured in a dusty location, perform as follows: • Rotate the crankshaft pulley clockwise (as seen from the front of engine) and bring the No.1 cylinder to 30° BTDC on its compression stroke. • Disconnect the injection pipe 1 with a little amount of fuel remained at the top of the delivery valve holder 3. • Slowly rotate the crankshaft pulley clockwise. When the injection timing is reached, the fuel at the top of the delivery valve holder 3 starts to move. • If the injection timing is out of the specification, adjust as follows: [Adjustment] • Loosen the nuts 12 that hold the timer case 11 onto the pump drive or air compressor 13. • If the fuel injection timing is overly retarded, incline the injection pump toward the crankcase. • If the fuel injection timing is overly advanced, incline the injection pump away from the crankcase.

NOTE 11

c

13 01852

Turning the injection pump by one of the gradations inscribed on the timer case flange C causes a 6° change in the injection timing. • Tighten the nuts 12, then check the fuel injection timing again.

NOTE If the fuel injection timing is so far out of specification that adjustment with the injection pump is not possible, the engine timing gear and injection pump drive gear may not be meshing correctly. If this occurs, remove and refit the air compressor or injection pump drive. • Air compressor: CO Gr. 61 • Injection pump drive: P.13A-40

m

• After checking that the fuel injection timing is up to specification, fit the delivery valve 6, delivery valve spring 5, and stopper 4.

13A-23

ON-VEHICLE INSPECTION AND ADJUSTMENT • Tighten each part to its specified torque.

3

2

01853

<6D16-TLE> Service standards Maintenance item

Location

-

o

Limit

Standard value Depends on specifications

Fuel injection timing (BTDC)

-

Tightening torques Tightening torque

Remarks

59 to 64 {6 to 6.5}

Bolt

2

Adjust

Unit: N· m {kgf' m}

Parts to be tightened

Location 1--

Remedy

-

[Inspection] • Turn the crankshaft by 180 0 or more in the forward direction to bring cylinder No.1 to TDe on its compression stroke. Set the injection timing by aligning the specified value shown on scale A stamped on the periphery of the flywheel with pointer 1 on the flywheel housing.

CAUTION~--------------------------If the engine is turned in reverse while the engine is stationary, the automatic timer can move to an advanced position. To return the automatic timer to a normal position, it may be necessary to manually rotate the engine forward by 180 or more. 0

• The injection timing is correct if line B inscribed in the injection pump aligns with line C inscribed in the automatic timer. • If out of alignment, adjust using the following procedures.

~I

~

B

)j

C

P46823

[Adjustment] • Loosen adjusting bolt 2. Turn the automatic timer to align line B with lineC. • Tighten adjusting bolt 2 to the specified torque. • Repeat the injection timing inspection.

CAUTION~----------------------------­ Only adjusting bolt 2 should be loosened.

2 P47366

13A-24

113A I 2. Checking and Adjusting Minimum and Maximum No-load Speeds Service standards Location

-

Standard value

Maintenance item

Limit

Remedy

No-load minimum speed

Depends on specifications

-

Adjust

No-load maximum speed

Depends on specifications

-

Adjust

Start the engine and allow it to warm up before carrying out the following inspections.

A

• No-load minimum speed

B

[Inspection] Confirm that the control lever 1 is touching the idling set bolt 3. Then check that the minimum speed is up to specification.

1

A: Idling position

18231



[Adjustment] If the minimum speed is out of specification, adjust it using the idling set bolt 3.

• No-load maximum speed

A_

[I nspection] Confirm that the control lever 1 is touching the full-speed set bolt 2. Then, check that the maximum speed is up to specification. B: Full-speed position

18232

~----------------------------~

[Adjustment] If the maximum speed is out of specification, adjust it using the full-speed set bolt 2.

NOTE Check that the engine does not stall and that no hunting occurs when the control lever 1 is moved quickly from the full-speed position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

9

• No-load minimum speed [I nspection] Confirm that the load control lever 7 is touching the idling set bolt 6. Then check that the minimum speed is up to specification.

B

A: Idling position

8 A 18233

[Adjustment] If the minimum speed is out of specification, adjust it using the idling set bolt 6.

13A-25

ON-VEHICLE INSPECTION AND ADJUSTMENT • No-load ma~imum speed [Inspection] Move the load control lever 7 to the full-load position B. Then, check that the maximum speed is up to specification. [Adjustment] If the maximum speed is out of specification, adjust position of the speed control lever 8 using the maximum speed stopper bolt 9 and stopper bolt

10.

NOTE • Do not alter the position of the full-load stopper bolt 11. • Check that the engine does not stall and that no hunting occurs when the load control lever 7 is moved quickly from the full-load position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

3. Cleaning Fuel Feed Pump Gauze Filter

o

Tightening torques Parts to be tightened

Location

1

Unit: N· m {kgf' m}

Eyebolt

Tightening torque

Remarks

BOSCH AUTOMOTIVE SYSTEMS

20 to 25 {2 to 2.5}

-

DENSO

15 to 20 {1.5 to 2}

-

• • • •

Remove the eyebolt 1 from the suction port side of the fuel feed pump. Remove the gauze filter 2 from the eyebolt 1. Clean the gauze filter 2. Refit the gauze filter 2 and eyebolt 1 in the opposite order to their removal. • Bleed all air out of the fuel system. • Start the engine and check for fuel leaks.

13A-26

\13A

I

MEMO

13A-27

FUEL FILTER

il---- 30





5

f

~

01

~1

2

@

Z~10

2

2

2

®47190

~30



@

®47191



5 5

~---­

Ii

@

4

2 ®47193

®47192

• Disassembly sequence 4 Fuel filter 5 Fuel filter head

1 Eyebolt 2 Fuel pipe 3 Air vent plug

• Assembly sequence Reverse the order of disassembly.

o

Tightening torques Parts to be tightened

Location

~

Unit: N· m {kgf· m}

1

Eyebolt

3

Air vent plug

Tightening torque

Remarks

34 {3.5}

-

9.8 ± 2.0 {1 ± 0.2}

-

Lubricant

Location

4

13A-28

Specified lubricant

Points of application Gasket between fuel filter and fuel filter head

Engine oil

Quantity As required

i13A i

r.g

Special tools

Location

Part No.

Tool name and shape

Application

Filter Wrench

4

Part No.

E

Filter model

MH061509

90.2

A,B

MH061572

94.2

C,D

~# ')

MH061509 MH061572

Removing fuel filter

;;

':;:/'

01882

• Service procedure

[!]

Fuel filter

[Removal]

WARNINGLh. - - - - - - - - - - - - - • Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel.

01883

~

[I nstaliation]

5

WARNINGLh. - - - - - - - - - - - - - Use of an unsuitable fuel filter 4 can lead to fuel leaks and fires. Be sure to use a genuine Mitsubishi filter.

13220

• To fit the fuel filter 4, turn it until the gasket C touches surface B of the fuel filter head 5. Then, tighten the filter by 3/4 to 1 turn. Be sure to turn the filter by hand. • Start the engine and check for fuel leaks.

13A-29

SECONDARY FUEL FILTER • Disassembly sequence 1 2 3 4 5 6 7 8 9

i--2 ....

Eyebolt Air vent plug Drain plug Center bolt Case Spring Element O-ring Fuel filter head

0: Non-reusable part • Assembly sequence Reverse the order of disassembly.

-

~3

4

o

18237

Tightening torques

Location

1

J3A-30

Parts to be tightened Eyebolt

Unit: N . m {kgf· m} Tightening torque 34 {3.5}

Remarks -

WATER SEPARATOR 0

1

113A I • Disassembly sequence

--41 ~ 20 (0.\ ()~

1 2 3 4 5 6 7 8 9 10 11 12

8

Eyebolt Air vent plug O-ring Drain plug Ring nut Case Isolation plate Screen assembly Baffle plate Water level ring Head O-ring

.,: Non-reusable part

WARNING'&' - - - - - - - - - - • Fuel ignites easily. Do not get it near flame or heat. • Wipe up any spilled gas oil because it can cause a fire. 20305

• Assembly sequence Reverse the order of disassembly.

o

Tightening torques

Location

Parts to be tightened

1

Eyebolt

2

Unit: N· m {kgf· m} Tightening torque

Remarks

34 {3.5}

-

Air vent plug

7.8 to 12 {O.8 to 1.2}

-

4

Drain plug

2.9 to 3.9 {O.3 to OA}

-

5

Ring nut

5.9 to 7.8 {O.6 to O.8}

-

13A-31

INJECTION PUMP

®18238

• Disassembly sequence 1 2 3 4 5 6 7 8

Eyebolt Fuel feed hose Eyebolt Fuel suction pipe Eyebolt Fuel feed hose Eyebolt Fuel return pipe

9 10 11 12 13 14 15

Injection pipe Eyebolt Eyebolt Connector Oil pipe Injection pump stay Injection pump assembly

16 Driving disk 17 O-ring

*: Injection pump drive

CO P.13A-40, or air compressor CO Gr. 61 ., : Non-reusable part

• Assembly sequence Reverse the order of disassembly.

WARNING'&' - - - - - - - - - - - - - - - - - - - - - - - - • Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel.

CAUTION.&,----------------------------------------------------Dirt particles in the injection pump assembly 15 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal.

NOTE For maintenance of the injection pump assembly 15, please contact a BOSCH AUTOMOTIVE SYSTEMS service station or DENSO service station.

13A-32

\13A

o

Tightening torques

Location

1,7

3,5

Unit: N· m {kgf' m}

Parts to be tightened Eyebolt (fuel feed hose, fuel return pipe)

Eyebolt (fuel suction pipe, fuel feed hose)

Tightening torque

Remarks

20 to 29 {2 to 3}

-

DENSO

15 to 20 {1.5 to 2}

-

BOSCH AUTOMOTIVE SySTEMS

20 to 25 {2 to 2.5}

-

DENSO

15 to 20 {1.5 to 2}

BOSCH AUTOMOTIVE SySTEMS

9

Injection pipe union nut

25 {2.5}

10

Eyebolt (oil pipe; air compressor or pump drive side)

21 {2.1}

-

11

Eyebolt (oil pipe; injection pump side)

10 to 13 {1 to 1.3}

-

7.B to 13 {O.B to 1.3}

-

21 {2.1}

-

BOSCH AUTOMOTIVE SySTEMS DENSO

12

I

Connecter (oil pipe)

• Service procedure ~ Installing injection pump assembly • Bring cylinder No.1 of the engine to the TDC position of its compression stroke.

• Align the inscribed lines C on the timer case A and timer B. Then, fit the injection pump assembly 15 onto the air compressor or injection pump drive.

c

B 01886

13A-33

INJECTION PUMP <Mechanical Governor>

8

18~ o

19

@ ('

o 9

2

\il

@

~ 70

*a

\,

\

13

25 P46821

<Electronic Governor>

*a

23

3

P46822

13A-34

113A I • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Eye bolt Fuel feed hose Eye bolt Fuel suction pipe Eye bolt Fuel feed hose Eye bolt Fuel return pipe Injection pipe Eye bolt Eye bolt Eye bolt Oil pipe Eye bolt Oil return pipe Eye bolt (mechanical governor)

17 Boost hose (mechanical governor) 18 Eye bolt (mechanical governor) 19 Oil pipe (mechanical governor) 20 Bolt 21 Cotter bolt 22 Driving coupling 23 Injection pump assembly 24 Bolt 25 Injection pump bracket 26 Key *a: Injection pump drive CD P.13A-44 or air compressor CD Gr. 61 *b: Engine speed sensor CD Gr. 13E 0: Non-reusable part

• Assembly sequence Reverse the order of disassembly.

CAUTION~----------------------------------------------------• Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel. • For maintenance of the injection pump assembly 23, please contact a Bosch Automotive Systems service station or Denso service station. • Dirt particles in the injection pump assembly 23 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal. • Never carry around the injection pump assembly 23 by holding it at the lever or the engine speed sensor *b. Removing the lever may result in deteriorated pump performance. • Do not remove the injection pump bracket 25 unless it is faulty.

13A-35

INJECTION PUMP Service standards

Unit: mm

o

Standard value

Maintenance item

Location

-

Fuel injection timing (BTDC)

25

Injection pump bracket (eccentricity between injection pump centering tool and injection pump drive or air compressor crankshaft)

Remedy

Depends on specifications

-

Adjust

0.2

-

Adjust

Tightening torques

Unit: N . m {kgf· m} Tightening torque

Parts to be tightened

Location

Limit

Remarks

1,7

Eye bolt (for fitting fuel feed hose and fuel return pipe)

20 to 29 {2 to 3}

-

3,5

Eye bolt (for fitting fuel suction pipe and fuel feed hose)

20 to 25 {2 to 2.5}

-

25 {2.5}

-

9

Injection pipe (for fitting union nut)

10

Eye bolt (for fitting oil pipe on either injection pump drive or air compressor side)

20.6 {2.1}

-

11 12

Eye bolt (for fitting oil pipe on injection pump side)

10 to 13 {1 to 1.3} 20.6 {2.1}

-

14

Eye bolt (for fitting oil return pipe)

20 to 25 {2 to 2.5}

-

20 to 29 {2 to 3}

-

10 to 13 {1 to 1.3}

-

25 {2.6}

-

59 to 64 {6 to 6.5}

-

83 to 93 {8.5 to 9.5}

-

Eye bolt (for fitting oil pipe on crankcase side) Mechanical governor Electronic governor

16

Eye bolt (for fitting boost hose)

19

Oil pipe

20

Bolt (for fitting driving coupling)

21

Cotter bolt

[,Q Special tools Location

25

Tool name and shape

Part No.

Injection Pump Centering Tool

MH063393

Application

Locating injection pump bracket

®13221

• Service procedure ~ Installing injection pump assembly • Crank the engine to set cylinder No.1 at the specified injection timing position.

13A-36

j13A *a

I

• Ensure that the key way A on the injection pump drive or air compressor (*a) crankshaft is facing upwards. • If key way A is not facing upwards, rotate the engine crankshaft by one turn.

13222

• Align line B inscribed on the injection pump and line C inscribed on the automatic timer.

®46823

*a

25

13223

22

• Set driving coupling 22 apart from coupling plate E by 0.5 mm as shown in the illustration. Tighten cotter bolt 21 to the specified torque.

O.5mm

E

~y~2~FE

21

• Fit driving coupling 22 to the injection pump drive or air compressor *a crankshaft D. Push the driving coupling against the injection pump drive or air compressor crankshaft D. • Fit injection pump assembly 23 to injection pump bracket 25.

13185

• Using bolts 20, fit driving coupling 22 and coupling plate E.

~ I E

20

13186

13A-37

INJECTION PUMP ~ Injection pump bracket [I nspection] • Set dial gauge B at rod A of I.Q Injection Pump Centering Tool for zeropoint correction.

A 13224

25

• Slide dial gauge B against the injection pump drive or the air compressor *a and measure the eccentricity between rod A and the crankshaft C of the injection pump drive or the air compressor at D, E and F. • If one of the measurements exceeds the specified value, adjust as follows.

*a

c

D E F

13225

[Adjustment] • When the measured value at point E is higher than the standard value: Insert shims G into four points equally. • When the measured value at point D is higher than the standard value: Insert shims G into lower side H. • When the measured value at point F is higher than the standard value: Insert shims G into upper side J.

CAUTION~--------------------------­ 13226

Insert shims G observing the following conditions: • Number of shims per point is three or less. • The same number of shims should be used for the front and the rear. • The difference in number of shims used for bottom and top is none or one. • Tighten bolts 24 to the specified torque and repeat the inspection.

13A-38

\13A

I

MEMO

13A-39

INJECTION PUMP DRIVE • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

Injection pump drive assembly Nut Lock washer Drive gear Collar Bolt Pin Coupling Bolt Cover Bolt Bearing Bearing holder 14 Shaft 15 Pump drive case 16 O-ring

160

*a: Injection pump assembly CD P.13A-32 *b: Oil pipe CD P.13A-32 • Assembly sequence Reverse the order of disassembly.

®47199

Service standards

Unit: mm Maintenance item

Location

14 14,15

o

Shaft end play Shaft-to-pump drive case clearance

Standard value

Limit

Remedy

-

0.59

Replace

0.12

Replace pump drive case

Tightening torques

Location

Parts to be tightened

1

Eyebolt

2

Unit: N· m {kgf· m} Tightening torque

Remarks

21 {2.1}

-

Nut (drive gear mounting)

167 to 211 {17 to 21.5}

-

6

Bolt (coupling mounting)

30 to 36 {3.1 to 3.7}

-

9

Bolt (cover mounting)

25 to 29 {2.5 to 3}

-

11

Bolt (bearing holder mounting)

5.9 to 6.9 {0.6 to 0.75}

-

13A-40

113A I ~

Lubricant 16

Specified lubricant

Points of application

Location

Engine oil

O-ring

Quantity As required

• Service procedure

[JJ

Installing injection pump drive assembly

• Bring cylinder No.1 of the engine to the TDG position of its compression stroke. CD Gr. 11 • Align the inscribed line A on the drive gear 4 of the injection pump drive assembly 1 with the inscribed line A on the pump drive case 15.

01919

• Remove the plug C from the flywheel housing B, then check that the inscribed line A on the drive gear 4 is aligned with the pointer D. If the line and pointer are not aligned, remove and refit the injection pump drive assembly.

B

[!]

"O~

Installing drive gear

• Fit the drive gear 4 such that its "0" alignment mark is aligned with the "0" alignment mark on the shaft 14. Then, fit the lock washer 3 such that its notch A is aligned with the drive gear alignment mark, and tighten the nut 2 to the specified torque.

• When the assembly is complete, bend the lock washer 3 down onto the nut 2.

3 P46828

13A-41

INJECTION PUMP DRIVE B] ~

c

B

Shaft-to-pump drive case clearance

If the clearance exceeds the specified limit, replace the pump drive case 15. A: Bushing B: Measurement directions C: Measurement positions

14 01923

B 15

02116

13A-42

113A I

MEMO

13A-43

INJECTION PUMP DRIVE • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Injection pump drive assembly Nut Lock washer Drive gear Collar Bolt Oil seal Bearing holder O-ring Sleeve Bearing Shaft Pump drive case O-ring

*a: Injection pump assembly OJ P.13A-34 *b: Oil pipe OJ P.13A-34 11

09

10

1~~~

• Assembly sequence Reverse the order of disassembly.

13

rG

o

®46824

Service standards

Unit: mm Maintenance item

Location

12

o

Shaft end play

Standard value -

Tightening torques

Location

Limit

Remedy

0.59

Replace

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

2

Nut (drive gear mounting)

167 to 211 {17 to 21.5}

6

Bolt (bearing holder mounting)

13.7 to 17.7 {1.4 to 1.8}

Remarks

-

~ Lubricant Location

14

13A-44

Points of application O-ring

Specified lubricant Engine oil

Quantity As required

i13A i • Service procedure

ITJ Installing injection pump drive assembly • Set cylinder No.1 of the engine at TDC on the compression stroke. CD Gr. 11 • Align line A inscribed on drive gear 4 of injection pump drive assembly 1 with line A inscribed on pump drive case 13.

®46825

• Remove plug C from flywheel housing B. Check if line A inscribed on drive gear 4 is aligned with pointer D. If not, remove and refit injection pump drive assembly 1 to obtain the alignment.

m

Installing drive gear

• Install drive gear 4 such that its "0" alignment mark is aligned with the "0" alignment mark on shaft 12. • Fit lock washer 3 such that its notch A is aligned with the "0" alignment mark on drive gear 4. Tighten nut 2 to the specified torque.

®46827

• After the drive gear is installed, bend lock washer 3 over nut 2.

3 P46828

13A-45

INJECTION PUMP DRIVE [i]

Installing oil seal

Face oil seal 7 as shown in the illustration. Then, fit it in bearing holder 8 by pressing evenly until it is flush with the end face A of the holder.

®46829

13A-46

113A I

MEMO

J3A-47

INJECTION NOZZLE <1-spring Type> • Pre-disassembly Inspection

CD P.13A-49 • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

@-70 <0

~8

Eyebolt Fuel leak-off pipe Injection pipe Bolt Injection nozzle assembly Connector Cap nut Adjusting screw Spring Push rod Retaining nut Nozzle Needle valve Pin Nozzle holder Dust seal Gasket

0: Non-reusable part Repair kit: Nozzle Service Kit (for BOSCH AUTOMOTIVE SYSTEMS nozzles only)

14

• Assembly sequence Reverse the order of disassembly. 04555

WARNING&' - - - - - - - - - - - - - - - - - - - - - - - - - To minimize the risk of fire, wipe up any spilled fuel.

CAUTION&.--------------------------------Under no circumstances change the needle valve 13 and nozzle 12 combination used in each injection nozzle assembly 5.

NOTE • Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly. • When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

13A-48

\13A Service standards Location

5

o

Unit: mm Maintenance item

Standard value

Limit

17.7 +g.49 MPa {180+g kg/cm2}

Injection pressure

1

3

Injection pipe union nut

4

Bolt (injection nozzle mounting)

Tightening torque

Connector

Remarks

BOSCH AUTOMOTIVE SYSTEMS

9.8 to 15 {1.0 to 1.5}

-

DENSO

15 to 20 {1.5 to 2.0} 25 {2.5}

-

15{1.5}

-

12to 14{1.2to 1.4}

-

BOSCH AUTOMOTIVE SYSTEMS

69 to 78 {7 to 8}

-

DENSO

59 to 69 {6 to 7}

-

BOSCH AUTOMOTIVE SySTEMS DENSO

6

Adjust

Unit: N . m {kgf· m}

Parts to be tightened Eyebolt (fuel leak-off pipe mounting)

Remedy

-

Tightening torques

Location

7

Cap nut

29 to 39 {3 to 4}

-

11

Retaining nut

59 to 78 {6 to 8}

-

~ Special tools Location

-

I

Unit: mm Tool name and shape

Part No.

Nozzle Cleaning Tool

*105789-0010

Application Cleaning nozzles

* BOSCH AUTOMOTIVE SYSTEMS part number

• Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for inspection.

NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement. (1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the adjusting screw 8. • If the measurement is still out of specification after adjustment, replace the injection nozzle assembly 5.

WARNING&' - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

13A-49

INJECTION NOZZLE <1-spring Type> Good

(2) Inspecting spray condition

Bad

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke, and maintain a continuous spray.

~

~

!

J B

C

D

I E

~

F

G

06931

B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) D: Asymmetrical spray (Bad) E: Branched spray (Bad) F: Thin spray (Bad) G: Irregular spray (Bad) • If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING&' - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm 2 } below the specified valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 still appears defective, it must be replaced.

Good

Bad

05388

[]] Injection nozzle assembly [Disassembly]

CAUTION&,-------------• Do not touch the sliding parts A of the needle valve 7. • Do not change the needle valve 13 and nozzle 12 combination on each cylinder.

04744

[Cleaning] Wash the needle valve 13 and nozzle 12 in gas oil, then use the r.g Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 13 using the Cleaning Bar of the r.g Cleaning Tool Set.

CAUTION&,-------------Do not use a wire brush or any hard metallic object for cleaning. 04556

13A-50

113A I • Remove carbon from the injection orifice of the nozzle 12 using the Needle Cleaner of the LQ Cleaning Tool Set. Insert the Needle Cleaner and rotate it to dislodge the carbon.

• Clean the seat of the nozzle 12 using the Cleaning Scraper of the LQ Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

01894

[Inspection] • Wash the needle valve 13 and nozzle 12 in gas oil, then fit them together. • Pull up the needle valve 13 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 13 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 12 as a set.

13 12

01911

NOTE Whenever a nozzle 12 is replaced, the nozzle and needle valve 13 must be replaced as a set using Nozzle Service Kit. (This applies to BOSCH AUTOMOTIVE SYSTEMS products only.)

13A-51

INJECTION NOZZLE <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> • Pre-disassembly inspection

CD P.13A-54 • Disassembly sequence

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

18239

Eyebolt Fuel leak-off pipe Injection pipe Bolt Injection nozzle assembly Cap nut Adjusting screw Lock nut 2nd spring Set screw 2nd push rod Shim (for adjusting prelift) Spacer Shim (for adjusting valve opening pressure) 1st spring 1st push rod Retaining nut Nozzle Needle valve Pin Nozzle holder Nozzle holder joint Dust seal Gasket

0: Non-reusable part • Assembly sequence

Reverse the order of disassembly.

WARNING~---------------------------------------------------­ To minimize the risk of fire, wipe up any spilled fuel.

CAUTION~----------------------------------------------------Under no circumstances change the needle valve 19 and nozzle 18 combination used in each injection nozzle assembly 5.

NOTE • Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly. • When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

13A-52

113A I Service standards Maintenance item

Standard value

1st valve opening pressure

+g.49 MPa {170 +6 21.6 +g.49 MPa {220 +6 kgf/cm 2 }

Location

5

Injection pressure

Unit: mm

2nd valve opening pressure (cover pressure)

16.7

Prelift

o

kgf/cm 2 }

Remedy Adjust

-

-

0.08

Tightening torques

Location

Limit

Adjust

Unit: N· m {kgf' m}

Parts to be tightened

Tightening torque

Remarks

9.8 to 15 {1.0 to 1.5}

-

1

Eyebolt (fuel leak-off pipe mounting)

3

Injection pipe union nut

25 {2.5}

-

4

Bolt (injection nozzle mounting)

15 {1.5}

-

6

Cap nut

39 to 49 {4 to 5}

-

8

Lock nut

20 to 25 {2 to 2.5}

-

10

Set screw

49 to 59 {5 to 6}

17

Retaining nut

59 to 79 {6 to 8}

-

22

Nozzle holder joint

69 to 79 {7 to 8}

-

~ Special tools Location

Unit: mm Tool name and shape

Nozzle Cleaning Tool

Part No.

(ga *105785-1010

Adjusting Device 'Retaining Nut (for adjustment) 'Gasket 'Adjusting Device

5

'Dial Gauge 'Base 'Pin (€ = 60.5 mm) 'Connector 'Pin (€ = 50 mm) 'Gasket

Application Cleaning injection nozzle assemblies

*105789-0500

(gb (gc (gd (ge (gf (gg (gh (gj (gk

*157892-1420 *157892-1500 * 157892-0220 *157954-3800 *157892-1800 *157892-1100 *157892-1320 * 157892-1200 *026508-1140

* BOSCH AUTOMOTIVE SYSTEMS product number , Component of Adjusting Device (105789-0500)

13A-53

INJECTION NOZZLE <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> • Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for inspection.

NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement. (1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the shims 12, 14. • If the measurement is still out of specification after adjustment, replace the injection nozzle assembly 5.

WARNING&' - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

(2) Inspecting spray condition

Bad

Good

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke, and maintain a continuous spray.

~

~ B

C

o

f J

J ~ E

F

G

06931

B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) 0: Asymmetrical spray (Bad) E: Branched spray (Bad) F: Thin spray (Bad) G: Irregular spray (Bad) • If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING&' - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm2} below the specified 1st valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 still appears defective, it must be replaced.

Good

J3A-54

Bad

05388

113A

I

[]] Injection nozzle assembly [Disassembly]

CAUTION~--------------------------• Do not touch the sliding parts A of the needle valve 19. • Do not change the needle valve 19 and nozzle 18 combination on each cylinder.

06932

a

19

[Cleaning] Wash the needle valve 19 and nozzle 18 in gas oil, then use the ~a Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 19 using the Cleaning Bar of the ~a Cleaning Tool Set.

CAUTION~ --------------------------Do not use a wire brush or any hard metallic object for cleaning. 01892

• Remove carbon from the injection orifice of the nozzle 18 using the Needle Cleaner of the ~a Cleaning Tool Set. Insert the needle cleaner and rotate it to dislodge the carbon. Cleaning needle diameter: 0.31 mm or smaller.

01893

• Clean the seat of the nozzle 18 using the Cleaning Scraper of the ~a Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

01894

[Inspection] • Wash the needle valve 19 and nozzle 18 in gas oil, then fit them together. • Pull up the needle valve 19 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 19 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 18 as a set. 01911

13A-55

INJECTION NOZZLE <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> NOTE After replacing any nozzle 18, be sure to readjust the prelift and ensure that the valve opening pressure is up to specification. [Adjustment] During reassembly, make adjustments in the sequence shown below.

CAUTION~--------------------------• Before making adjustments, wash all parts in gas oil and ensure that they are free of dirt and other foreign material. • Do not touch the sliding surfaces of the needle valve 19.

• Adjust nozzle opening pressure (1 st valve opening pressure)

• Select prelift adjustment shim

• Adjust 2nd spring setting pressure

•

* • Check needle valve full lift

*

I.

Install preHft shim

I.

Check prelift

* •

I.

Check 2nd spring setting pressure

Inspection * Carry out if necessary.

13A-56

113A I • Adjusting nozzle opening pressure (1st valve opening pressure) • Fit the nozzle 18 and needle valve 19 into the nozzle holder using the ~b Retaining Nut for Adjustment and ~c Gasket.

NOTE

21

• Before tightening the ~b Retaining Nut for Adjustment, check that the pin 20 is fully seated in the nozzle 18. Tighten the retaining nut to finger tightness, then tighten it to the specified torque using a torque wrench. Specified torque: 59 to 79 N . m {6 to 8 kgf· m}

19

• Remove the bolt from the end of the ~b retaining nut.

20 18

c

18240

• Insert the 1st push rod 16, 1st spring 15, valve opening pressure adjustment shim 4, and spacer 13 into the nozzle holder. (For the time being, use a shim of approximately 1 mm in thickness.) Then, tighten the set screw 10 to the specified torque.

10

13

14 15 16

18241

13A-57

INJECTION NOZZLE <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> • Fit the nozzle holder 21 onto the nozzle tester A and measure the 1st valve opening pressure. • If the measurement is out of the specification, adjust by shim 14. Shims are available in the following thicknesses: 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70, 0.80, 0.90, 1.00, 0.10, 0.20, 0.30, and 0.40 mm.

NOTE 18242

• Before using any shim, check its thickness using a micrometer. • These shims are also used for prelift adjustment. • A 0.02 mm change in shim thickness corresponds to a 24 kPa {2.4 kgflcm 2} change in valve opening pressure. • Leave the bolt off the end of the Retaining ~b Nut. • Selecting prelift adjustment shim • Fit the ~e Dial Gauge onto the ~d Adjusting Device. Then, fit the 2nd push rod 11 into the ~f Base and mount the assembly in a vise. Next, set the ~g Pin and Adjusting Device as shown in the illustration, and zero the Dial Gauge. • Fit the 2nd push rod 11 into the nozzle holder.

NOTE Do not install the 2nd spring 11 and prelift adjustment shim 12.

18243

• Using the intermediate screw A of the ~d Adjusting Device, mount the Adjusting Device on the set screw 10. Then, hold the holder B of the ~e Dial Gauge and move it up and down to check that the gauge operates smoothly. Still holding the holder of the dial gauge, push down the gauge and read its lift measurement h.

~e

NOTE Read to a precision of 1/100 mm. 10

A

10

21

• Select the prelift adjustment shim 12 as follows: t=f+h where t: Shim thickness (as measured) f: Prelift (nominal value) h: Dimension measured in previous step of procedure T: = t ± 0.015 mm T = t ± 0.015 mm where T: Thickness of shim to be used • Remove the ~d Adjusting Device from the nozzle holder 21.

13A-58

113A I • Adjusting 2nd spring setting pressure (open pressure) 8--~

• Fit the 2nd spring 9 and adjusting screw 7 into the nozzle holder 21. • Tighten the lock nut 8 to the specified torque.

7----ii§'1 9--~

NOTE Do not install the prelift adjustment shim.

21

18245

• Measure the 2nd spring setting pressure (open pressure) using the nozzle tester A.

NOTE Leave the bolt off the end of the ~b Retaining Nut.

• If the measurement is out of the specification, adjust by the adjusting screw 7. Nominal value: 24.7 to 25.3 MPa {252 to 258 kgf/cm2} • After adjustment, tighten the lock nut 8 to the specified torque.

• Adjusting needle valve full lift

• Fit the special tools shown in the illustration, then zero the ~e Dial Gauge. ~h Connector tightening torque: 39 to 49 N . m {4 to 5 kgf· m}

e

A: Bolt

~h

• Fit the nozzle 5 onto the nozzle tester, then operate the nozzle tester lever to bleed all air out of the ~b Retaining Nut (for adjustment). Also, check for fuel leaks. • Using the nozzle tester lever, increase the pressure to 34.3 to 44.1 MPa {350 to 450 kgf/cm2} such that the nozzle's needle valve 19 lifts fully. Read the lift dimension shown by the Dial Gauge. • Remove the ~e Dial Gauge, ~h Connector, and ~j Pin.

~j

~b

~k

~A

18246

J3A-59

INJECTION NOZZLE <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> • Installing prelift adjustment shim

7

8

• Remove the set screw 10, lock nut 8, and adjusting screw 7 from the nozzle holder 21 as an assembly.

10

CAUTION~--------------------------Do not loosen the lock nut 8. Loosening the lock nut would alter the 2nd spring setting pressure.

18247

'------------------'

• Fit the prelift adjustment shim 12 between the spacer 13 and push rod 11. Use the shim selected previously in accordance with the "Selecting Prelift Adjustment Shim" procedure. • Install the 2nd push rod 11 and 2nd spring 9. • Fit the set screw 10, lock nut 8, and adjusting screw 7 as an assembly, and tighten the set screw to the specified torque. • Measure the needle valve lift in accordance with the previously described procedure. The lift measured this time should be the value of "(full lift) - (prelift)". • Checking prelift • Check the prelift based on the previously measured "full lift" and "lift" dimensions. L-S=LlC where 0.02 ~ Ll C ~ C + 0.02 Ll C: Prelift (as measured) C: Prelift (nominal value) L: Needle valve full lift dimension (as measured) S: Needle valve lift dimension (as measured) with prelift subtracted

e-

If Ll C is out of the specified range (C ± 0.02 mm), replace the prelift adjustment shim 12 in accordance with the previously described procedure, then repeat the last two procedures such that the Ll C dimension falls within C ± 0.02 mm. Select the thickness of the replacement shim (t') as follows: t' = t + (C - Ll C) T = t' ± 0.015 mm

t: Thickness of shim installed t': Shim thickness T: Thickness of shim to be used C: Prelift (nominal value)

J3A-60

\13A\ • Checking 2nd spring setting pressure (cover pressure) • Check the prelift in accordance with the previously described procedure. Then, use the nozzle tester to increase the pressure again to 34.3 to 44.1 MPa {350 to 450 kgf/cm 2 } such that the needle valve 19 lifts fully.

NOTE The [,gb Retaining Nut (for adjustment) must have its end bolt fitted. 18248

• With the needle valve 19 fully lifted, stop operating the lever of the nozzle tester A. The pressure will start to decrease, and the needle valve will drop. • At the moment when the nozzle lift decreases to 0.05 mm, read the pressure gauge indication. Nominal value: 23.1 to 23.6 MPa {235 to 240 kgf/cm2} • If the measured value is out of specification, adjust it. CD P.13A-59 • Remove the special tools.

• Inspection • Fit the injection nozzle assembly 5 onto the nozzle tester A, then check the 1st valve opening pressure, the spray condition, and the airtightness of the seat. Check also for fuel leaks.

5

NOTE

A

If the 1st valve opening pressure is out of specification, make adjustments again starting with the preliminary procedures.

01910

13A-61

INJECTION NOZZLE <2-spring Type: DENSO> • Pre-disassembly inspection

CD P.13A-63 • Disassembly sequence 1 2 3 4 5 6 7 8 9

10 11

12 13 14 15 16 17

18 19 20 21 22 23

Eyebolt Fuel leak-off pipe Injection pipe Bolt Injection nozzle assembly Cap nut Lock nut Screw plug Shim (for adjusting valve opening pressure) 2nd spring 2nd push rod Shim (for adjusting prelift) Capsule screw 1st spring 1st push rod Retaining nut Nozzle Needle valve Pin Nozzle holder Nozzle holder joint Dust seal Gasket

18249

0: Non-reusable part • Assembly sequence Reverse the order of removal.

WARNING~---------------------------------------------------­ To minimize the risk of fire, wipe up any spilled fuel.

NOTE Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly.

CAUTION~----------------------------------------------------Under no circumstances change the needle valve 18 and nozzle 17 combination used in each injection nozzle assembly 5.

NOTE When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

13A-62

113A Service standards Injection pressure

5

Unit: mm Maintenance item

Location

16.67

1st valve opening pressure 2nd valve opening pressure (cover pressure)

21.57

+g.98 +g.98

MPa

{170+6 0

kgf/cm2}

MPa

{220+6 0

kgf/cm2}

0.08 ± 0.02

Tightening torques

Remedy

-

Adjust

-

Adjust Unit: N· m {kgf· m}

Tightening torque

Parts to be tightened

Location

r.g

Limit

Standard value

Prelift

o

I

Remarks

15 to 20 {1.5 to 2.0}

-

25 {2.5}

-

12 to 14 {1.2 to 1.4}

-

Cap nut

39.2 to 49 {4 to 5}

-

7

Lock nut

58.8 to 68.6 {6 to 7}

-

8

Screw plug

29.4 to 39.2 {3 to 4}

-

16

Retaining nut

58.8 to 78.5 {6 to 8}

21

Nozzle holder joint

58.8 to 68.6 {6 to 7}

-

1

Eyebolt (fuel leak-off pipe mounting)

3

Injection pipe union nut

4

Bolt (injection nozzle mounting)

6

Special tools

Location

Tool name and shape

-

Nozzle Cleaning Tool

-

2-Spring Nozzle Adjustment Tool

Part No.

[ga *105789-0010 Holder

[gb

Probe

[gc

*95091-10770

Application Cleaning nozzles Measuring prelift

* DENSO product number * BOSCH AUTOMOTIVE SYSTEMS product number

• Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for inspection.

NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement. (1) Checking valve opening pressure

5

• Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the shims 9, 12. • If the measurement is still out of specification after adjustment, replace the injection nozzle assembly 5. 01910

WARNING&' - - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

13A-63

INJECTION NOZZLE <2-spring Type: DENSO> (2) Inspecting spray condition

Bad

Good

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke and maintain a continuous spray.

,----A---,

~ B

C

o

t l

J \ E

F

G

B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) 0: Asymmetrical spray (Bad) E: Branched spray (Bad) F: Thin spray (Bad) G: Irregular spray (Bad)

06931

• If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING~ - - - - - - - - - - - - - Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm2} below the specified 1st valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly still appears defective, it must be replaced.

Good

Bad

05388

[II

Injection nozzle assembly

[Disassembly]

CAUTION~-------------------------• Do not touch the sliding parts A of the needle valve 18. • Do not change the needle valve 18 and nozzle 17 combination on each cylinder.

06932

[Cleaning] Wash the needle valve 18 and nozzle 17 in gas oil, then use the (;ga Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 18 using the cleaning bar of the (;ga Cleaning Tool Set.

18--::::;;~1

CAUTION~-------------DO not use a wire brush or any hard metallic object for cleaning. 01892

13A-64

113A I • Remove carbon from the injection orifice of the nozzle 17 using the needle cleaner of the ~]a Cleaning Tool Set. Insert the needle cleaner and rotate it to dislodge the carbon. Cleaning needle diameter: 0.315 mm or smaller.

01893

• Clean the seat of the nozzle 17 using the cleaning scraper of the ~a Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

01894

[I nspection] • Wash the needle valve 18 and nozzle 17 in gas oil, then fit them together. • Pull up the needle valve 18 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 18 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 17 as a set.

18

01911

[Adjustment] During reassembly, make adjustments in the sequence shown below.

CAUTION~--------------------------• Before making adjustments, wash all parts in gas oil and ensure that they are free of dirt and other foreign material. • Do not touch the sliding surfaces of the needle valve 18.

• Adjust 1st valve opening pressure

• Adjust 2nd valve opening pressure

__ I. 1~·

A_d_jU_s_t_p_re_l_ift__- ,_________~

•

Check 1st valve opening pressure

13A-65

INJECTION NOZZLE <2-spring Type: DENSO> • Adjusting 1st valve opening pressure (injection pressure) • Assemble the parts as shown in the illustration.

7

13

NOTE Check that the pin 19 is fully seated in the nozzle 17 before tightening the retaining nut 16 to the specified torque.

--+-~

• Fit the injection nozzle assembly onto the nozzle tester, then adjust the valve opening pressure of the 1st spring by loosening the capsule screw 13. • Lock the capsule screw 13 in position and tighten the lock nut 7 to the specified torque.

14

---..1'-..1"

15

---;-"!~II

18 17 - - . ! 7 16 01913

• Adjusting 2nd valve opening pressure

~i----8

• Fit the 2nd push rod 11, 2nd spring 10, valve opening pressure adjustment shim 9, and screw plug 8. If the thickness of the valve opening pressure adjustment shim is not known, a 1.9 mm shim should be used as a guide.

~----9

e~--10

NOTE Do not install the prelift adjustment shim 12.

1------11

• Fit the assembled arrangement onto the nozzle tester, then adjust the shim 9 thickness to achieve the specified nominal injection pressure. Shims are available in thicknesses from 0.50 to 2.50 mm.

NOTE • A 0.02 mm change in shim thickness corresponds to a 22 kPa {2.2 kgf/cm2} change in valve opening pressure. • These shims 12 are also used for prelift adjustment.

01914

• Adjusting prelift • Remove the screw plug 8, valve opening pressure adjustment shim 9, and 2nd spring 10. Then, assemble the dial gauge A, [gb Holder, and [gc Probe as shown in the illustration. • Zero the dial gauge A.

[gb ~-[gc

20

11 01915

13A-66

\13A I • Remove the 2nd push rod 11 and fit the prelift adjustment shim 12. Then, refit the dial gauge as described above and note the needle deflection. If the prelift measurement is out of specification, adjust it by changing the shim.

01916

• Checking 1st valve opening pressure

~: I [-11 ®

• Assemble the parts shown in the illustration.

NOTE Be sure to use the shims 12 selected in accordance with the procedures described earlier. Take care not to confuse the valve opening pressure shim 9 with the prelift shim 12.

9

10

@

• Fit the injector nozzle assembly onto the nozzle tester and check the 1st valve opening pressure.

NOTE If the 1st valve opening pressure is out of specification, carry out the entire adjustment procedure again.

12

01917

13A-67

113El

GROUP 13E ELECTRONICALLY CONTROLLED FUEL SYSTEM SPECIFICATIONS ........................................

13E-2

STRUCTURE AND OPERATION 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Electronic Control System ...................................... 3. Pin Configuration of Electronic Control Unit. . . . . . . . . . . . . . . . . . . . . .

13E-3 13E-5 13E-8

TROUBLESHOOTING 1. 2. 3. 4. 5. 6. 7. 8.

Inspection Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Connection of Multi-Use Tester-II ............................... Reading and Erasing Diagnostic Trouble Codes .................. Diagnostic Trouble Codes and Check Items ...................... Service Data of Multi-Use Tester-II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Actuator Test by Multi-Use Tester-II ............................. Check at Connector of Electronic Control Unit ................... Checks on Transient Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

13E-12 13E-14 13E-16 13E-18 13E-24 13E-26 13E-27 13E-29

INSPECTION OF ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .. 13E-30

13E-1

SPECIFICATIONS Item Injection pump assembly

Specification

Manufacturer

BOSCH AUTOMOTIVE SYSTEMS Electronically controlled in-line pump

Model Injection pump model

NP-PE6MD105

Governor model

RED-4 (RED-4 with internal circuit)

Timer model

SPG

Feed pump model

KE

Manufacturer Rated voltage

13E-2

BOSCH AUTOMOTIVE SYSTEMS V

24

[13EJ

STRUCTURE AND OPERATION 1. GENERAL

• With the electronically controlled injection pump system, electronic control is applied to the governor (the components of the injection pump assembly) to realize the optimum fuel injection rate. • The electronic governor ECU optimally controls the governor in accordance with data signals from sensors mounted on the engine and other parts of the vehicle.

1.1 Principle of Operation

~------------~II

5

7

18 6

16

15

17

f

19

C:=::JI: Fuel supply line _ _ _ : Fuel return line

o

9

10

- - - : Electric line

1 RED-4 internal circuit 2 Control rack position sensor 3 Engine speed sensor 2 4 Control rack 5 Engine speed sensor 1 6 Automatic timer 7 Engine ECU

8 Injection nozzle 9 Combustion chamber

10 Fuel tank 11 Feed pump 12 Control sleeve 13 Plunger

14 Camshaft 15 Injection pump 16 Sensing gear 17 Linear DC motor 18 Electronic governor actuator 19 Fuel filter

• The extent of operation of the linear DC motor 17 are determined by signals from the engine ECU 7. • The linear DC motor 17 moves the control rack 4, thereby changing the fuel injection quantity. • The RED-4 internal circuit 1 is incorporated into the electronic governor actuator 18. It contains a control rack position sensor processing circuit and a linear DC motor drive circuit, which are conventionally incorporated into the engine ECU. This arrangement eliminates noise in the harness and thus prevents erroneous ECU operation. More accurate electronic control is possible as a result. • The engine speed is sensed by engine speed sensor 1 5 and engine speed sensor 2 3. Each of these sensors acts as a backup if the other fails.

13E-3

STRUCTURE AND OPERATION 1.2 Electronic Governor Actuator 1 2 3 4 5 6 7 8 9

Cover RED-4 internal circuit Control rack position sensor Housing Sensing gear Emergency engine stop lever Link Coil assembly Linear DC motor

P35899

(1) Linear DC motor • The linear DC motor 9 moves the coil assembly 8 vertically in accordance with signals from the engine ECU and RED-4 internal circuit. • Via the link 7, this movement is transmitted to the control rack A, which moves longitudinally to increase and decrease the fuel quantity.

(2) Control rack position sensor • The control rack position sensor 3 senses whether the control rack A is moved to the correct position by the linear DC motor 9. • In the event of a discrepancy between the actual control rack position and the target control rack position (this is determined by the engine ECU and RED-4 internal circuit 2), the engine ECU causes the linear DC motor 9 to perform a corrective movement.

(3) Emergency engine stop lever

02718

• The emergency engine stop lever 6 is connected to the link 7. Via a wire, it enables the link to be moved from the driver's seat. • In the event of a system fault that prevents the engine from being stopped normally, operation of the emergency engine stop lever forces the control rack A to move to the position at which fuel injection is terminated. This operation takes place irrespective of the position of the linear DC motor 9.

(4) Engine speed sensor 2 The engine speed sensor 2 B is located inside the governor. It converts rotation of the sensing gear 5 into electric signal and outputs the signal to the engine ECU.

B

15722

13E-4

\ 13E\ 2. Electronic Control System 2.1 System Block Diagram Input signals

Output signals

[--C;~t~~~POSitio~~ig~aI1---J~l--.--RED~4 internal circuit

J----~Qi~;~Dc~ot-o-r-d-riv-e-9-~

(incorporated into electronic governor)

__ Engine Engine speed signal 2 Engine start signal 3 Coolant temperature signal 4 Accelerator pedal position signal 5 Fault diagnosis signal 6 Fuel injection quantity signal 7 Boost pressure signal 8

Ecul~_-----,

Quel injection quantity control

Glow control

J

----~

CFault diagnosis functi-;~~

Warning lamp I

Glow relay

I

Glow lamp

L

Tachometer ou_t_pu_t_ _---"

'------------~-----~--

Signal

Part

Main function/operation

1

Control rack position signal

Control rack position sensor

Sensing of control rack position

2

Engine speed signal

Engine speed sensors 1, 2

Sensing of engine speed Use of two sensors allows for backup if one sensor fails.

3

Engine start signal

Starter switch

Recognition of engine startup with starter switch in START position

4

Coolant temperature signal

Coolant temperature sensor

Sensing of coolant temperature

5

Accelerator pedal position signal

Accelerator pedal position sensor

Sensing of extent of depression of accelerator pedal

Accelerator pedal switch (ON with pedal released)

Detection of pedal depressed/released condition

Diagnosis switch

Callup of diagnosis codes

Memory clear switch

Deletion of diagnosis codes; callup of past diagnosis codes

Fuel injection quantity adjusting resistor

Correction of fuel injection quantity

6

7

Fault diagnosis signal

Fuel injection quantity signal

8

Boost pressure signal

Boost pressure sensor

Detection of boost pressure

9

-

Linear DC motor

Moving of control rack

13E-5

STRUCTURE AND OPERATION Injection quantity adjusting resistor The injection quantity adjusting resistor makes fine adjustments to achieve optimal commensuration of injectied fuel quantity with fuel feed from the common rail.

NOTE This resistor, selected as the best from among several types, determines the final injection quantity. DO NOT change it for any other type. A: Resistor No.

2.2 Fuel Injection Quantity Control

Control rack position sensor

~I-----------------'l Engine ECU

E

~

r-

• • • •

Engine speed sensor 1 Engine speed sensor 2 Coolant temperature sensor Accelerator pedal position sensor • Fuel injection quantity adjusting resistor

RED-4 internal circuit

r-~

I-

--

I I I

Target rack position

I

Idling characteristics

I

Running characteristics

I

---;.

Linear DC motor

l!UII rack characteristics ] I

Starting characteristics

I

(1) Control effected by engine ECU and RED-4 internal circuit • The RED-4 internal circuit processes control rack position signals and transmits the results to the engine ECU. • The engine ECU effects control during engine operation using the stored idling characteristics or running characteristics, and it determines the target control rack position appropriate for the amount of fuel injection in accordance with signals issued by the sensors. • The control rack position signal issued by the engine ECU is sent to the RED-4 internal circuit. It causes activation of the linear DC motor such that the control rack is moved.

(2) Feedback control effected using control rack position sensor • The control rack position sensor enables the RED-4 internal circuit to calculate whether the linear DC motor has moved the control rack to the target position. This arrangement enables the RED-4 to ensure that the control rack position always corresponds to the target value. • The engine ECU receives signals indicating the control rack's actual position from the RED-4 internal circuit and uses them to evaluate control rack position errors.

13E-6

113E\ 2.3 Glow Control Glow control improves startability when the engine's coolant temperature is low.

Operating modes (1) Engine coolant temperature higher than 60 ~

START Starter switch Glow lamp

ON~­

OFF

0

e

No preheating is necessary at the time of engine startup, so the heater relay is kept OFF.

ON

OFF

Running Not running - - - - '

Engine Glow relay

ON

OFF-------®47053

Starter switch Glow lamp . Engine

START ON

r--~'

OFF .J ON

OFF

.....- - - -

I_--i ....

J

1 ...._ _ _ __

Running I Not running -:-,------!II t8 ON

Glow relay

n I

(2) Engine coolant temperature 60 0

1+I

l'

L

OFF -J141._ _--<0~1-._____01 Preglow

Afterglow

®47054

e or lower

• "ts" seconds after the starter switch is turned ON, the glow relay is turned ON, causing preglowto begin. The glow lamp illuminates simultaneously. • When preheating finishes, the glow lamp goes off to indicate that the engine can be started. The glow relay remains ON until the engine is started. • When the engine is started, the engine ECU determines whether afterglow is necessary in accordance with the engine coolant temperature. If the engine ECU determines that afterglow is not necessary, preglow control is terminated. If it deems that afterglow is necessary, the glow relay remains ON for a certain period after engine startup to cause afterglow.

13E-7

STRUCTURE AND OPERATION 3. Pin Configuration of Electronic Control Unit A: CW32A

B: CW25A

<>

C: CW31A

A

B

0: CW16A

c

®43639

A: CW32A Terminal No.

Item(s) to which terminal is connected

Terminal No.

Item(s) to which terminal is connected

1

-

17

2

-

18

Boost pressure sensor (SIG)

19

Engine speed sensor 2 (GND), RED-4 ECU (SIGNAL GND-2) -

3

RED-4 ECU (PULL DOWN)

4

-

20

5

-

21

-

Engine speed sensor 1 (GND)

6

Boost pressure sensor (+5V)

22

-

7

Engine speed sensor 2 (SIG)

23

8

Engine speed sensor 1 (SIG)

24

9

-

25

-

10

-

26

-

27

-

11

Glow relay

--

12

-

28

13

-

29

Boost pressure sensor (GND)

30

Coolant temperature sensor (GND)

14

RED-4 ECU (LIMP HOME)

15

-

31

-

16

-

32

-

ECU: Electronic Control Unit

13E-8

113E\ B: CW25A Terminal No.

Item(s) to which terminal is connected

Terminal No.

Item(s) to which terminal is connected

1

Warning lamp (orange)

14

REO-4 ECU (+5 VCC-2)

2

Accelerator pedal switch

15

REO-4 ECU (PWM SOL-2)

16

REO-4 ECU (V-1ST) Frame ground (MN POWER GNO)

-

3 4

Injection quantity adjusting resistor (SIG)

17

5

REO-4 ECU (+5 VCC-1)

18

-

6

REO-4 ECU (PWM SOL-1)

19

-

7

REO-4 ECU (VB2)

20

MUT-II connector (K-LlNE)

8

REO-4 ECU (VB 1)

21

9

Accelerator pedal position sensor 2 (SIG)

11

-

12

-

13

Injection quantity adjusting resistor (GNO)

10

-

22

Shield (SHIELD) of VB-1, VB-2, GNO-1, and GNO-2

23

REO-4 ECU (SIGNAL GNO-1)

24

REO-4 ECU (GNO-2)

25

REO-4 ECU (GNO-1)

Terminal No.

Item(s) to which terminal is connected

----

1

-

17

c: CW31A

Terminal No.

2

Engine speed output signal (NE OUT SIG)

18

3

Starter switch S terminal (STARTER SW S)

19

Item(s) to which terminal is connected Accelerator pedal position sensor 1 (SIG)

Diagnosis switch

4

-

20

-

5

-

21

-

22

-

7

Battery relay (STARTER SW M-2)

23

-

8

Battery relay (STARTER SW M-1)

24

-

6

9 10

-

MUT-II connector (OCT)

11 12

-

Control rack position output signal (RAC OUT SIG)

Battery ground (CASE GNO)

25

-

26

Glow lamp (GLOW LAMP)

27

Accelerator pedal position sensor 2 (GNO)

28

Accelerator pedal position sensor 1 (GNO) Memory clear switch

13

-

29

14

-

30

-

31

-

15

Coolant temperature sensor (SIG)

16

----

D: CW16A Terminal No.

Terminal No.

Item(s) to which terminal is connected

1

Engine ECU main power relay (+VB-2)

9

-

2

Engine ECU main power relay (+VB-1)

10

-

3

Warning lamp (red)

11

-

12

-

4

--

Item(s) to which terminal is connected

-

5

00S-3 connector (00S3)

13

Engine ECU main power relay (MAIN RELAY-2)

6

Battery ground (GNO-2)

14

-

7

Battery ground (GNO-1)

15

-

8

Engine ECU main power relay (MAIN RELAY-1)

16

-

13£-9

STRUCTURE AND OPERATION

Starter switch ~

sf-oc

M SI .. 51

~

~ ~ ..

f-

"TART

~

.-STARTER SW(S 03 STARTER SW(M)-l

1

Engine ECU main power relay 1---.

1 Battery rela

!,

STARTER SW(M)-2 MAIN RELAY-l MAIN RELAY-2 EOU POWER(+V8H EOU POWER(+VB)- 2

!

L_ ..... 1

r---'-:

08 013 01 02

GNO-l 07 GNO-2 06 GNO(OASE GNO 024 GNO(MN PWR GNO) B17

Yrf +

-,-:Ei I

C8

OJ

~

Battery ~

II

:mIl

SIG A8 GNO A21

Engine speed sensor 1

\V Battery ground

Frame ground

f-

rrRED-4 intemal circuit

f-

r-

I

V 1ST PWM-SOL-l PWM-SOL-2 PULL DOWN UMPHOME V8-1 VB-2 GNO-l

B16 B6 B15 A3 A14 88 B7 B25

GNO-2 SHIELD +5V(V00H +5V(V00)-2 SIGNAL GNO-l

B24 B22 B5 814 823 SIGNAL GND-2 A19 Engine speed sensor 2 SIGNAL A7

RED-4 ECU

Injection quantity adjusting resistor Coolant temperature sensor

III ~

SIG B4 GNO 813

III

SIG C15 GNO A30

IIIIII

+5V A6 SIG A18 GNO A29

~

Boost pressure sensor

,.

~

m'--"""m

Warning lamp (red) Warning lamp (orange) Memory clear switch Diagnosis switch

-

DDS-3 connector

DDS-3

MUT-I1 connector

1MUT-21

~

029 C19

:~ .~

m

,-----, ~

Control rack position output signal Engine speed output signal

03 81

:---~III

m~--~:"

111

DATA

05

K-Line 820 DOT Cl0 012 02 '---

P47052-1

13E-10

113EI

Engine ECU

c261-------UR:m'""'~~·M.-.KIl-m----+

Alll---------+:-J,.;n~"'-:-,_i_---_+

,

,

--+r~+---s - '- - '

Glow lamp Glow relay

' - - 1

:

:

Glow relay

L____-.-J

I Glow plug

C17 C26

Accelerator pedal position sensor 1

~I~D

69 SIG

i

C27 GND

,

62i----=Dc-ep-re-s-se-od"""C:OO-:P:=E77N,-----+-!--<:r Released: GND

,,

~!

I_____-=.J

Accelerator pedal position sensor 2 Accelerator pedal switch

-4; CASE GND

P47052-2

13E-11

TROUBLESHOOTING 1. Inspection Procedures Diagnostic function • Whenever the starting switch is placed at ON, the diagnostic function is activated to check all the sensors, etc. If any of them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same time, the fault location is stored in memory, and the system enters the backup mode. • The stored fault location can be read as a diagnostic trouble code by the Multi-Use Tester-II or the diagnostic switch. • Warning lamp indications Warning lamp Safety-critical error (Vehicle must not be driven) Non-safety-critical error (Vehicle can be driven despite poor control feeling)

Red Orange

CAUTION~----------------------------------------------------• Check to ensure that the battery voltage is within the specified range. • Check all the harness and device connectors for looseness. Always remove a connector at least 20 seconds after placing the starting switch at the LOCK position. • Do not forget to clear the diagnostic trouble code by the Multi-Use Tester-II or memory clear switch after a fault has been rectified. • As a rule, inspection operations should be performed with the starting switch at the LOCK position. Some checks, however, may have to be made with the starting switch at the ON position. In such a case, use care to make sure that no short circuit develops between pins of the connectors or with the body. • The resistance value of each component is affected by the temperature and the accuracy of the tester. The reading, therefore, does not always fall within the standard limits. Note that the check values shown in the text are the values obtained at normal temperature (10 to 35°C). • Whether or not the system automatically returns to normal from the backup mode after a fault has been removed depends on the diagnostic trouble code (fault location). • Even when the fault has been removed and the system has been automatically returned to the normal mode, the diagnostic trouble code of the fault remains stored in the engine control unit. • When a fault occurs at a point where the system is not automatically reset, perform the memory clear procedure to let the system exit from the backup mode. CD P13E-16

13E-12

113EI Inspection flowchart The system inspection can be performed effectively by use of the Multi-Use Tester-II. The types of system inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic trouble code outputs. • Inspections based on diagnostic trouble codes stored in the engine control unit • Inspections of transient troubles

l

Vehicle brought into workshop

J

l

Read diagnostic trouble codes

I

OJ P13E-16

I No communications can be made with Multi-Use Tester-II.

Normal code output

Trouble code output

Normal code output after erasure 'II 'II Check for 'II transient troubles Identify cause for diagnostic OJ P13E-29 trouble code issue and rectify OJ P13E-18

I 'II

'II

l •

•

Driving test

I

If no communications can be made with all the other systems, it is highly likely that the diagnostic circuit is faulty. If no communications can be made with this system only, an open circuit in the diagnostic output circuit or power supply circuit (including the ground circuit) of this system is suspected.

If the same diagnostic trouble code is issued during test driving, reexamine the cause for the diagnostic trouble code issue and rectify. OJ P13E-18 If none of the diagnostic trouble codes stored in the engine control unit before the test driving is issued, perform the checks on transient troubles in addition to the checks based on the diagnostic trouble codes.

Erace the dianostic trouble codes. OJ P13E-16

13E-13

TROUBLESHOOTING 2. Connection of Multi-Use Tester-II ~ Special Tools Application

Part No.

Tool name and shape

Location

Multi-Use Tester-II

MB991496

Inspection of system

MC887252

To supply power to Multi-Use Tester-II proper and communicate with vehicle side electrical devices

MK369392

Data for inspection and control of engine control unit

MB991500

To write data

MB991499

To use Multi-Use Tester-II as a circuit tester

MK320193

Power supply to Multi-Use Tester-II in vehicle without cigarette lighter; detection of start signal in vehicle without cigarette lighter

19492

Multi-Use Tester-II harness (for communications)

19141

Read-only memory pack (MRI-E1)

19493

Memory card (set in MultiUse Tester-II proper)

20538

Multi-Use Tester-II harness

20536

Battery clamp harness

20537

13E-14

113EI The Multi-Use Tester-II typically draws power from the cigarette lighter. In a vehicle without a cigarette lighter, the power connection of the Multi-Use Tester-II is different depending on the type of the starter switch as follows: Multi-Use Tester-II power supply connection

With cigarette lighter socket

Without cigarette lighter socket

Starter switch type A*a

Starter switch type A *b

Cigarette lighter socket

0

-

-

Battery

-

0

0

*a With starter switch type A, power supply to cigarette lighter continues while engine is being cranked. *b With starter switch type B, power supply to cigarette lighter is suspended while engine is being cranked.

(1) Power supplied to Multi-Use Tester-II from cigarette lighter

C

• Place the starting switch at the LOCK position. • Connect the ~ Multi-Use Tester-II harness to ~ Multi-Use Tester-II and insert the ~ read-only memory in the tester. • Connect the connector A to the cigar lighter socket. • Connect the Multi-Use Tester-II connector C (16 pins) to the data link connector B (16 pins).

NOTE ®41163

For the operating procedures for the Multi-Use Tester-II, refer to the instruction manual for the Multi-Use Tester-II. (2) Power supplied to MUlti-Use Tester-II from battery • Place the starter switch in the LOCK position. • Connect the ~ Multi-Use Tester-II harness (for communication) to the ~ MUlti-Use Tester-II, then insert the ~ ROM pack. • Connect the EB clamp 0 (red) of the ~ battery clamp harness to the EB terminal E of the battery and the clamp F (black) to the terminal G of the battery. • Fit the connector A into the socket H of the ~ battery clamp harness. • Fit together the Multi-Use Tester-II connector B (16 pins) and connectorC (16 pins).

e

E

e

NOTE Connect the EB clamp 0 (red) of the ~ battery clamp harness before connecting the clamp F (black).

e

13E-15

TROUBLESHOOTING 3. Reading and Erasing Diagnostic Trouble Codes Two types of methods are available for reading or erasing a diagnostic trouble code; one using the Multi-Use Tester-II and one using the vehicle side diagnostic functions.

(1) Method using Multi-Use Tester-II • Current diagnostic trouble code • Check to see that the memory clear switch 1 is connected. • Set the starting switch to ON. • Operate the Multi-Use Tester-II to read the current diagnostic trouble code and determine the fault location.

• Past diagnostic trouble code • Set the starting switch to ON. • Disconnect the memory clear switch 1. • Operate the Multi-Use Tester-II to read the past registered diagnostic trouble codes and determine the fault location.

• Erasing diagnostic trouble codes • Set the starting switch to ON. • Operate the Multi-Use Tester-II to erase all of the diagnostic trouble codes stored in the engine control unit.

(2) Method Not Using Multi-Use Tester-II (Method Using Diagnostic Switch and Memory Clear Switch) • Current diagnostic trouble code • Set the starting switch to ON. • Disconnect the diagnostic switch 2. • The diagnostic trouble code is displayed by flashes of the warning lamp 3.

• Reading diagnostic trouble code 1Os digit

Units digit

~

r-~

• Diagnostic trouble codes are indicated by the number of times the warning lamp 3 flashes and their duration. • The flashing intervals also differ between the 10s digit and units digit. • 10s digit: 1.2 second interval • Units digit: 0.4 second interval • Each diagnostic trouble code is displayed from the 1Os digit followed by the units digit. As for a code which has no 10s digit, units digit only is displayed. • Each diagnostic trouble code is displayed three times in succession. • If there is no more code stored, the sequence is then repeated from the beginning with each code indicated three times. • When the diagnostic switch 2 is connected, the engine control unit will immediately stop displaying codes.

ON

OFF

0.4

o.4---+---l-Diagnostic switch disconnected First diagnostic trouble code disp~ayed (Diagno~rOUble ~e 12) ON OFF

!

H

2.4

Second u,~ ___--1+ ~~agnos-

2.4

2.4

-; -8 .

trouble code displayed

®13705

• Past diagnostic trouble codes • After reading the current diagnostic trouble codes (with the diagnostic switch 2 disconnected), disconnect the memory clear switch 1. Then the 0 warning lamp 3 will restart flashing. • This time, the warning lamp displays the past diagnostic trouble codes. Determine the fault locations based on the indicated codes.

13E-16

113EI • Erasing diagnostic trouble codes A second or more 3 seconds

Connected

J11-

Released

Disconnect the memory clear switch then reconnect it. Then all the diagnostic trouble codes stored in the engine control unit will be cleared.

·1=--

i-- - - -

_~.1

L...

t

Memory cleared at this point

®02739

CAUTION,&-------------• Remember that the stored codes are cleared only by disconnecting and reconnecting the memory clear switch. • If the contents of memory are not to be cleared after display of the stored codes, set the starting switch to OFF with the memory clear switch disconnected. Thereafter, connect the memory clear switch. • When you change the combination of the injection pump and engine control unit, you must rewrite the pump data stored in the engine control unit. For this purpose, be sure to perform the memory clear operation by disconnecting both the memory clear and diagnostic switches, then reconnecting them.

13E-17

TROUBLESHOOTING 4. Diagnostic Trouble Codes and Check Items 4.1 Diagnostic Trouble Code List Multi-Use Tester-II display Message

Diagnostic trouble code

Multi-Use Tester-II display

Page of reference

Diagnostic trouble code

mP13E-18

Message

24

ACCEL. SNSR-1

32

BST PRES SNSR

33

ECU SYSTEM

34

Q RESISTOR

45

ENG. REVERSE

AIR PRES SNSR

65

ACCELSW

21

WTR TEMP SNSR

78

HEATER RELAY

22

RACK SNSR

07

OVER REV.

11

GOV. SERVO

14

SUB NE SNSR

15

NE SNSR

16

ACCEL. SNSR-2

19

mP13E-19 mP13E-20

Page of reference

mP13E-21 mP13E-22 mP13E-23

mP13E-21

4.2 Diagnostic Trouble Code Issue Conditions and Check Items Perform service operations with reference to the diagnostic trouble code issue conditions and probable causes shown below. 07 OVER REV.

Code issue condition [Reset condition]

Diagnostic trouble code 07 indicates that the engine speed is too high. [The code is reset when the engine speed returns to a specified range.]

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

Injection pump assembly's control sleeve faulty • Over-revving of engine (for example, on downhill road) • ECU faulty

Inspection of injection pump assembly (Have inspection performed by BOSCH AUTOMOTIVE SYSTEMS service station.)

11 GOV. SERVO

Code issue condition [Reset condition]

Diagnostic trouble code 11 indicates that the difference between the target control rack position and actual control rack position is too large. [No reset condition]

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

•

Control rack position sensor faulty

•

ECU faulty

•

•

13E-18

Perform checks on basis of Multi-Use Tester-II service data.

mP13E-24

No. 09: Measurement of target rack position No. OA: Measurement of actual rack position Inspection of control rack position sensor (Have inspection performed by BOSCH AUTOMOTIVE SYSTEMS service station.)

113E\ 14 SUB NE SNSR (electronic governor side)

Code issue condition [Reset condition]

Diagnostic trouble code 14 indicates that the number of pulses from engine speed sensor 2 (on the electronic governor) is smaller than the number of pulses from engine speed sensor 1 (on the auto-timer). [The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed sensor 2 returns to normal].

Action taken by ECU

• •

Normal control is effected using only engine speed sensor 1. If engine speed sensor 1 is also faulty, governor operation is stopped.

Probable cause and check item

•

Open circuit or short circuit in harness between ECU and engine speed sensor 2 Engine speed sensor 2 faulty ECU faulty

• •

• • •

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24 No. 02: Measurement of engine speed Inspection of engine speed sensor 2 (Have inspection performed by BOSCH AUTOMOTIVE SYSTEMS service station.) Check of circuit between ECU and engine speed sensor 2

14 SUB NE SNSR (electronic governor side) 15 NE SNSR (auto-timer side)

Code issue condition [Reset condition]

Diagnostic trouble codes 14 and 15 are both issued if engine speed sensor 1 (on the auto-timer) and engine speed sensor 2 (on the electronic governor) fail at the same time. [The code is reset when pulses are applied from engine speed sensor 1 or engine speed sensor 2 following engine startup.]

Action taken by ECU

Fuel injection timing control is stopped, and governor operation is stopped.

Probable cause and check item

•

• •

Open circuit or short circuit in harness between ECU and engine speed sensors 1 and 2 Engine speed sensors 1 and 2 faulty ECU faulty

• • •

• •

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24 No. 02: Measurement of engine speed Inspection using ECU connector CD P13E-27 CiJ) : Measurement of resistance of engine speed sensor 1 Inspection of engine speed sensor 1 CD P13E-30: Inspection of Electrical Equipment f100 Inspection of engine speed sensor 2 (Have inspection performed by BOSCH AUTOMOTIVE SySTEMS service station.) Check of circuit between ECU and engine speed sensors 1 and 2

15 NE SNSR (auto-timer side)

Code issue condition [Reset condition]

Diagnostic trouble code 15 indicates that the number of pulses from engine speed sensor 1 (on the auto-timer) is smaller than the number of pulses from engine speed sensor 2 (on the electronic governor). [The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed sensor 1 returns to normaL]

Action taken by ECU

• •

Probable cause and check item

• •

•

Normal control is effected using only engine speed sensor 2. If engine speed sensor 2 is also faulty, governor operation is stopped. Open circuit or short circuit in harness between ECU and engine speed sensor 1 Engine speed sensor 1 faulty ECU faulty

•

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24

•

No. 02: Measurement of engine speed Inspection using ECU connector CD P13E-27 CiJ) : Measurement of resistance of engine speed sensor 1 Inspection of engine speed sensor 1

•

P13E-30: Inspection of Electrical Equipment f100 Check of circuit between ECU and engine speed sensor 1

•

13E-19

TROUBLESHOOTING 16 ACCEL. SNSR-2 Code issue condition [Reset condition]

Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24 must also be perforrned.) The code is issued when accelerator position sensor 2 voltage is out of specified limits. [When accelerator position sensor 2 voltage is back within specified limits, a reset is made.]

Action taken by ECU

• •

Normal control is effected using only non-faulty accelerator pedal position sensor 1. If accelerator pedal position 1 is also faulty, control is effected using assumptions of 100% with the pedal depressed and 0% with the pedal released.

Probable cause and check item

•

Open or short circuit in harness between ECU and accelerator position sensor 2 Accelerator position sensor 2 faulty or poorly adjusted ECU faulty

•

•

•

•

•

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24 No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor NO.5: Measurement of accelerator pedal position sensor's output voltage Inspection of accelerator pedal position sensor Check of circuit between ECU and accelerator pedal position sensor 2

19 AIR PRES SNSR Code issue condition [Reset condition]

Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air pressure sensor (built in ECU). The code is issued when air pressure sensor voltage is out of specified limits. [When air pressure sensor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Air pressure is defaulted to 100 kPa {760 mmHg}.

Probable cause and check item

•

•

Air pressure sensor (built in ECU) faulty. ECU faulty

•

Perform checks on the basis of Multi-Use Tester-II service data. P13E-24 No. 18: Air pressure measurement

m

21 WTR TEMP SNSR Code issue condition [Reset condition]

Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor proper. The code is issued when water temperature sensor voltage is out of specified limits. [When water temperature sensor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Controls are continued assuming that coolant temperature is -20°C when engine is started and 80°C when engine is running.

Probable cause and check item

• •

•

Open or short circuit in harness between ECU and water temperature sensor Water temperature sensor faulty

• •

ECU faulty

• •

13E-20

Perform checks on basis of Multi-Use Tester-II service data.

rn P13E-24

No. 16: Measurement of engine coolant temperature Inspection using ECU connector P13E-27 (!fJ : Measurement of resistance of coolant temperature sensor Inspection of coolant temperature sensor CD P13E-30: Inspection of Electrical Equipment ~ Check of circuit between ECU and coolant temperature sensor

113EI 22 RACKSNSR Code issue condition [Reset condition]

Diagnostic trouble code 22 indicates that the control rack position sensor's output voltage is outside specified limits. [No reset condition]

Action taken by ECU

Governor is temporarily stopped. (Feedback control is resumed after the engine is restarted.)

Probable cause and check item

• • • •

•

Control rack position sensor faulty Control rack not moving smoothly Governor actuator's link faulty ECU faulty

•

Perform checks on basis of Multi-Use Tester-II service data.

OJ P13E-24 No.OA: Measurement of actual rack position Inspection of control rack position sensor and control rack (Have inspection performed by BOSCH AUTOMOTIVE SYSTEMS service station.)

24 ACCEL. SNSR-1 Code issue condition [Reset condition]

Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and faulty sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16 must also be performed.) The code is issued when accelerator position sensor 1 voltage is out of specified limits. [When accelerator position sensor 1 voltage falls back within specified limits, a reset is made.]

Action taken by ECU

•

• Probable cause and check item

•

• •

Normal control is effected using only non-faulty accelerator pedal position sensor 2. If accelerator pedal position 2 is also faulty, control is effected using assumptions of 100 % with the pedal depressed and 0 % with the pedal released.

•

Open or short circuit in harness between ECU and accelerator position sensor 1 Accelerator position sensor 1 faulty or poorly adjusted ECU faulty

• •

Perform checks on basis of MUlti-Use Tester-II service data.

CO P13E-24 No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No.5: Measurement of accelerator pedal position sensor's output voltage Inspection of accelerator pedal position sensor Check of circuit between ECU and accelerator pedal position sensor 1

32 BST PRES SNSR Code issue condition [Reset condition]

Diagnostic trouble code 32 indicates short or open circuit in boost pressure sensor harness and faulty sensor proper. The code is issued when boost pressure sensor voltage is out of specified limits. [When boost pressure sensor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Control is effected with the boost pressure assumed to be fixed at 0 kPa {O mmHg}.

Probable cause and check item

• • •

Open or short circuit in harness between ECU and boost pressure sensor Boost pressure sensor faulty

•

ECU faulty

•

•

Perform checks on basis of Multi-Use Tester-II service data.

CO P13E-24 No.2D: Measurement of boost pressure Inspection of boost pressure sensor main body P13E-31: Inspection of Electrical Equipment §13 Check of circuit between ECU and boost pressure sensor

m

33 ECU SYSTEM Code issue condition [Reset condition]

Diagnostic trouble code 33 indicates a processing error or memory error in the ECU. [No reset condition]

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

ECU faulty

-

I 13E-21

TROUBLESHOOTING 34 Q RESISTOR Code issue condition [Reset condition]

Diagnostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor harness and faulty adjusting resistor. The code is issued when injection quantity adjusting resistor voltage is out of specified limits. [When injection quantity adjusting resistor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Injection quantity correction value is fixed at NO.1 value.

Probable cause and check item

•

• •

Open or short circuit in harness between ECU and injection quantity adjusting resistor

•

Injection quantity adjusting resistor faulty ECU faulty

• • •

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24 No. 14: Check of resistor number of fuel injection quantity adjusting resistor Inspection using ECU connector [lJ P13E-27 : Measurement of resistance of fuel injection quantity _ adjusting resistor Inspection of fuel injection quantity adjusting resistor CD P13E-32: Inspection of Electrical Equipment l:lij:1 Check of circuit between ECU and fuel injection quantity adjusting resistor

45 ENG. REVERSE Code issue condition [Reset condition]

Diagnostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that resulting from cranking with the starter) has been detected with the starter switch in the OFF position. [The code is reset when the engine speed is no longer detected with the starter switch in the OFF position or when the starter switch is turned to the ON position.]

Action taken by ECU

Governor operation is stopped

Probable cause and check item

• •

•

Operating error at time of engine startup Poor matching of connected devices ECU faulty

-

65 ACCELSW Code issue condition [Reset condition]

Diagnostic trouble code 65 indicates short or open circuit in accelerator pedal switch harness and faulty accelerator switch. The code is issued when accelerator pedal is released (accelerator switch ON) and accelerator pedal opening signal is input. [When accelerator pedal opening signal returns to normal, a reset is made.]

Action taken by ECU

Normal control is effected.

Probable cause and check item

•

Open or short circuit in harness between ECU and accelerator pedal switch

•

Accelerator pedal switch faulty

•

ECU faulty

•

•

• •

13E-22

Perform checks on basis of Multi-Use Tester-II service data.

CD P13E-24 No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No. 69: Check of operation of accelerator pedal switch Inspection using ECU connector CD P13E-27 Check of continuity of accelerator pedal switch Inspection of accelerator pedal switch Check of circuit between ECU and accelerator pedal switch

m :

113EI 78 HEATER RELAY

Code issue condition [Reset condition]

Diagnostic trouble code 78 is issued in the following circumstances: (1) The ECU issues a command to turn the glow relay OFF following a short circuit in the glow relay. [The code is reset when the glow relay returns to normaL] (2) The ECU issues a command to turn the glow relay ON following an open circuit in the glow relay. [No reset condition]

Action taken by ECU

Preglow control is stopped.

Probable cause and check item

• •

Open circuit or short circuit in harness between ECU and glow relay Glow relay faulty

•

ECU faulty

•

Perform checks on basis of Multi-Use Tester-II service data.

mP13E-24

•

No. 92: Check of operation of glow relay Actuator test using Multi-Use Tester-II P13E-26

• •

No. Be: Check of operation of glow relay Inspection of glow relay Gr 16 Check of circuit between ECU and glow relay

m

13E-23

TROUBLESHOOTING 5. Service Data of Multi-Use Tester-II

Item

No.

Normal condition

Condition at time of inspection

Multi-Use Tester-II display Data

01

BATT VOLTAGE

••.•• V

Idling

20 to 30 V

02

ENGINE SPEED

• • • • . rpm

Racing (with engine running)

Same as tachometer indication

03

ACCEL (%)

•••.• %

Accelerator pedal released

0%

Accelerator pedal gradually depressed

Gradually increases

04

ACCEL (%) REAL

•••.• %

Accelerator pedal fully depressed

100 %

Accelerator pedal released

0%

Accelerator pedal gradually depressed

Gradually increases

Accelerator pedal fully depressed

100 %

05

ACCEL (V)

•.••• V

Accelerator pedal gradually depressed from released position

Depends on vehicle specifications

09

TARGET RACK

• • . • • mm

Starter switch ON

3mm

OA

REAL RACK

• • . • • mm

Starter switch ON

3mm

12

TCV ANG. DIFF.

• • . • • oCA

Depends on vehicle specifications

• • . • • deg 14

Q RESISTOR

•••••

-

Same as number marked on fuel injection quantity adjusting resistor

16

WATER TEMP

• • • . • oC

Engine cold

Approximately same as ambient temperature

During engine warmup

Gradually increases

Engine stopped after warmup

Gradually decreases

• • • . • oF

18

20

AIR PRESS

BOOST PRESS

• • • • . kPa

Altitude 0 m

101 kPa

• • • • . mmHg

Altitude 600 m

95 kPa

Altitude 1,200 m

88 kPa

Running at high idle speed

Depends on vehicle specifications

Diagnosis switch ON (connected to connector)

ON

Diagnosis switch OFF (disconnected from connector)

OFF

Starter switch in ON position (engine not started)

ON

• • • • . kPa

• • • • . mmHg 4F

51

52

56

62

13E-24

DIAGNOSIS SW

DIAG LAMP (U)

DIAG LAMP (R)

KEYSW

DIAG RESET SW

ON/OFF

ON/OFF

ON/OFF

ON/OFF

ON/OFF

Starter switch in OFF position

OFF

Starter switch in ON position (engine not started)

ON

Starter switch in OFF position

OFF

Starter switch in ON position

ON

Starter switch in any position except ON

OFF

Memory clear switch ON (connected to connector)

ON

Memory clear switch OFF (disconnected from connector)

OFF

113EI Multi-Use Tester-II display No.

Item

67

PULL DOWN

69 73

91

92

ACCELSW

START SW

PRE-HEAT LAMP

HEATER RELAY

Condition at time of inspection

Normal condition

Data ON/OFF

ON/OFF

ON/OFF

ON/OFF

ON/OFF

Normal condition

OFF

Abnormal condition (during pulldown control)

ON

Accelerator pedal depressed

ON

Accelerator pedal released

OFF

Engine cranked with starter switch in START position

ON

Starter switch in any position except START

OFF

Starter switch ON

Coolant temperature low

ON

Coolant temperature high

OFF

Coolant temperature low

ON

Coolant temperature high

OFF

Starter switch ON

13E-25

TROUBLESHOOTING 6. Actuator Test by Multi-Use Tester-II Multi-Use Tester-II display Item

No. AC

Method of checking operation

DIAG LAMP (U)

• •

•

Create warning lamp illumination conditions. Perform test with engine speed of zero and vehicle speed of zero. Cause warning lamp five times to be on for one second then off for one second.

AD

DIAG LAMP (R)

• • •

Create warning lamp illumination conditions. Perform test with engine speed of zero and vehicle speed of zero. Cause warning lamp five times to be on for one second then off for one second.

BB

PRE-HEAT LAMP

• • •

Create indicator lamp illumination conditions. Perform test with engine speed of zero and vehicle speed of zero. Cause indicator lamp five times to be on for one second then off for one second.

BC

HEATER RELAY

• • •

Create air glow operating conditions. Perform test with engine speed of zero and vehicle speed of zero. Cause air heater five times to be on for one second then off for one second.

13E-26

113E\ 7. Check at Connector of Electronic Control Unit These checks allow correct transmission of ECU signals via vehicle harnesses and connectors to be verified. They are intended to assist in troubleshooting. The numbers (OJ , ,etc.) in the tables correspond to reference numbers in section

m

3.4, "Causes of Diagnostic Trouble Code Issue, and Inspection Items".

Pin configuration of ECU A:CW32A

B: CW25A

[@1~~1-16~~~1I~~4J 5 2

C: CW31A 1

1

1 2

4

1 14 6

11 2

0: CW16A

®43639

Item

No.

OJ

Resistance of engine speed sensor 1

m

Resistance of coolant temperature sensor

C!D

Resistance of fuel injection quantity adjusting resistor

m

Continuity of accelerator pedal switch

Page of reference

CD P13E-28

Checking Procedures

CAUTION~----------------------------------------------------Some inspections are performed with the connector removed, and others are performed with the connector fitted. Note the following instructions: • Do not touch any terminal other than the ones specified for the inspections. Be particularly careful not to cause short circuits between terminals using the tester probes. • Terminal numbers shown in the tables are the numbers of terminals on the ECU. Be careful not to select the wrong terminals for inspections.

13E-27

TROUBLESHOOTING Method

Check item

m

Resistance of engine speed sensor 1

[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal condition] Between terminals A (8) and A ~D: 2.1 to 2.5 kQ

(U Resistance of coolant temperature sensor

[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal conditions] Between terminals C il~ and A ~~: 2.3 to 2.6 kQ (at 20°C) 0.3 to 0.34 kQ (at 80°C)

W

Resistance of fuel in- [Check conditions] jection quantity adjust- • Starter switch OFF ing resistor • Connector removed. Check performed on vehicle-side harness. [Normal conditions] Between terminals B No.

(4)

and B 03):

Resistance

No.

270Q

1

Resistance

No.

Resistance

4

1300 Q

7

5600Q

2

510 Q

5

8

15000 Q

3

820Q

6

2000Q 3300Q·

.~----~--

----'--------

W

--

~i=~ ___

______

L...----_

Continuity of accelera- [Check conditions] tor pedal switch • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal conditions] Between terminals (EB and 8) B (2) and D @: • Accelerator pedal depressed: Continuity does not exist.

•

13E-28

Accelerator pedal released: Continuity exists .

113EI 8. Checks on Transient Troubles A transient trouble often occurs in a specific condition. Therefore, pinpointing the condition will make it easy to estimate the cause. To pinpoint the condition for a transient trouble, ask the customer in detail about the driving condition when the trouble occures, weather, occurrence frequency and symptoms, and reproduce the symptoms of the trouble. Depending on the condition where the trouble occurs, determine whether the cause of the trouble is vibration, temperature or any other factor. If the probable cause is vibration, perform the following checks on the relevant connectors harnesses, etc. and check whether the symptoms of the trouble are reproduced. • Lightly move the connector up and down and to the right and left. • Lightly move the harness up and down and to the right and left. • Lightly shake the sensors and other devices by hand. • Lightly shake the wiring harness located in the moving components such as the suspension. The connectors and other parts to be checked are identifiable from the descriptions in the Probable Causes orthe Checking Procedures forthe displayed diagnostic trouble code.

02598

I I

02599

13E-29

INSPECTION OF ELECTRICAL EQUIPMENT _

Checking Water Temperature Sensor

• Put the water temperature sensor in a container filled with engine oil. • Heat the engine oil to various specified temperatures while stirring the engine oil. • Measure the resistance value between pins 1 and 2 (body). Standard value

20°C

2.3 to 2.6 kQ

BO°C

0.30 to 0.34 kQ Referance value in parentheses

®34629

• If the reading is out of the standard value, replace the water temperature sensor. CD Gr 14 _

Engine Speed Sensor 1

[Inspection] • Measure the resistance value between pins 1 and 2. Standard value (at 20°C)

2.1 ± 2.5 kQ

• If the reading is out of the standard value range, replace the engine speed sensor. 05049

[Installation] • Adjust the clearance C between the engine speed sensor 1 A and the timer flange protrusion B to the standard value, then lock the sensor by tightening the lock nut D.

D Standard value

B 24985

13£-30

O.B to 1.0 mm

113EI

o

Checking Boost Pressure Sensor

NOTE The boost pressure checking conditions differ between when the boost pressure is checked by use of the Multi-Use Tester-II and when it is checked without use of the Multi-Use Tester-II. So the standard values also differ. P13E-26

m

• Disconnect the chassis side harness 0 and connect the ~ inspection harness between them.

A

8

C

'if

Part No.

Tool name and shape Inspection Harness

MC854336

02806

• Mount pressure gauge A for measurement of the boost pressure. C: To inlet manifold • Set the starting switch to ON. • Measure the output voltage of the boost pressure sensor B according to the following table. ®42415

Connector Pin

Item 1 Power (+) Power voltage

0

2 GND (-)

3 Output (+)

~----O

*Output voltage (Refer to the output characteristics shown at left.)

0

*: Start the engine before measurement.

Output Characteristics Temperature 25°C

?: CD

Ol

3.22

g

1.86

~

Standard Value

4.9 4.5

1-2

5V O.5V/-34.3 kPa {-255 mmHg} 1.86V/33.7 kPa {250 mmHg} 3.22V/98.7 kPa {740 mmHg}

0.5

o

2-3

4.5V/163.7 kPa {1230 mmHg} -34.3 (-255)

98.7 {740}

163.7 {1230}

Boost pressure (kPa (mmHg})

02783

• If the results of the above mentioned checks show any deviation from the standard values, replace the boost pressure sensor B.

13E-31

INSPECTION OF ELECTRICAL EQUIPMENT No.

If&) Checking injection quantity adjusting resistor • Measure the resistance of the fuel injection quantity adjusting resistor. The standard value corresponds to the resistor number marked on the case.

e

Standard value (at 20°C)

AL2A

02786

Resistor No.

1

2700

2

5100

3

8200

4

13000

5

20000

6

33000

7

56000

8

150000

• If the measurement is out of specification, replace the fuel injection quantity adjusting resistor.

NOTE The fuel injection quantity adjusting resistor is matched to the injection pump. Replace it only with one that has the same resistor number.

13E-32

14

GROUP 14 COOLING SPECIFICATIONS ........................................

14-2

STRUCTURE AND OPERATION 1. Cooling System (Water Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Thermostat ....................................................

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-2 14-3 14-3

14-4

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacing Coolant and Cleaning Coolant System . . . . . . . . . . . . . . . . . 2. Air Bleeding of Cooling System ................................. 3. Gas Leak Testing .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-6 14-8 14-8

RADIATOR ..............................................

14-9

COOLING FAN AND V-BELT. ... . ... . . . . .. . . . . .. . . . . . .. . . . .

14-10

WATER PUMP

14-14

THERMOSTAT

14-18

14-1

SPECIFICATIONS I STRUCTURE AND OPERATION SPECIFICATIONS Item

Specifications

Cooling system

Forced water circulation type

Water pump type

Belt-driven involute type

Thermostat type

Wax pellet, bottom bypass type (with jiggle valve)

Automatic cooling fan coupling type Radiator type

Constant control type Tube and corrugated fin type

Coolant capacity dm3 {L} (engine main body only)

13 {13}

STRUCTURE AND OPERATION 1. Cooling System (Water Flow) 1 2 3 4 5 6 7 8 9

1

4

7 16951

14-2

Reservoir tank Thermostat Cylinder head Drain plug Oil cooler Water pump Drain cock Radiator Bypass hose

14 2. Water Pump <With cover>

<Without cover>

7

7

8

8 2

2

9

9

1

1

10

11 16934

11

1 2 3 4 5 6 7

16935

8 9 10 11

Water pump shaft Flange Snap ring Bearing Spacer Bearing Water pump case

Washer Impeller Cover Unit seal

A: Drain hole

3. Thermostat 1 Thermostat cover 2 Thermostat 3 Thermostat case

AA: To radiator B: With low coolant temperature C: With high coolant temperature D: From cylinder head E: To water pump

1

2

E 06361

Thermostat 2 is a bottom bypass type that uses wax-charged pellets as its regulating element. As the wax changes from solid to liquid in line with temperature increases, the total wax volume changes. As a result, the position of the valve, changed by the coolant temperature, regulates the flow of coolant to the radiator and water pump (bypass side) and controls the coolant temperature.

14-3

TROUBLESHOOTING Symptoms

0> .!: (5 0

u c

en en

Q)

·u :E ::J en c

~ Q)

Q)

Cl C

(5

en ·0

Q)

> 0

Possible causes V-belt

Loose or damaged

0

u

Cii

> E ·iii en

Water pump

Water pump fitted poorly Gasket defective Bearing defective Impeller defective Unit seal defective Loose fit between shaft and flange and/or shaft and impeller

Thermostat

Case fitted poorly Gasket defective Valve opening temperature too high; valve remains closed

0 0 0 0 0 0

Radiator

Space between core and fins clogged Core cracked and/or separation of soldered joints Pressure cap not sufficiently airtight

Cooling fan

Fan shroud fitted poorly

Automatic cooling fan coupling

Bearing defective Bimetal damaged Bimetal contaminated with foreign particles Silicon oil leaking

Oil cooler

Oil cooler fitted poorly Gasket defective

Cylinder head

Cylinder head fitted poorly Gasket defective

Coolant quantity insufficient and/or coolant dirty Coolant passages dirty and/or clogged Hoses fitted poorly Ambient temperature extremely low

14-4


Q)

xu

w

0 0 0 0

0

0 0 0

0 0 0 0

Valve opening temperature too low; valve remains open Water leaking from water temperature sensor

.0

0 0

0

Excessive tension Oil on belt

0

U Q)

Q)

> 0

res

(5

C

... ... ...c0

..c.

C

......Cl C

Remarks

..Q

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

0 0

rn Gr 12 rn Gr 11

14 I

MEMO

14-5

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacing Coolant and Cleaning Coolant System 1 Pressure cap 2 Crankcase drain plug 3 Radiator drain cock

3

16941

o

Tightening torques

Remarks

Tightening torque

Parts to be tightened

Location

2

Unit: N· m {kgf· m}

-

115 {12}

Crankcase drain plug

Using the radiator for extended periods without cleaning the cooling system will cause overheating since rust and scale deposits will accumulate. The cooling system must be cleaned periodically. • Draining coolant Before draining the coolant, loosen pressure cap 1 to reduce the pressure in the cooling system.

WARNING~---------------------------------------------------• To avoid being scalded, ensure that the coolant has cooled sufficiently before draining it out. • Unless care is exercised, opening pressure cap 1 when the coolant is hot can cause the coolant to spray out. Cover the pressure cap with a cloth, and loosen the cap slowly to bleed off the pressure before opening it fully. • Cleaning procedure • Run the engine and keep the coolant at a temperature of approximately 90°C so that the thermostat valve remains open and the coolant continues to circulate in the radiator. • To increase the coolant temperature quickly, cover the front of the radiator with cardboard or a similar material. • If cleaning is carried out after a large amount of rust has accumulated, the radiator may start to leak. Carefully examine the radiator for leaks after cleaning the cooling system. • Soft water to be used should have the following properties.

CAUTION~----------------------------------------------------Do not use hard water as it causes scale and rust. Required propertiies of soft water Total hardness

300 ppm or less

Total dissolved solids

500 ppm or less

Sulfate S04

100 ppm or less

pH

6 to 8

Chloride CI-

100 ppm or less

-

--

14-6

14 Method of cleaning the cooling system depends on its condition.

• Extremely dirty coolant

• Ordinary condition

Cleaning method by water

• Clogged radiator

Cleaning method using cleaning solution (FUSO Radiator cleaner Radipet 7) Drain the coolant.

(Work procedure)

Make a solution of FUSO Radiator Cleaner (Radipet 7) at a rate of 5 to 10% to the total volume of coolant.

I Fill the radiator with the solution. Keep the solution temperature at 90°C and let the engine idle for 30 minutes.

CAUTION~--------­ Be sure to allow the engine to idle for 30 minutes only. Circulating the solution in the system for more than an hour might cause the system to breakdown.

Drain the water and the solution. r

-

-

-

-

-

-

-

-

- .....

Fill with soft water (boiled preferably).

Keep the water temperature at 90°C and let engine idle for 10 minutes.

Drain the water.

If the drained water is clear, cleaning has been successful. If it is still muddy, repeat the procedure. ~

__________

.J

L..

________________________ I

DANGER~---------------------------------------------------­ If you accidentally splash FUSO Diesel Long Life Coolant, Fuso Antifreeze, or Radiator Antirust (Radipet 9) in your eyes, wash it out immediately with water and seek medical attention.

WARNING~ ------------------------------------------------FUSO Diesel Long Life Coolant is flammable. Keep them away from heat and flames.

NOTE • After cleaning the cooling system with cleaning fluid, fill it with coolant as son as possible. • To prevent freezing of the coolant and corrosion of the cooling system, add to the coolant the specified proportion of FUSO Diesel Long Life Coolant. (See the Maintenance Manual for instructions on the use of these products).

14-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Air Bleeding of Cooling System • Remove the pressure cap. Keeping the coolant temperature at 90°C, let the engine idle until the cooling system is completely bled of air. While the engine is idling, keep the heater controller's adjustment lever at its maximum-temperature position so that coolant flows freely in the heater piping. • After bleeding the cooling system of air, add coolant to the radiator and reservoir tank as required.

3. Gas Leak Testing The presence of air or exhaust gas in the coolant increases corrosion and rust in the cooling system. Check for air or exhaust gas in the coolant using the following procedure: • Remove pressure cap 1.

WARNING'&' - - - - - - - - - - - - - Make sure the coolant is sufficiently cool before loosening the pressure cap. If the coolant is hot, it will spray out. • Run the engine until the coolant temperature reaches approximately 90°C. • If bubbles A appear continuously, there is air or exhaust gas in the coolant. • If the coolant contains air, the cylinder head bolts, water pump mounting bolts, or hose connections may be loose. Alternatively, the hoses may be damaged. • If the coolant contains exhaust gas, it is possible that the cylinder head gasket is damaged or that the cylinder head is cracked.

A

gllllh-lDDi

14-8

00187

14

RADIATOR • Disassembly sequence

1 Wire net 2 Shroud 3 Frame 4 Drain cock 5 Drain hose 6 Pressure cap 7 Radiator

/~

• Assembly sequence 1

/~

Reverse the order of disassembly.

2

i

~/\ 3

7

5 16943

Service standards Location

6

7

Standard value

Maintenance item Pressure valve opening pressure

Remedy

69 ± 15 kPa {O.? ± 0.15 kg/cm2}

Limit -

o cc

-

Correct or replace

Radiator air leakage (with air pressure of 150 kPa {1.5 kgf/cm2})

Replace

• Service procedure

[§J

Pressure cap inspection

Measure the pressure valve's opening pressure. If the measurement does not conform with the standard value, replace pressure cap 6.

6 00194

[ZJ

Radiator inspection

• Fit hose A and radiator cap tester B to the radiator upper tank. • Fit plug C to the lower tank, then immerse the radiator in a tank of water. • Using radiator cap tester B, apply the specified air pressure of 150 kPa {1.5 kgf/cm 2 }, and check for air leakage. • If air leakage is apparent, correct or replace radiator 7.

7

07386

14-9

COOLING FAN AND V-BELT • Disassembly sequence 1 V-belt 2 Automatic cooling fan coupling 3 Cooling fan 4 Spacer 5 Water pump pulley

* : Water pump assembly CD P.14-14 • Assembly sequence Reverse the order of disassembly.

CAUTION&------• Automatic cooling fan coupling 2 is an integrated unit and cannot be disassembled. If any fault is apparent, replace the whole assembly. • When replacing V-belts 1, be sure to replace them as a set to maintain even tension between them.

16946

16947

Service standards Location

1

Unit: mm Standard value

Maintenance item V-belt tension

10 to 15

Limit

-

~ Special tools Location

Tool name and shape

Part No.

Application

~ 1

Belt tension gauge

~

MH062345

03612

14-10

V-belt tension measurement

Remedy Adjust

14 • Service procedure 1

[JJ

c

V-belt

[I nspection] Apply force of approximately 98 N {1 0 kgf} to the center of the V-belt 1 and measure the extent of V-belt deflection A. B: Alternator pulley C: Water pump pulley D: Crankshaft pulley

A

D

16948

• Set upper O-ring E of ~ belt tension gauge to 8 N {1 0 kgf} (push load) on scale F. • Set lower O-ring G of ~ belt tension gauge to the V-belt's correct maximum deflection value on scale H.

E F

G

H

03613

• Apply the ~ belt tension gauge to the center of V-belt 1 and push until O-ring E reaches the flange K.

03614

• Measure the extent of V-belt 1 deflection A. If the measurement does not conform with the standard value, adjust the V-belt as shown below.

1

03615

14-11

COOLING FAN AND V-BELT [Adjustment]



CAUTION~---------------------------

L

• Excessive tension in V-belt 1 may damage the belt and related bearings. • Be sure to replace the V-belts 1 as a set to maintain even tension between them. • Keep V-belt 1 free of oil. If the belt becomes oily, it will slip, resulting in overheating of the engine and insufficient charging of the battery.

M 00203

• Loosen alternator mounting bolts L (2 places) and adjust the V-belt tension by moving alternator M to the left or right. • When the adjustment is complete, tighten the bolts and nuts securely. • Loosen alternator retaining bolts L (2 places) and adjust the tension of V-belt 1 using adjuster bolt N. • After the belt tension is adjusted, tighten the bolts and nut firmly.



1

®47060

[I]

Automatic cooling fan coupling

[Inspection] Inspect automatic cooling fan coupling 2 in accordance with the following procedure. If any defect is evident, replace the unit. • Check for leakage of oil from the coupling body. • Rotate automatic cooling fan coupling 2 by hand and check for irregular movement or abnormal noise caused by a defect in the bearing. • Check for excessive axial play in automatic cooling fan coupling 2 when the engine is cool. 16949

[Cleaning] If any foreign particles have adhered to bimetal A, brush them off gently.

16950

14-12

I 14 I

MEMO

14-13

WATER PUMP <With cover>

<Without cover>

13

®16925

®16926

• Disassembly sequence 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16

Bolt Water pump assembly Impeller Flange Snap ring Bearing Spacer Bearing Washer

o :Non-reusable part

• Assembly sequence

16-15-14-2-1 2:1

13 12 10-9-8-7-6

J

• Inspection after assembly P.14-16

m

14-14

Water pump shaft Unit seal Grease nipple Water pump case Gasket (pump with cover) Cover (pump with cover) Gasket

14 Service standards

Unit: mm Maintenance item

Location

o

Limit

Remedy

3,10

Impeller-to-water pump shaft interference

[13] 0.03 to 0.06

-

Reassemblyallowed only twice

4,10

Flange-to-water pump shaft interference

[26] 0.05 to 0.08

-

Reassemblyallowed only twice

Tightening torque 1

Unit: N . m {kgf· m}

Parts to be tightened

Location

~

Standard value (Basic diameter in [ ])

Tightening torque

Remarks

9.8 {1.0}

Bolt (water pump assembly mounting)

-

Lubricant and/or sealant Points of application

Location

Specified lubricant and/or sealant

Quantity

Bearings

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

11

Unit seal outer periphery

THREEBOND 1102

As required

12

Grease nipple

Wheel bearing grease [NLGI No.2 (Li soap)]

6,8

60 g

lQ Special tools Location

3

Unit: mm Tool name and shape

Impeller Puller

Part No.

MH061417

Application

Removing impeller

14-15

WATER PUMP • Service procedure • Inspection after assembly • After assembly, rotate flange 4 by hand and check that it turns smoothly without hindrance. • If the flange does not turn smoothly, disassemble and inspect the water pump again.

16928

4

W Impeller [Removal]

(g: Impeller Puller

16929

[I nstallation]

CAUTION~---------------------------

®46285

• Before refitting impeller 3, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the impeller can be refitted. Ensure to punch a mark in location A for future reference before refitting the impeller. • The punch mark is used to show how many times in the past impeller 3 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the impeller again. Replace it with a new impeller. Press-fit impeller 3 until its end face B is in line with end face A of water pump shaft 10.

13

c: Press

NOTE Press-fit the impeller such that flange side D of water pump shaft 10 is the load receiving surface.

16930

14-16

14 W[!QIlmpelier-to-water pump shaft interference If the measurement does not conform with the standard value, replace the defective part(s).

CAUTION.&.-------------Even if the standard value is satisfied, reassembly must not be carried out more than twice.

[!]

Flange

[Removal]

16932

__________________

~

L -_ _ _ _ _ _ _ _

~

A: Gear puller

[Installation]

CAUTION.&.--------------------------• Before refitting flange 4, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the flange can be refitted. Ensure to punch a mark in location A for future reference before refitting the flange. • The punch mark is used to show how many times in the past flange 4 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the flange again. Replace it with a new flange. ®46284

[Press-fitting] With a load of 9,81 0 N {4,OOO kgf}, press-fitflange 4 until ittouches bearing

6. B: Press C: Cylindrical jig 20 mm or more

-4

--c 16933

[!] [!QI

Flange-to-water pump shaft interference

If the measurement does not conform with the standard value, replace the defective part(s).

CAUTION'&' - - - - - - - - - - - - - - - - - - - - - - - - - Even if the standard value is satisfied, reassembly must not be carried out more than twice.

10 00212

14-17

THERMOSTAT

16945

16944

• Disassembly sequence

8 Front hanger 9 Bypass hose 10 O-ring 11 Joint

1 Water temperature sensor Thermostat cover 3 Gasket 4 Thermostat 5 Bolt 6 Thermostat case 7 Gasket

2

0: Non-reusable part

NOTE Do not remove thermostat case 6 and front hanger 8 unless they are leaking water or otherwise defective . • Assembly sequence

Reverse the order of disassembly.

Service standards Location 1

4

Maintenance item Water temperature sensor resistance (Between terminal CD and body) Thermostat

Limit

SO°C

(136 Q)

-

80°C

48±SQ

-

100°C

27.2± 2 Q

-

Valve opening temperature

76.S ± 2°C

-

10 mm or more at 90°C

-

Valve lifVtemperature

14-18

Standard value

Remedy Replace

Replace

14

o

Tightening torque

Location

1

rCi

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened Water temperature sensor

Remarks

34 ± 6.9 {3.5 ± o.?}

-

Specified lubricant and/or sealant

Quantity

Lubricant and/or sealant Points of application

Location

5

Threads of bolts (thermostat case mounting)

THREEBOND 2302

As required

10

Periphery of O-ring

Soapy water

As required

• Service procedure

OJ Water temperature sensor inspection • Place water temperature sensor 1 in a container of engine oil. • Heat the oil until it reaches the specified temperatures. Stir the oil to ensure that it heats up evenly. • Measure the resistance between terminal CD and body ® of the water temperature sensor. • If the measurements do not conform with the specified values, replace the water temperature sensor 1.

m

Thermostat inspection

c

Place the thermostat in a container of water. While stirring the water with a rod A to ensure that it is heated evenly, carry out the following inspection procedure. If the measurements do not conform with the standard values, replace the thermostat 4.

(1) Valve opening temperature • Support thermostat 4 with wire E to keep it away from heat source

D. 00218

• Gradually heat the water until it reaches the valve opening temperature. • Maintain this temperature for 5 minutes and check that valve B is open. • When the water temperature drops below 65°C, check that valve B is completely closed. C : Thermometer

(2) Valve lift Heat the water to slightly higher than the valve opening temperature. With valve B fully open, maintain this water temperature for 5 minutes. Measure the extent of valve lift F.

14-19

15

GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS ........................................

15-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5.

Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Type Air Cleaner ...................................... Pre-Cleaner .................................................... Dust Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbo Charger .................................................

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3 15-4 15-4 15-5 15-6

15-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Dust Indicator

15-10

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

15-12

. • • . . • . . • • . . • . • . . • . . . • • . . • • . . • • . • • . • • . • • . • • . • • . • • .• ..............................................

15-16 15-19

TURBOCHARGER ..................................................

15-20 15-30 15-42

INTERCOOLER <6016-TL, 16-TLE> • • • • • • • • • • • • . • • • . • • . . • . . . • . • • . • • . • • • . • • .•

15-52

INTAKE MANIFOLD <6014, 16, 16-E> . . • • . • • . • • . . • • . . • • . • • . • • . . • . . • . . • • . • • . . • . .• <6014-T, 15-T, 16-T, 16-TE> • • . . • . . . • • . • • . • • • . • . . • . • • • • • • • • • • • • <6016-TL> ............................................... <6016-TLE> •.••.••.••..•..••••.••••.•••••••••••••.••.••.•

15-54 15-56 15-58 15-60

EXHAUST MANIFOLD <6014, 16, 16-E> • • • • • • • • • • . • • • • • • • • • • . • • . . • . . • • . • • . . • • . • • .• <6014-T, 16-T, 16-TE, 16-TL, 16-TLE> • • • • • • • • • • • • • • • • • • • • • • • • • •• <6014-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE> .•..••.•.•••..•..••..•

15-62 15-63 15-64

15-1

SPECIFICATIONS Air cleaner element Item Type

Specifications

I

Cyclone type, filter paper type

Cartridge type, filter paper type

Nihon Donaldson

Manufacturer

Dust indicator Item

Specifications Mechanical type

Type

Electrical type

Turbocharger Item Type

Specifications T04B

Manufacturer

I

T04E

I

TBP4

Honeywell

TF07 Mitsubishi Heavy Industries

Intercooler Item Type

15-2

Specifications Tube & corrugated fin air cooled type

15

STRUCTURE AND OPERATION 1. Air Cleaner Cyclone type air cleaner 1 Element 2 Vane

<Single element type>

A: Outside air B: To engine

A The element 1, which comes in two types; the single and double element types, is the filter paper type. Coated with plastics and given heat treatment, the element offers outstanding resistance to water and oils. The air that has been drawn in is made to rotate by the vane 2, and large particles of dust are centrifugally separated. Furthermore, small particles of dust are filtered out by the filter paper element, and the air thus made clean is drawn into the engine. 18251

18252

<Single element type> A

1 Element 2 Guide vane 3 Vacuator valve



1

1

A

A: Outside air B: To engine

2

2 18253

18254

3

c

The element 1, which comes in two types; the single and double element types, is the filter paper type. Coated with plastics and given heat treatment, the element offers outstanding resistance to water and oils. The air that has been drawn in is made to rotate by the guide vane 2, and large particles of dust are centrifugally separated. Furthermore, small particles of dust are filtered out by the filter paper element, and the air thus made clean is drawn into the engine. The vacuator valve 3 automatically discharges the separated dust and dirt. When the engine speed lowers to a certain speed, the elasticity of the rubber valve overcomes the negative pressure in the air cleaner, thus opens and discharges the dust and dirt C.

TftT

Iyr 18268

15-3

STRUCTURE AND OPERATION 2. Cartridge Type Air Cleaner 1 Element 2 Inlet slot A: Outside air B: Into engine The element 1 is the filter paper type. The outside air is directly drawn in from the inlet slot 2 of the air cleaner proper.

A

18266

3. Pre-Cleaner 1 Pre-cleaner body 2 Guide vane A: Outside air B: To air cleaner

1 The pre-cleaner removes relatively large particles of dust contained in the air that has been drawn in. The air that has been drawn in is made to rotate by the guide vane 2 in the pre-cleaner, and the centrifugally separated particles of dust are accumulated in the pre-cleaner body 1.

B 18267

15-4

15 4. Dust Indicator <Mechanical type> 1 Dust indicator 2 Signal 3 Spring 4 Transparent portion 5 Reset button

5

1

A: Negative pressure

2

,

4

3

A

18269

The mechanical type dust indicator 1 is located near the intake air outlet of the air cleaner. Operated by the negative pressure which is produced when the air is drawn into the engine, the dust indicator indicates that it is high time to clean or replace the element. In other words, when the element is clogged with dust, the suction resistance increases. When the negative pressure A reaches 6.23 kPa {635 mmH 20}, the signal 2 (red) is pulled down against the spring pressure of the spring 3. So the signal (red) appears in the transparent portion 4 of the body to indicate that it is high time to clean or replace the element. After cleaning or replacing the element, press the reset button 5, and the signal will return to its original position.

<Electric type>

1 Dust indicator

2 1

2 Warning lamp

3

3 Starter switch 4 Battery

~

14

5 Air cleaner A: Negative pressure When the negative pressure A reaches 6.23 kPa {635 mmH20}, the electric type dust indicator closes its contact to light the warning lamp 2 and alert the driver that it is high time to clean or replace the element. 18270

15-5

STRUCTURE AND OPERATION 5. Turbo Charger
14

13

5

4

3

2

1

10

9

5

6

7

11

10

11

12

7

6

8

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Compressor housing Piston ring Thrust collar Thrust bearing Center housing Wheel shroud Turbine housing Turbine wheel Piston ring Retaining ring Bearing Seal ring Back plate Compressor wheel

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Compressor cover Piston ring Snap ring Insert Thrust bearing Bearing housing Turbine back plate Turbine housing Shaft & turbine wheel assembly Piston ring Bearing Oil deflector Thrust ring Snap ring Thrust sleeve Compressor wheel

18271



1

16

15-6

2

15

14

3

13 12

4

8

9

18272

15

1 2 3 4 5 6 7 B 9 10 11 12 13 14 15 16

16

15

14

Compressor housing Piston ring Thrust collar Thrust bearing Center housing Wheel shroud Exhaust coupler Actuator assembly Turbine housing Turbine wheel Piston ring Retaining ring Bearing Seal ring Back plate Compressor wheel

13 18273

15-7

STRUCTURE AND OPERATION • Waste gate mechanism • The waste gate mechanism has the actuator assembly 8 to let extra exhaust gas escape. By so doing, the boost pressure is properly controlled to prevent the turbine wheel from overrunning and prevent an excessive pressure produced in the intake manifold. • The boost pressure is led from the compressor housing 1 through a rubber hose to the chamber A of the actuator assembly 8. When the boost pressure that acts on the chamber A is below the setting, the actuator assembly does not operate, and the waste gate valve remains closed, and the exhaust gas 0 is blown against the turbine wheel 10.

01510

• When the boost pressure that acts on the chamber A exceeds the setting, the waste gate valve is opened. As a result, the amount of exhaust gas blown against the turbine wheel 10 decreases, and the rotating speed of the compressor wheel 16 also decreases, and the boost pressure falls.

01511

• Operation of overboost valve • The overboost valve E operates when the boost pressure becomes abnormally high due to the failure of the waste gate mechanism.

E

01512

• When the boost pressure F of the overboost valve E exceeds the setting, the valve releases the boost pressure into the atmosphere to make sure that a boost pressure more than necessary is not applied to the engine. The valve whistles when it is in operation.

01513

15-8

15

TROUBLESHOOTING "'0

Symptoms

c

co Q)

-

~

co

-:::l

0..

:::l

t

--co (/)

(/)

co

OJ

(/)

co

OJ

.8 (/) (/) :::l "E :::l co co ..c co ..c ..c x

0

Q)

c .0, C

c ..!: c

0 :;::::

0..

E

:::l (/) c 0 U

c

0

.~

..... ..c .::;:

°E

"'OQ)

Q)

·0

c_ :::l(/)

c

Q)

0>-

Q)

·0

> ·00

(/)(/)

Q)

.~

(/)

U

:E :::l

c:::l COCO

w

as

~

-c

0

0 0 0

0 0 0

0

0

0

0

0 0 0

0 0 0

0 0 0

Compressor wheel interfering with compressor housing

0

0

0

Thrust sleeve, thrust collar and thrust bearing seizure

0

0

0

Damaged compressor wheel

0

0

0

Q)

c .0, c

Possible causes Air cleaner

Clogged air cleaner element

Turbocharger

Defective bearing Carbon deposited on turbine wheel Turbine wheel interfering with wheel shroud and turbine back plate Turbine wheel interfering with turbine housing Bent turbine wheel Damaged turbine wheel

x Q)

~

co

..c

(/)

0

Oil leaks due to worn piston ring and insert

0

Improperly mounted compressor housing

0

0 0

Improperly mounted turbine housing Intercooler

Foreign substances deposited on front core of intercooler

0 0

Worn valve and valve seat and deposited carbon Sagging valve spring

0 0 0 0

CD Gr 11 CD Gr 11 CD Gr 11 CD Gr 11

0 0

Worn or damaged piston ring Worn or damaged piston ring groove of piston Malfunctioning cooling equipment

0 0

0 0

Improperly mounted front pipe, muffler, tail pipe

Defective head gasket

..... ..c

-x

(J)Q)

0

Deformed front pipe, muffler, tail pipe

Incorrect valve clearance

OJ(/)

0 0

Damaged oil seals due to clogged oil return pipe

u

x w

Q)-

0 0

Improperly mounted piston ring Unsmooth sliding of internal parts due to clogged lubrication oil pipe and eyebolt

Q)

Remarks

.....

0

CD Gr 11 CD Gr 11 CD Gr 14

0

Excessive engine oil

0 0

CD Gr 12

Seizure of major moving parts

0

CDGr11

Uneven or excessive fuel injection

0

CD Gr 13

15-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Dust Indicator Service standards Location

-

Standard value

Maintenance item Negative pressure for operation of dust indicator

A

B 2

6.23 ± 0.57 kPa {635 ± 58 mmH20}

<Mechanical Type>

<Electric Type>

18275

15-10

-

Remedy -

• Before checking the dust indicator 1, clean or replace the air cleaner element. • Start the engine, and cover the inlet of the air cleaner through use of a wooden block B in such a way that the negative pressure of the dust indicator 1 will have the nominal value and check that the mechanical type will show the red signal or the electric type will light the warning lamp. If there is anything wrong in operation, replace defective parts. 2 Air cleaner

18274

Limit

A: Negative pressure gauge

15

MEMO

15-11

AIR CLEANER 1

5 1

18276

10

2

7

18277

1

10

18278

• Disassembly sequence 1 2 3 4 5

Clamp Baffle Dust cup O-ring Nut gasket Bolt gasket 6 Element

7 8 9 10

Nut gasket Safety element Dust indicator Air cleaner body

., : Non-reusable part

NOTE Do not disassemble the safety element 8 except when it need be replaced . • Reassembly sequence Reverse the order of disassembly.

15-12

15 Service standards Location

Standard value

Maintenance item Negative pressure for operation of dust indicator

9

6.23 ± 0.57 kPa {635 ± 58 mmH 2O}

Limit

-

Remedy Replace

~ Sealant Points of application

Location

Specified sealant

Apply to threads of dust indicator

9

ThreeBond 1401 B

Quantity As required

• Service procedure

[i]

Dust cup

Reassemble the dust cup 3 with the arrow mark A toward the inlet B.

A

A

18279

~ Element [Cleaning] • Blow compressed air 685 kPa {7 kg/cm2} or less from inside the element 6. • Blow the compressed air, working along the creases of filter paper of the element 6 up and down throughout the element.

6

CAUTION&-------------13996

• Do not strike the element 6 to loosen dust. • Do not blow the air from outside the element 6. [Inspection] • Put a light inside the element 6. • If the filter paper is broken or partially thin, or if the packing on the top of the element 6 is broken, replace the element. • If the dust deposited on the element 6 is wet with oil smoke or soot, replace the element irrespective of the replacement intervals.

6

13997

15-13

AIR CLEANER

rn

Inspection of dust indicator

Perform the following checks. If there is anything wrong, replace the dust indicator.

<Mechanical type> A

• Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check whether the red signal appears.

9 18281

<Electric type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check that there is continuity between terminals CD and ®. • Check that when there is no negative pressure applied to the dust indicator 9, there is no continuity between the terminals CD and ®.

A

9 18282

9

18280

15-14

15

MEMO

15-15

AIR CLEANER <Single Element Type>

"\

5 18283



1

2

3

4

18284

11



10

\

5

6 7

18285



11

18286

10

• Disassembly sequence

1 2 3 4 5 6 7

Clip Wing nut Cover Gasket Nut gasket Element Nut gasket

8 Safety element 9 Dust indicator 10 Vacuator valve 11 Air cleaner body

0: Non-reusable part

NOTE Do not disassemble the safety element 8 except when it need be replaced . • Reassembly sequence

Reverse the order of disassembly.

15-16

15 Service standards Maintenance item

Location

Standard value

Negative pressure for operation of dust indicator

9

6.23 ± 0.57 kPa {635 ± 58 mmH20}

Limit -

Remedy Replace

~ Sealant Points of application

Location

Apply to threads of dust indicator

9

Specified sealant ThreeBond 1401 B

Quantity As required

• Service procedure

WElement

[Cleaning] • Blow compressed air 685 kPa {7 kg/cm2} or less from inside the element 6. • Blow the compressed air, working along the creases of filter paper of the element 6 up and down throughout the element.

6

CAUTION&-------------13996

• Do not strike the element 6 to loosen dust. • Do not blow the air from outside the element 6. [Inspection] • Put a light inside the element 6. • If the filter paper is broken or partially thin, or if the packing on the top of the element 6 is broken, replace the element. • If the dust deposited on the element 6 is wet with oil smoke or soot, replace the element irrespective of the replacement intervals.

6

13997

~ Inspection of dust indicator Perform the following checks. If there is anything wrong, replace the dust indicator.

<Mechanical type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check whether the red signal appears.

A

9 18281

15-17

AIR CLEANER <Electric type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check that there is continuity between terminals (1) and (2) • Check that when there is no negative pressure applied to the dust indicator 9, there is no continuity between the terminals CD and ®.

A

9 18282

9

18280

15-18

15

AIR CLEANER • Disassembly sequence

1 Clamp 2 Air cleaner 3 Dust indicator

• Reassembly sequence Reverse the order of removal.

0---1

18287

Service standards Location

3 ~

Standard value

Maintenance item Negative pressure for operation of dust indicator

6.23 ± 0.57 kPa {635 ± 58 mmH20}

Limit

-

Remedy Replace

Sealant

Location

3

Points of application Apply to threads of dust indicator

Specified sealant ThreeBond 1401B

Quantity As required

• Service procedure ~ Cleaning air cleaner [Cleaning] Blow compressed air 685 kPa {7 kg/cm2} or less from inside the air cleaner 2, working along the creases of filter paper up and down to clean the air cleaner.

2

CAUTION&--------------

18288

• Do not strike the element and do not blow the air from the suction portion. • Make sure that the loosened dust is not blown into the element.

@] A

Inspection of dust indicator

• Mount a hand vacuum pump A on the dust indicator and apply the standard operating negative pressure to check whether the red signal appears.

3 18281

15-19

TURBOCHARGER
,--------------------------,

• Removal sequence 1 2 3 4 5

Eyebolt Oil inlet pipe Oil return pipe Nut Turbocharger assembly CD P.15-22 6 Gasket

rG5

* : Exhaust manifold CD P.15-63, 64

o :Non-reusable part 2

• Installation sequence Reverse the order of removal.

3 ;>

<~

18289

o

Tightening torque

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

Remarks

1

Eyebolt (for mounting oil inlet pipe)

21 {2.1}

-

4

Nut (for mounting turbocharger assembly)

41 {4.2}

-

~ Lubricant Location 5

Points of application

Specified lubricant

Supply when installing turbocharger assembly

Engine oil

Quantity As required

• Service procedure

rn A

When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18290

15-20

Installation of turbocharger assembly

15

MEMO

15-21

TURBOCHARGER
21rGO

18291

• Operations before disassembly

CD P.1S-24 • Disassembly sequence

1 2 3 4 5 6 7 8

Bolt Lock plate Clamp Turbine housing Bolt Clamp Compressor housing Center housing and rotating assembly

9 10 11 12 13 14 15 16 17

Lock nut Compressor wheel Turbine wheel Piston ring Wheel shroud Bolt Back plate Seal ring Thrust collar

18 Thrust bearing 19 Piston ring 20 Retaining ring 21 Bearing 22 Retaining ring 23 Center housing

0: Non-reusable part

CAUTION~----------------------------------------------------­ Carefully remove piston rings 12 and 19, as they are readily broken. • Cleaning after disassembly

CD P.1S-24 • Reassembly sequence

CAUTION~----------------------------------------------------Do not widen the piston rings 12 and 19 more than necessary, as they are readily broken. • Inspection after reassembly

CD P.1S-2S 15-22

15 Service standards Standard value (Basic diameter in [ ])

Maintenance item

Location 11

Unit: mm

Turbine wheel

Bearing journal outside diameter

-

Shaft bend Hub diameter Piston ring mounting portion

15

17

Back plate

Thrust collar

Groove width Groove diameter

23

o

10.152 or more

Replace

0.01 or less 17.25 or more

1.69

1.74 or less

[14.46]

14.40 or more

0.076 to 0.150

Play in thrust direction

0.025 to 0.076

-

T04B

11.652

11.658 or less

T04E

11.672

11.684 or less

Seal bore inside diameter

[12.687]

12.712 or less

1.640

1.659 or less

[10.35]

10.29 or more

Seal land height

1

Replace

Piston ring mounting portion

Groove width

Thrust bearing mounting portion

Groove width

4.43

4.44 or less

Groove diameter

[9.53]

9.40 or more

Groove diameter

[6.358]

6.363 or less

Bearing inserting portion inside diameter

[15.800]

15.806 or less

Seal bore inside diameter

[18.03]

18.06 or less

Tightening torque

Location

rG

Remedy

[17.31]

Play in radial direction

Inside diameter Center housing

[10.156]

Limit

Replace

Replace

Unit: N· m {kgf· m}

Parts to be tightened Bolt (for mounting turbine housing)

Tightening torque

Remarks

T04B

18 to 21 {1.85 to 2.19}

-

T04E

20 to 22 {2.07 to 2.29}

-

16 to 19 {1.67 to 1.89}

-

2.1 to 2.3 {0.21 to 0.23}

After tightening, turn down 90°C to 110°C further from that position.

12 to 14 {1 .26 to 1.45}

-

5

Bolt (for mounting compressor housing)

9

Lock nut (for mounting compressor wheel)

14

Bolt (for mounting back plate)

Lubricant

Location

1

5, 14 11,12, 17 to 22

Points of application

Specified lubricant

Quantity

Apply to threads and bearing surface of bolt

MOLYKOTE

As required

Apply to threaded portion of bolt

LOCTITE

As required

Apply to all of the parts

Engine oil

As required

15-23

TURBOCHARGER
Tool name and shape

Location

Application

T-handle

801059-0

Holding fixture

801053-0

11

Measuring element

801098-0

Inspection of play of turbine wheel in radial direction

12 20,22

Piston ring inserter

801050-0

Installation of piston ring

Retaining ring remover

801058-0

Removal and installation of retaining ring

10

Removal and installation of compressor wheel

Part numbers listed above are Honeywell part numbers.

• Service procedure • Operations before disassembly Make alignment marks A on the turbine housing 4, compressor housing 7 and center housing rotating assembly 8.

4

8

7

18292

• Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace. • Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

15-24

15 • Scrape off deposits. B: Plastic scraper or stiff brush

A

• Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly

(1) Manually rotate the compressor wheel 10 and turbine 11 to check whether they rotate smoothly.

18358

(2) Play of turbine wheel in radial direction

• Mount the ~ Probe to the dial indicator A and insert it from the oil outlet and press it against the shaft of the turbine wheel 11 at right angles. • Move the shaft of the turbine wheel 11 up and down by both hands to measure the play in the radial direction. • If the reading is in excess of the limit, replace the bearing 21.

11

t 21

18294

(3) Play of turbine wheel in thrust direction • Set the dial indicator A on the end of the turbine wheel 11 and move the shaft of the turbine wheel'in the axial direction to measure the play. • If the reading exceeds the limit, worn or defective back plate 15, thrust collar 17 and thrust bearing 18 are suspected. Replace.

15

17 18295

15-25

TURBOCHARGER
CAUTION&.--------------

A

18296

• While using care to prevent damage to the turbine housing 4, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the turbine wheel are readily bent, use care to make sure that they do not hit the turbine housing 4.

[Installation] • Apply the MOLYKOTE to the threads and bearing surface of the bolt 1, partially tighten the bolt, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque. • Bend the lock plate 2 at two places against the bolts 1.

CAUTION&.-------------Use care to prevent damage to the blades of the turbine wheel 11. 18297

o Compressor housing [Removal] A: Rubber hammer

CAUTION&.--------------

A

7

18298

• While using care to prevent damage to the compressor housing 7, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 10 are readily bent, use care to make sure that they do not hit the compressor housing 7. [Installation] Place the center housing & rotating assembly 8 on the compressor housing 7, line up the alignment marks made before disassembly, and tighten the bolt 1 to the specified torque.

7

18299

~ Compressor wheel [Removal] • Hold the ~a Holding Fixture in a vice, and slowly insert the center housing & rotating assembly 8. • Using the ~b T-handle, remove the lock nut 9 and slowly withdraw the compressor wheel 10 upward.

CAUTION&.-------------Use care to prevent bending the shaft of the turbine wheel 11. 18300

15-26

15 [Installation] • Hold the shaft of the turbine wheel 11 and center housing 23 by hand, and slowly insert them into the (ga Holding Fixture.

11

CAUTION.&-------------• When they are inserted, use care to prevent damage to the blades of the turbine wheel 11. • Do not release the shaft before insertion, as the turbine wheel 11 falls down.

23-----H

18301

• Hold the (ga Holding Fixture in a vice and slowly insert the compressor wheel 10. • Using the (gb T-handle, tighten the lock nut 9 to the specified torque, and then turn it down 90°C to 110°C further from that position.

CAUTION.&-------------Use care to prevent bending the shaft of the turbine wheel 11.

[1] ~ Turbine wheel, wheel shroud [Removal] Place the back plate 15 side of the center housing 23 on the compressor housing 7 removed beforehand, and remove the turbine wheel 11 and wheel shroud 13.

11 13

23

15

7

18303

[Installation] After installation, lightly rotate the turbine wheel 11 by hand to check whether it continues to rotate. If it does not rotate lightly, re-perform the disassembly and reassembly procedures.

18304

[I nspection] 11

(1) Bend of shaft • Using the dial indicator, measure at the illustrated position . • If the reading exceeds limit, replace the turbine wheel 11.

13655

15-27

TURBOCHARGER
11

A: Journal B:Hub

A-'---~

18305

(3) Width and outside diameter of piston ring groove

11

If any reading exceeds of the limit, replace the turbine wheel 11. A: Width B : Outside diameter

B

18306

[§jlnstallation of piston ring 11

Insert the ~ Piston Ring Inserter into the turbine wheel 11 and install the piston ring 12.

18307

~ Backplate 23

[I nstallation] Slowly install the back plate 15 on the center housing 23, while lining up the alignment marks made before disassembly, and tighten the bolt 14 to the specified torque.

18308

[I nspection] • Measure the seal land height A and seal bore inside diameter B of the back plate 15. • If any reading exceeds the limit, replace the back plate 15.

18309

15-28

15 I!ZI Piston ring groove and groove diameter of thrust collar and 17

thrust bearing groove width, groove diameter and bore inside diameter If any reading exceeds the limit, replace the thrust collar.

T"'-+--+E

D A

B

18311

A: Piston ring groove B: Thrust bearing groove C: Groove width D: Groove diameter E: Bore inside diameter

~ Installation of thrust bearing

A

Install the thrust bearing 18 on the thrust collar 17 with the oil groove A toward the center housing 23, and insert it onto the positioning pins B of the center housing.

23

18312

~ ~ Retaining ring

20,22

[Removal] ~:

Retaining Ring Remover

CAUTION,&-------------When the retaining rings 20 and 22 are removed, hold your hand over the rings to make sure that they do not bounce out.

18313

[Installation] Install the retaining rings 20 and 22 securely in the groove of the center housing.

20,22

CAUTION,&-------------When the retaining rings 20 and 22 are installed, hold your hand over the rings to make sure that they do not bounce out.

18313

~ Check the bearing inserting portion inside diameter and seal bore diameter of the center housing.

23

If any reading exceeds the limit, replace the center housing 23. A: Bearing inserting portion inside diameter B: Seal bore diameter

18314

15-29

TURBOCHARGER • Removal sequence 1 2 3 4 5 6

.l l:

Eyebolt Oil inlet pipe Oil return pipe Nut Turbocharger assembly Gasket

CD P.15-32

*: Exhaust manifold CD P.15-63, 64

o :Non-reusable part

~

• Installation sequence Reverse the order of removal.

2

*

18387

o

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

1

Eyebolt (for mounting oil inlet pipe)

21 {2.1}

4

Nut (for mounting turbocharger assembly)

41 {4.2}

Remarks

-

~ Lubricant Location

5

Points of application

Specified lubricant

Supply when installing turbocharger assembly

Engine oil

Quantity As required

• Service procedure

[I]

When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

5

18388

15-30

Installation of turbocharger assembly

15

MEMO

15-31

TURBOCHARGER Turbocharger Assembly

18315

• Operations before disassembly

CD P.15-34 • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

Hose clamp Hose Retaining ring Nut Nut Actuator assembly Rod end Bolt Bracket Bolt Exhaust coupler Gasket Bolt

14 15 16 17 18 19 20 21 22 23 24 25

Clamp Turbine housing Bolt Clamp Compressor housing O-ring Center housing & rotating assembly Lock nut Compressor wheel Turbine wheel Piston ring Wheel shroud

26 27 28 29 30 31 32 33 34 35

Bolt Back plate Seal ring Thrust collar Thrust bearing Piston ring Retaining ring Bearing Retaining ring Center housing

., : Non-reusable part

CAUTION~----------------------------------------------------­ Carefully remove the piston rings 24 and 31, as they are readily broken.

15-32

15 • Cleaning after disassembly

CD P.15-35 • Reassembly sequence 35 -7 34 -7 33 -7 32 -7 29 -7 30 -7 31 -7 28 -7 27 -7 26

~

22 -7 21 -720 -719 -718 -717 -716

24-723

L

=' ~

15 -714 -713 -712 -711 -710 -7 9 -7 8 -7 6 -7 4 -7 5 -7 7 -7 3 -7 2-71

CAUTION~----------------------------------------------------Do not widen the piston rings 24 and 31 more than necessary, as they are readily broken. • Inspection after reassembly

CD P.1S-35 Service standards Location

6 23

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item Actuator assembly set pressure Turbine wheel

83 to 90 kPa {625 to 675 mmHg}

Bearing journal outside diameter Shaft bend

-

Hub diameter Piston ring mounting portion

Groove width Groove diameter

27

Back plate

Thrust collar

[14.46]

14.40 or more

-

11.672

11.658 or less

[12.687]

12.712 or less

1.640

1.659 or less

[10.35]

10.29 or more

Groove width

4.43

4.44 or less

Groove diameter

[9.53]

9.40 or more

Inside diameter

[6.358]

6.363 or less

Bearing inserting portion inside diameter

[15.800]

15.806 or less

Seal bore inside diameter

[18.03]

18.06 or less

Piston ring mounting portion

Thrust bearing mounting portion

35

1.74 or less

0.025 to 0.076

Groove width

Remedy Adjust Replace

0.01 or less

1.69

Play in thrust direction

Groove diameter

Center housing

10.152 or more

17.25 or more

0.076 to 0.150

Seal land height

-

[17.31]

Play in radial direction

Seal bore inside diameter

29

[10.156]

Limit

Check

Replace

Replace

Replace

15-33

TURBOCHARGER

o

Tightening torque 4

Nut (for mounting actuator assembly)

5.6 to 7.8 {0.57 to 0.80}

-

5

Nut (for mounting rod end)

5.6 to 6.8 {0.57 to 0.70}

-

8

Bolt (for mounting bracket)

20 to 22 {2.07 to 2.29}

-

10

Bolt (for mounting exhaust coupler)

20 to 22 {2.07 to 2.29}

-

13

Bolt (for mounting clamp)

20 to 22 {2.07 to 2.29}

-

16

Bolt (for mounting clamp)

16 to 19 {1 .67 to 1.89}

-

21

Lock nut (for mounting compressor wheel)

26

Bolt (for mounting back plate)

2.1 to 2.3 {0.21 to 0.23}

After tightening, turn down 90 0 G to 11 OOG further from that position.

12 to 14 {1.26 to 1.45}

-

Lubricant

Location 13 16,26

Specified lubricant

Points of application

Quantity

Apply to threads and bearing surface of bolt

MOLYKOTE

As required

Apply to threaded portion of bolt

LOGTITE

As required

Engine oil

As required

19,23, Apply to all of the parts. 24, 29 to 34

~

Remarks

Tightening torque

Parts to be tightened

Location

rG

Unit: N· m {kgf· m}

Special tools

Location

Tool name and shape

Part No.

Application

T-handle

801059-0

Holding fixture

801053-0

23

Measuring element

801098-0

Inspection of play of turbine wheel in radial direction

24

Piston ring inserter

801050-0

Installation of piston ring

Retaining ring remover

801058-0

Removal and installation of retaining ring

22

32,34

Removal and installation of compressor wheel

Part numbers listed above are Honeywell part numbers .

• Service procedure • Operations before disassembly

11

Make alignment mark A on the turbine housing 15, compressor housing 18 and center housing & rotating assembly 20.

18

15 18316

15-34

15 • Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace.

CAUTION~---------------------------Do not immerse the actuator assembly 6 in the solvent. Clean it with a cloth dipped in kerosene.

• Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

• Scrape off deposits. B: Plastic scraper or stiff brush

A

• Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly (1) Manually rotate the compressor wheel 22 and turbine wheel 23 to check whether they rotate smoothly.

22 ~im--+--23

18358

15-35

TURBOCHARGER (2) Play of turbine wheel in radial direction • Mount the r.g Measuring Element to the dial gauge A and insert it from the oil outlet and press it against the shaft of the turbine wheel 23 at right angles. • Move the shaft of the turbine wheel 23 up and down by both hands to measure the play in the radial direction. • If the reading exceeds the limit, replace the bearing 33.

18317

(3) Play of turbine wheel in thrust direction

27

• Set the dial gauge A on the end of the turbine wheel 23 and move the shaft of the turbine wheel in the axial direction to measure the play. • If the reading exceeds the limit, worn or defective back plate 27, thrust collar 29 and thrust bearing 30 are suspected. Replace.

30

A

29 18318

B

¢

(4) Measurement of operating pressure of actuator assembly • Set the dial indicator A on the end of the rod end 7. (In this case, set the scale of the dial indicator to 0.) • Extend the rod end 0.38 mm by use of the external air B.) (The scale of the dial indicator A is 0.38 mm.) • With the scale of the dial indicator A at 0.38 mm, read the value of the pressure gauge C, and check to ensure that the reading is between 83 and 90 kPa {625 to 675 mmHg}.

_-.J-------<_ _---...

(5) Adjustment of operating pressure of actuator assembly • If the reading of the pressure gauge C is not between 83 and 90 kPa {625 to 675 mmHg}, remove the retaining ring 3, loosen the nut 5, and adjust the length of the rod end 7. Rod end length adjusting direction Rod end extending direction ~ Reduces the pressure. Rod end retracting direction ~ Increases the pressure.

CAUTION&------------When the rod end length is adjusted, if the piston assembly 0 is rotated, damage to the diaphragm in the actuator assembly 6 will result. Secure the piston assembly through use of a vice, pliers, etc. to make sure that it is not rotated.

3 18325

15-36

15 [!] B

Air-tightness check on actuator assembly

Slowly apply the air pressure A to the actuator assembly 6 to check that there are no air leaks when the air pressure is 87 kPa {650 mmHg}. If there are air leaks, replace the actuator assembly. B: Pressure gauge

18366

~ Turbine housing [Removal] A: Rubber hammer

CAUTION~----------------------------

A

15 18319

• While using care to prevent damage to the turbine housing 15, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the turbine wheel 23 are readily bent, use care to make sure that they do not hit the turbine housing 15. [Installation] Apply MOLYKOTE to the threads and bearing surface of bolt 13, partially tighten the bolt, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque.

CAUTION~ ----------------------Use care to prevent damage to the blades of the turbine wheel 23.

18320

~ Compressor housing [Removal] A: Rubber hammer

CAUTION~----------------

18321

• While using care to prevent damage to the compressor 18, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 22 are readily bent, use care to make sure that they do not hit the compressor housing 18. [Installation] • Place the center housing & rotating assembly 20 on the compressor housing 18, line up the alignment marks made before disassembly, and tighten the bolt 16 to the specified torque.

18322

15-37

TURBOCHARGER ~ Compressor wheel [Removal] • Hold the [.ga Holding Fixture in a vice, and slowly insert the center housing & rotating assembly 20. • Using the [.gb T-handle, remove the lock nut 21 and slowly withdraw the compressor wheel 22 upward.

CAUTION~--------------------------Use care to prevent bending the shaft of the turbine wheel 23. 18300

[I nstallation] • Hold the shaft of the turbine wheel 23 and center housing 35 by hand, and slowly insert them into the [.ga Holding Fixture.

23_--==c~""",

CAUTION~ --------------------------• When they are inserted, use care to prevent damage to the blades of the turbine wheel 23. • Do not release the shaft before insertion, as the turbine wheel 23 falls down.

35--_H

18301

• Hold the [.ga Holding Fixture in a vice and slowly insert the compressor wheel 22. • Using the [.gb T-handle, tighten the lock nut 21 to the specified torque, and then turn it down 90°C to 110°C further from that position.

CAUTION~--------------------------­ Use care to prevent bending the shaft of the turbine wheel 23.

18302

~ ~ Turbine wheel, wheel shroud [Removal] Place the back plate 27 of the center housing 35 on the compressor housing 18 removed beforehand, and remove the turbine wheel 23 and wheel shroud 25.

23 25

35

27

18

18303

[I nstallation] After installation, lightly rotate the turbine wheel 23 by hand to check whether it continues to rotate. If it does not rotate lightly, re-perform the disassembly and reassembly procedures.

18304

15-38

15 [Inspection]

23

(1) Bend of shaft • Using the dial indicator, measure at the illustrated position. • If the reading exceeds the limit, replace the turbine wheel 23.

13655

(2) Outside diameters of journal and hub If any reading exceeds the limit, replace the turbine wheel 23.

23

A: Journal B:Hub

18305

(3) Width and outside diameter of piston ring groove

23

If any reading exceeds the limit, replace the turbine wheel 23. A: Width B: Outside diameter

B

18306

~ Insta"ation of piston ring 23

Insert the ~ Piston Ring Inserter into the turbine wheel 23 and install the piston ring 24.

18307

~ Back plate 35

[I nstallation1 Slowly install the back plate 27 on the center housing 35, while lining up the alignment marks made before disassembly, and tighten the bolt 26 to the specified torque.

18308

15-39

TURBOCHARGER [Inspection] • Measure the seal land height A and seal bore inside diameter B of the back plate 27 . • If any reading exceeds the limit, replace the back plate 27.

27

B 18309

~ Piston ring groove and groove diameter of thrust collar and 29

thrust bearing groove width, groove diameter and bore inside diameter If any reading exceeds the limit, replace the thrust collar 29.

A

B

18311

A: Piston ring groove B: Thrust bearing groove C: Groove width 0: Groove diameter E: Bore inside diameter

@Qjlnstallation of thrust bearing

A

Install the thrust bearing 30 on the thrust collar 29 with the oil groove A toward the center housing 35, and insert it onto the positioning pins B of the center housing.

35

18312

~ ~ Retaining ring

32,34

[Removal]

[.g: Retaining Ring Remover

CAUTION~--------------------------­ When the retaining rings 32 and 34 are removed, hold your hand over the rings to make sure that they do not bounce out.

18313

[I nstallation] Install the retaining rings 32 and 34 securely in the groove of the center housing.

32,34

CAUTION~--------------------------When the retaining rings 32 and 34 are installed, hold your hand over the rings to make sure that they do not bounce out.

18313

15-40

15 ~ Check the bearing inserting portion inside diameter and seal bore diameter of the center housing.

35

If any reading exceeds the limit, replace the center housing 35. A: Bearing inserting portion inside diameter B: Seal bore diameter

18314

15-41

TURBOCHARGER • Removal sequence 1 2 3 4 5 6

Eyebolt Oil inlet pipe Oil return pipe Nut Turbocharger assembly Gasket

CD P.15-44

*: Exhaust manifold CD P.15-63, 64 ., : Non-reusable part • Installation sequence Reverse the order of removal.

2

*

<~

3 18389

o

Tightening torque

Unit: N . m {kgf· m} Tightening torque

Parts to be tightened

Location

Remarks

1

Eyebolt (for mounting oil inlet pipe)

21 {2.1}

-

4

Nut (for mounting turbocharger assembly)

41 {4.2}

-

r;&] Lubricant Location

5

Specified lubricant

Points of application Supply when installing turbocharger assembly

Engine oil

Quantity As required

• Service procedure

W Installation of turbocharger assembly

A

When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18390

15-42

15

MEMO

15-43

TURBOCHARGER Turbocharger Assembly

18323

• Operations before disassembly

CD P.15-45 • Disassembly sequence 1 2 3 4 5 6 7

Bolt Lock plate Turbine housing Snap ring Compressor cover O-ring Wheel and bearing assembly 8 Lock nut

housing

9 10 11 12 13 14 15 16 17

Compressor wheel Snap ring Insert Piston ring Oil deflector Thrust sleeve Thrust bearing Thrust ring Shaft & turbine wheel

18 19 20 21 22

Turbine back plate Piston ring Bearing O-ring Bearing housing

0: Non-reusable part

CAUTION~----------------------------------------------------Carefully remove piston rings 12 and 19, as they are readily broken. • Cleaning after disassembly

CD P.15-46 • Reassembly sequence 22 ~ 21 ~ 20 ~ 18 11-------7 ~ ) 19 ~ 17

16~15

I

, 10 ~ 9 ~ 8 ~ 7 ~ 6 ~ 5 ~ 4 ~ 3 ~ 2 ~ 1

14~13~12~11 ~

CAUTION~--------------------------------------------------Do not widen the piston rings 12 and 19 more than necessary, as they are readily broken. • Inspection after reassembly

CD P.15-46 15-44

15 Service standards

Unit: mm Standard value

Maintenance item

Location

0.55 to 0.65

-

Check

12

Clearance between open ends of piston ring (Measure the clearance of a new piston ring.)

0.05 to 0.25

-

Replace insert

17

Shaft & turbine wheel

Outside diameter of bearing journal

-

9.9962

Replace

Bend of shaft

-

0.015

Replace

End play

17, 18 20

22

Clearance between shaft & turbine wheel back surface and turbine back plate Bearing

0.057 to 0.103

-

Check

0.677 to 1.123

-

Check

Inside diameter

-

10.0328

Outside diameter

-

16.901

Length

-

11.84

-

17.006

Bearing inserting portion inside diameter of bearing housing

Tightening torque

Location

~

Remedy

Clearance between shaft & turbine wheel and turbine housing

3,17

o

Limit

Replace

Replace

Unit: N . m {kgf' m}

Parts to be tightened

Tightening torque

1

Bolt (for mounting lock plate)

8

Lock nut (for mounting compressor wheel)

Remarks

12 to 14 {1.2 to 1.4}

-

18 to 21 {1.85 to 2.19}

-

Lubricant

Location

Points of application

Specified lubricant

Quantity

1

Apply to threads of bolt

MOLYKOTE

As required

8

Apply to threads of lock nut

MOLYKOTE

As required

Engine oil

As required

Apply to all of the parts. 6,12, 14 to 17, 19 to 21

• Service procedure • Operations before disassembly

A

Make alignment marks on the turbine housing 3, compressor cover 5 and wheel & bearing housing assembly 7.

18324

15-45

TURBOCHARGER • Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace. • Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

18359

• Scrape off deposits. B: Plastic scraper or stiff brush

A

• Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly Manually rotate the compressor wheel 9 and turbine wheel 17 to check whether they rotate smoothly.

9 ,m'!?-,---

17

18360

15-46

15 @]

Turbine housing

[Removal] A

A: Rubber hammer

CAUTION&.--------------

13633

• While using care to prevent damage to the turbine housing 3, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the shaft & turbine wheel 17 are readily bent, use care to make sure that they do not hit the turbine housing 3.

[I nstallation] Apply MOLYKOTE to the threaded portion of the bolt 1, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque.

CAUTION&.-------------Use care to prevent damage to the blades of the shaft & turbine wheel 17.

18297

@] [!Z]

Measurement of clearance between turbine housing and shaft & turbine wheel

If the reading exceeds the nominal value, disassemble and check to locate the cause.

18326

[!]

Installation of snap ring

Line up the alignment marks made before disassembly and install the snap ring 4 as shown. A: Tapered surface

A~

CAUTION&.-------------18327

When the snap ring 4 is installed, hold it by hand to make sure that it does not bounce out.

rn

Removal of compressor cover

A: Rubber hammer

CAUTION&.-------------------• While using care to prevent damage to the compressor cover 5, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 9 are readily bent, use care to make sure that they do not hit the compressor cover 5.

5 18328

15-47

TURBOCHARGER [1]

Compressor wheel

[Removal] Hold the turbine housing 3 in a vice, and install the wheel & bearing housing assembly 7.

CAUTION~--------------------------­ Since the blades of the shaft & turbine wheel 17 are readily bent, make sure that they do not hit the turbine housing 3 .

• While holding down the boss on the shaft & turbine wheel 17, remove the lock nut 8.

[Installation] Hold the turbine housing 3 in a vice and install the temporarily assembly wheel & bearing housing assembly 7.

CAUTION~--------------------------Since the blades of the shaft & turbine wheel 17 are readily bent, make sure that they do not hit the turbine housing 3 .

• While holding down the boss on the shaft & turbine wheel 17, apply MOLYKOTE to the threaded portion of the lock nut 8, and tighten the lock nut to the specified torque.

[!Q]

Snap ring

[Removal]

CAUTION~--------------------------When the snap ring 10 is removed, hold it by hand to make sure that it does not bounce out.

18332

15-48

15 A 22

\,

[Installation] • Install the snap ring 10 in the illustration direction in the bearing housing 22.

10

~

,

=~

A: Tapered surface 22

CAUTION.&-------------When the snap ring 10 is installed, hold it by hand to make sure that it does not bounce out.

• Install the snap ring 10 securely in the groove of the bearing housing 22. B: Hammer C: Screwdriver

CAUTION.&-------------Use care to make sure that the plain screwdriver C does not hit the bearing housing 22. 13647

IE] Insert [Removal] A: Screwdriver

18334

[Installation] Install the oil deflector 13 in the illustrated direction in the bearing housing 22. 22

~ Measurement of clearance between open ends of piston ring • Mount a new piston ring 12 in the insert 11. • Measure the clearance A between the open ends of the piston ring. • If the reading is out of the nominal value, replace the insert 11.

11 12

13650

15-49

TURBOCHARGER ~ ~ Installation of thrust bearing, thrust ring

CFJ-15

Install the thrust bearing 15 and thrust ring 16 in such a way that they will be directed as shown.

~16

18336

[!Z] 17

Shaft & turbine wheel

[Inspection] (1) Bend of shaft

• Using the dial indicator, measure at the illustrated position. • If the reading exceeds the limit, replace the shaft &turbine wheel 17 .

13655

(2) Outside diameter of journal

17

If the reading exceeds the limit, replace the shaft & turbine wheel 17.

13656

(3) Rough journal

If the journal is rough, repair by the following procedures. [Repair] • Install the shaft & turbine wheel 17 on a lathe with both centers supported. • Lightly grind the journal through use of emery paper #400 and engineoil.

CAUTION~------------After the journal has been ground, be sure to measure the outside diameter of the journal.

15-50

15 (4) End play

17

If the reading exceeds the nominal value, disassemble and check to locate the cause.

[!ZI ~

Clearance between shaft & turbine wheel back surface and turbine back plate

• Using two thickness gauges, measure the clearance at the end of blade. • If any reading exceeds the nominal value, disassemble and check to locate the cause.

~ 20

~ Inspection of bearing

B

A

20

~

• Measure at the illustrated position

~

A : Outside diameter B: Inside diameter C: Length

20

• If any reading exceeds the limit, replace the bearing 20.

C

13657

~ Inspection of bearing housing 22

• Measure the inside diameter of the bearing 20 mounting portion. • If the reading exceeds the limit, replace the bearing housing 22.

13658

15-51

INTERCOOLER <6D16-TL, 16-TLE> • Disassembly sequence 1 Clamp 2 Rubber hose 3 Intercooler

• Reassembly sequence Reverse the order of disassembly.

2

> 18348

Service standards Location

Intercooler (air leak at the air pressure of 150 kPa {1.S kgf/cm2})

3

o

Standard value

Maintenance item

o

cm 3

{O mL}

Tightening torque

Location

Remedy

-

Replace

Unit: N· m {kgf· m}

Parts to be tightened Clamp (for mounting rubber hose)

1

Limit

Tightening torque 4.9 to 9.8 {O.S to 1.0}

Remarks -

• Service procedure ~ Inspection of intercooler Put a cap A on either of the air ports of the intercooler 3 and connect a hose to the other, immerse the intercooler 3 in a water tank, and apply the standard pressure from the hose side to check for air leaks. If there are air leaks, replace the intercooler.

A

18349

15-52

15

MEMO

15-53

INTAKE MANIFOLD <6014, 16, 16-E>

06

/"

7

rG

2 18338

18337

• Disassembly sequence

1 2 3 4 5

6 Bolt 7 Intake manifold

Earth plate Coupler Gasket Air heater Gasket

*3 : Non-reusable part

• Reassembly sequence

Reverse the order of removal.

o

Tightening torque

Location

6

Unit: N· m {kgf· m}

Parts to be tightened Bolt (for mounting intake manifold)

Tightening torque

Remarks

-

23 {2.37}

~ Sealants Location

7

15-54

Points of application Apply to cylinder head mounting surface of the intake manifold

Kinds ThreeBond 1207B

Quantity As required

15 • Service procedure

WInstallation of air heater A

The air heater 4 should be installed with its arrow mark A directed toward the intake manifold 7.

4

18698

[1J

• The intake manifold is installed by use of either a seat gasket or sealant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold on the cylinder head in less than three minutes after application of sealant A.

At

Installation of intake manifold

1.5

18339

CAUTION&.-------------• Thoroughly clean the sealant applying surface of the intake manifold 7 beforehand. • When the intake manifold 7 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 6 was loosened, be sure to reapply sealant A to the intake manifold 7. • Do not start the engine in less than an hour after installation.

15-55

INTAKE MANIFOLD <6D14-T, 1S-T, 16-T, 16-TE> • Disassembly sequence

<Exhaust outlet forward specification>

1 2 3 4 5

Rubber hose Earth plate <with air heater> Air inlet pipe Gasket Air heater <with air heater> Spacer <without air heater> 6 Gasket 7 Bolt 8 Intake manifold

*: Turbocharger assembly

OJ P.15-20 ., : Non-reusable part • Reassembly sequence

Reverse the order of disassembly.

18340

<Exhaust outlet rearward specification>

*

18341

15-56

15

o

Tightening torque

Location

Tightening torque

Parts to be tightened

19{1.9}

Bolt (for mounting intake manifold)

7 ~

Unit: N . m {kgf· m} Remarks -

Sealant

Location

Apply to cylinder head mounting surface of the intake manifold

8

Specified sealant

Points of application

ThreeBond 1207B

Quantity As required

• Service procedure <With air heater>

~ Installation of air heater or spacer

A

The air heater 5 or the spacer 5 should be installed with its arrow mark A directed toward the intake manifold 8.

5

18698

<Without air heater>

A

5

18699

[]] Installation of intake manifold • The intake manifold 8 is installed by use of either a seat gasket or sealant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 8. • Install the intake manifold 8 on the cylinder head in less than three minutes after application of sealant A.

Al

1.5

18339

CAUTION&-------------• Thoroughly clean the sealant applying surface of the intake manifold 8 beforehand. • When the intake manifold 8 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 7 was loosened, be sure to reapply sealant A to the intake manifold 8. • Do not start the engine in less than an hour after installation.

15-57

INTAKE MANIFOLD <6D16-TL> *

~G~

~

1

20

"'.~~. ~l

3

. I ~/.~L ! 4

~ 9

18342

• Disassembly sequence 8 Bolt 9 Intake manifold

1 Rubber hose 2 Overboost valve 3 Air inlet pipe 4 Air inlet pipe 5 Gasket 6 Spacer 7 Gasket

*: Turbocharger assembly

CD P.15-30

o :Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

o

Tightening torque Parts to be tightened

Location

rG

Unit: N· m {kgf· m} Tightening torque

Remarks

2

Overboost valve

31 {3.2}

-

8

Bolt (for mounting intake manifold)

23 {2.37}

-

Sealant

Location

9

15-58

Points of application Apply to cylinder head mounting surface of the intake manifold

Specified sealant ThreeBond 1207B

Quantity As required

15 • Service procedure

!1J Installation of spacer A

The spacer 6 should be installed with its arrow mark A directed toward the intake manifold 9.

6

18699

~ Installation of intake manifold • The intake manifold 9 is installed by use of either a seat gasket or sealant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 9. • Install the intake manifold 9 on the cylinder head in less than three minutes after application of sealant A.

Al

1.5

18339

CAUTION,&-------------• Thoroughly clean the sealant applying surface of the intake manifold 9 beforehand. • When the intake manifold 9 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 8 was loosened, be sure to reapply sealant A to the intake manifold 9. • Do not start the engine in less than an hour after installation.

15-59

INTAKE MANIFOLD <6D16-TLE>

2

0

3

4

®47071

• Disassembly sequence 1 2 3 4 5

6 Bolt 7 Intake manifold

Rubber hose Overboost valve Air inlet pipe Air inlet pipe Gasket

*: Turbocharger assembly

mP.15-30

'* :

Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

o

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

2

Overboost valve

31 {3.2}

-

6

Bolt (for fitting intake manifold)

23 {2.37}

-

~ Sealant Location

7

15-60

Points of application Apply to cylinder head mounting surface of intake manifold

Specified sealant ThreeBond 1207B

Quantity As required

[ 15 • Service procedure

m

--------------

Installation of intake manifold

• Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold 7 on the cylinder head in less than three minutes after application of sealant A.

7

CAUTION&,--------------

12256

• Thoroughly clean the sealant applying surface of the intake manifold 7 beforehand. • When the intake manifold 7 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 6 was loosened, be sure to reapply sealant A to the intake manifold 7. • Do not start the engine in less than an hour after installation.

15-61

EXHAUST MANIFOLD <6014, 16, 16-E>

18344

18343

• Disassembly sequence 1 2 3 4

5 Gasket

Nut Gasket Nut Exhaust manifold

*: Cylinder head

mGr.11

0: Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

o

Tightening torque

Location

Unit: N . m {kgf· m} Tightening torque

Parts to be tightened

Remarks

1

Nut (for mounting exhaust pipe)

41 {4.2}

-

3

Nut (for mounting exhaust manifold)

58 {5.9}

-

• Service procedure

rn

Installation of gasket

Install the gasket 5 with the grommet fold-back portion A toward the cylinder head. A

7

* 15-62

12259

15

EXHAUST MANIFOLD <6D14-T, 16-T, 16-TE, 16-TL, 16-TLE> • Disassembly sequence

1 2 3 4

Cover Nut Exhaust manifold Gasket

*: Cylinder head

OJ Gr.11

o :Non-reusable part

• Reassembly sequence

Reverse the order of disassembly.

18346

o

Tightening torque

Location

2

Unit: N . m {kgf· m}

Parts to be tightened

Tightening torque

Nut (for mounting exhaust manifold)

58 {5.9}

Remarks -

• Service procedure

[I]

Installation of gasket

Install the gasket 4 with the grommet fold-back portion A toward the cylinder head. A

7

*

12259

15-63

EXHAUST MANIFOLD <6D14-T, 16-T, 16-TE, 16-TL, 16-TLE> • Disassembly sequence 1 2 3 4 5

Front insulator Rear insulator Nut Exhaust manifold Gasket

* :Cylinder head mGr.11 o :Non-reusable part • Reassembly sequence Reverse the order of disassembly.

18347

o

Tightening torque Parts to be tightened

Location

3

Unit: N· m {kgf· m} Tightening torque

Nut (for mounting exhaust manifold)

58 {5.9}

Remarks

-

• Service procedure ~ Installation of gasket Install the gasket 5 with the grommet fold-back portion A toward the cylinder head. A

7

*

15-64

12259

21

GROUP 21 CLUTCH SPECIFICATIONS ........................................

21-2

STRUCTURE AND OPERATION 1. Clutch Body ................................................... 2. Bearing Case ..................................................

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21-3 21-5

21-8

CLUTCH BODY

21-10 21-18

BEARING CASE .................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21-28 21-34 21-40

21-1

SPECIFICATIONS Clutch Item Clutch

Specifications Model

I

C5W33

Drive system

C8W38

Strap drive

Clutch disc

Type

Single dry plate

Pressure plate

Type

Coil spring

Bearing case Item

Specifications

Model

PC4

Type Oil quantity

21-2

dm 3 {L}

PC8

Direct coupling

Lateral transmission

Lateral transmission

-

0.4 {0.4}

0.3 {0.3}

21

STRUCTURE AND OPERATION 1. Clutch Body 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

2

14

Clutch housing Clutch cover Support lever Release lever Release bearing Clutch shifter Release fork Release fork shaft Pressure spring Strap plate Pressure plate Clutch disc Flywheel Drive pinion Release lever plate

When the clutch pedal is released • By the tension of pressure spring 9, pressure plate 11 presses clutch disc 12 up against flywheel 13. • Being pressed against flywheel 13, clutch disc 12 turns with the flywheel, transmitting power to drive pinion 14 of the transmission.

01208

When the clutch pedal is depressed

3

• The hydraulic pressure generated by the clutch master cylinder operates the clutch booster. This results in release fork shaft 8 moving release fork 7, pushing out release bearing 5 with clutch shifter 6. This pushes release lever plate 15 and release lever 4. • Release lever 4 pivots about support lever 3 to compress pressure spring 9, thereby pulling back pressure plate 11. As a result, a clearance is produced between clutch disc 12 and flywheel 13 and therefore no power from the engine is transmitted to the transmission.

6

- --7

8

11

01209

21-3

STRUCTURE AND OPERATION 1 Clutch housing 2 Clutch cover 3 Support lever 4 Release lever 5 Release bearing 6 Clutch shifter 7 Release fork 8 Release fork shaft 9 Pressure spring 10 Strap plate 11 Pressure plate 12 Clutch disc 13 Flywheel 14 Drive pinion

01213

When the clutch pedal is released • By the tension of pressure spring 9, pressure plate 11 presses clutch disc 12 up against flywheel 13. • Being pressed against the flywheel, the clutch disc turns with the flywheel, transmitting power to drive pinion 14 of the transmission.

14

01214

When the clutch pedal is depressed • The hydraulic pressure generated by the clutch master cylinder operates the clutch booster. This results in release fork shaft 8 moving release fork 7, pushing out release bearing 5 with clutch shifter 6. This pushes release lever 4. • The release lever pivots about support lever 3 to compress the pressure spring, thereby pulling back the pressure plate. As a result, a clearance is produced between the clutch disc and flywheel and therefore no power from the engine is transmitted to the transmission.

13

12 01215

21-4

21 2. Bearing Case

3

2

4

1

10

9

8

6

13

7 12 1 2 3 4 5 6 7

Clutch shifter Clutch release bearing Snap ring Ball bearing Clutch shaft Oil seal Bearing case

18600

8 9 10 11 12 13

Clutch release fork shaft Clutch release fork Return spring Stopper Clutch housing Oil seal

21-5

STRUCTURE AND OPERATION 3

4

5

6

2 1

13

12 16

11 10

1 2 3 4 5 6 7 8

21-6

Clutch shifter Clutch release bearing Bearing case A Roller bearing (outer) Bearing case B Roller bearing (outer) Oil seal cover Oil seal

14 15

9 10 11 12 13 14 15 16

18601

Clutch shaft Oil seal Clutch release fork shaft Clutch release fork Return spring Stopper Clutch housing Needle roller bearing

21

7

8 9

2

1~

16

15/ 14

17 18602

1 Clutch shifter Clutch release bearing Bearing retainer Oil seal Adjust screw cover Adjust screw Bearing case B Oil seal cover Oil seal

2 3 4 5 6 7 8 9

10 Clutch shaft 11 Taper roller bearing (inner) 12 Spacer 13 Bearing case A 14 Clutch release fork shaft 15 Clutch release fork 16 Return spring 17 Clutch housing 18 Bushing

21-7

TROUBLESHOOTING Symptoms

0>

c: .8> ctl 0>

c:

Q)

c: Q)

..c: ~

0>

c:

0>

....

0

Possible causes Pressure plate & lever assembly

Defective release bearing Uneven release lever plate height Distorted or faulty pressure plate

0 0 0

Sagging pressure spring

Co

U5

Deformed disc

0 0 0

0 0 0

Worn facing

z- z

Oil on facing

Defective flywheel pilot bearing Leak in clutch fluid circuit

21-8

Q)

c:

0 0

..c:

..c:

0

Q)

~

Q)

~

Q)

Q)

!/)

!/)

·0 ·0

0 0 0

Z

0

0 0 0

0 0

0 0 0 0

0 0

0 0 0 0

Low engine idle speed Distorted, deformed, or shouldered flywheel

ctl 0>

c:

0 0 0 0

Hardened facing

Worn clutch shaft splines

"0

Remarks

0 0

Sagging or broken disc torsion spring

Rusty splines

c: Q) .!:!1

0>

c: .8>

0

Loose disc rivet

Worn splines

0>

c:

Bent strap plate Clutch disc

Q)

0> ctl

..c:

.8> .5.. c: E !/) 0> ctl

"0

0

0 0

CO Gr.13 CO Gr.11 CO Gr.11

21

MEMO

21-9

CLUTCH BODY • Removal sequence

1 Bolt 2 Pressure plate & lever assembly CD P.21-12 3 Clutch disc

* ~:

Flywheel CD Gr. 11 Positioning pin (at 2 places)

CAUTION.&.------Handle with care pressure plate & lever assembly 2 as it is heavy.

• Reinstallation sequence

Reverse the order of removal.

CAUTION.&.------2

Ensure that no oil or grease is on clutch disc 3, as a slipping clutch results.

18603

Service standards Maintenance item

Location

3

Unit: mm

Clutch disc

1.1 or less

-

Replace

Vertical runout

1.0 or less

-

Replace

0.05 to 0.23

0.5

Replace

1.8 to 2.4

0.2

Replace

Depth from facing surface to rivet

Tightening torque

Location 1

Remedy

Horizontal runout

Play in spline turning direction

o

Limit

Standard value

Unit: N· m {kgf· m}

Parts to be tightened Bolt (securing pressure plate & lever assembly)

Tightening torque

Remarks

-

32 to 49 {3.3 to 5.0}

~ Lubricant Location

3

Points of application Clutch disc splines

Specified lubricant Molybdenum disulfide grease [NLGI No.2 (Li soap)]

~ Special tools Location

3

21-10

0.7 to 0.8 g

Unit: mm Tool name and shape

Clutch Alignment Arbor

Quantity

Part No.

MH061387

Application

Holding clutch disc in pOSition

21 • Service procedure

rn

Removal and installation of pressure plate & lever assembly

• Insert [.Q Clutch Alignment Arbor in pilot bearing A of the flywheel and support clutch disc 3. • Remove bolts 1 by gradually loosening them in diagonal order. • To reinstall, reverse the order of removal. • Mount clutch disc 3 so that part no. D is visible. • Tighten bolts 1 in diagonal order, gradually up to the specified torque. 18604

D

3

CAUTION~-------------When removing pressure plate & lever assembly 2, it is raised by the tension of pressure spring B. Use care not to allow it to come off positioning pin C of the flywheel.

18605

WClutch disc 3

(1) Facing height Measure dimension A of clutch disc 3 and, if the measurement falls short of the limit, replace the clutch disc.

D$l 18606

(2) Play in spline turning direction

•

C

Machine feeler gauge B to a width with which it can be inserted into splines C of the drive pinion. Take a measurement with this feeler gauge and, if the measurement exceeds the limit, replace clutch disc 3 or drive pinion. • Take the same measurement from new clutch disc 3 and, if the measurement exceeds the limit, replace the drive pinion.

18607

(3) Grease application Coat the entire tooth surfaces of splines D of clutch disc 3 with grease. Apply the specified amount of grease to the grease groove in the splines up to the larger diameter of the splines.

D

CAUTION~ An excessive amount of grease results in grease leaking from splines D, causing the clutch to slip.

3

18608

21-11

CLUTCH BODY Pressure Plate & Lever

18610

• Jobs before disassembly

CD P.21-14 • Disassembly sequence

1 2 3 4 5 6 7 8 9 10 11

Strap bolt Washer Washer Bolt Lock plate Support nut Clutch cover Pressure spring Pressure spring cap Return spring Release lever plate

12 13 14 15 16 17 18 19

Release lever pin Release lever assembly Support lever pin Support lever Bushing Release lever Bushing Pressure plate

* : Strut plate

CAUTION~----------------------------------------------------­ Remove bushings 16 and 18 only when defects are evident. • Reassembly sequence

Reverse the order of disassembly. Repair kit: Clutch Release Lever Kit • Inspection and adjustments after reassembly

CD P.21-14

21-12

21 Service standards Location

1, * 8

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

0.01 to 0.16

0.3

Replace

840 to 930 N {85.7 to 94.7 kgf}

755 N {77 kgf}

Replace

2.7 or less

5

Replace

[10] 0.06 to 0.16

0.4

Replace

53.8 ± 0.5

Mutual difference 0.5 or less

Adjust

[10] 0.06 to 0.16

0.4

Replace

23.6 ± 0.1

21

Replace

Flatness

0.05 or less

0.2

Correct or replace.

Strap bolt hole 1.0.

10.2 +~O5

10.5

Replace

Maintenance item Clearance between strap bolt and strap plate Pressure spring

Installed load (installed length 49.1) Squareness

12,18 13 r---

14,16 19

Clearance between release lever pin and bushing Release lever plate height

Clearance between support lever pin and bushing Pressure plate

Thickness c------

L - - -______ L-.

o

----------

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened

1

Strap bolt (securing strap plate)

4

Bolt (securing lock plate)

Tightening torque

Remarks

39 to 59 {4 to 6}

-

5.9 to 7.8 {0.6 to 0.8}

-

~ Lubricant Location

Points of application

Specified lubricant

Quantity

1 6 11,13

Threads of strap bolt

LOCTITE 212

As required

Threads and spherical surfaces of support nut

Anti-seizure compound

As required

Sliding surfaces of release lever plate and release lever assembly

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

12,18 14,16 15,17

Sliding surfaces of release lever pin and bushing

Molybdenum disulfide grease

As required

Sliding surfaces of support lever pin and bushing

Molybdenum disulfide grease

As required

Sliding surfaces of support lever and release lever

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

17, 19

Sliding surfaces of release lever and pressure plate

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

~ Special tools Location

Unit: mm Tool name and shape

Clutch Alignment Arbor

Part No.

MH061986

Application

Release lever plate height adjustment

21-13

CLUTCH BODY Part No.

Tool name and shape

Location

Application

7

Clutch Installer

MH061051

Removal and installation of clutch cover

11

Clutch Master Plate

MH062291

Release lever plate height adjustment

11065

• Service procedure • Jobs before disassembly

Make alignment marks on parts before disassembly. • Inspection and adjustments after reassembly (1) Measurement of release lever plate height

• Using ~a Clutch Master Plate and ~b Clutch Alignment Arbor instead of the clutch disc, install the pressure plate & lever assembly. • Mount ~a Clutch Master Plate so that the identification mark of "5" is visible.

11066

• Check that 0.05-mm feeler gage A cannot be inserted into the space between release lever 17 and release lever plate 11. If there is a clearance, push in the feeler gage hard, then slowly remove it and eliminate the gap.

01285

• Measure dimension 8 between ~ Clutch Master Plate and each release lever plate 11 (at 4 places). • If the measurements are outside the standard range, adjust by following the steps given below. Make this adjustment if there is a difference of 0.5 mm or more between each of the measurements taken, even if each falls within the standard range.

01286

21-14

21 (2) Adjustment of release lever height

17

4

• Remove bolt 4 and lock plate 5 and turn support nut 6 to adjust the height of release lever 17. • After the adjustment has been made, mount lock plate 5 and secure support nut 6; then, check the height of release lever plate 11.

(§fS 5 11

01287

OJ [!J Clearance between strap bolt and strap plate If the measurement exceeds the limit, replace the defective part.

*

[I]

Removal and installation of clutch cover

• Using ~ Clutch Installer, compress pressure spring 8 and remove strap bolt 1, washer 2, washer 3, bolt 4, lock plate 5, and support nut 6. • Gradually loosen ~ Clutch Installer until pressure spring 8 is inactive and then remove clutch cover 7. • To install, reverse the order of removal.

01281

[]] Installation of pressure spring If pressure plate 19 has been reground, insert adjusting washer A corresponding to the amount of regrind in the space between the pressure plate and pressure spring 8. Regrind amount

~19

01280

Type and no. of washers

Less than 1 mm

Not required

1 mm or more to less than 2 mm

One 1.2-mm

2 mm or more to less than 3 mm

Two 1.2-mm or one 2.3-mm

~

[!j

Clearance between release lever pin and bushing

If the measurement exceeds the limit, replace the defective part.

CAUTIONA-------------Check bushing 18 where it is press-fitted into pressure plate 19.

21-15

CLUTCH BODY ~

[!§]

Clearance between support lever pin and bushing

If the measurement exceeds the limit, replace the defective part.

CAUTION~--------------------------­ Check bushing 16 where it is press-fitted into support lever 14.

14

01283

~ Pressure plate (1) Thickness

ill}

lLJ

C

0

For pressure plate 19 thickness, use the following procedure to measure the thickness on friction surface A. If the measurement is below the limit, replace the pressure plate. • Measure reference dimension B (part 0 which is not in contact with clutch disc C) as follows:

17153

• Measure the friction amount of friction surface A (indicated in fig.) and subtract the amount from the reference dimension B. The result is the thickness of pressure plate 19.

17166 Measurement direction

19

@

(2) Flatness

Measure the clearance between pressure plate 19 and straightedge E over the entire surface (assuming that the pressure plate is flat). If the measurement exceeds the limit, correct or replace the pressure plate.

E

18024

(3) Strap bolt hole 1.0. If the measurement exceeds the limit, replace pressure plate 19.

( 19

01290

21-16

21

MEMO

21-17

CLUTCH BODY • Disassembly sequence

1 Bolt 2 Pressure plate & lever assembly CD P.21-22 3 Clutch disc

* :Flywheel CD Gr.11 ~:

Positioning pin (at 2 places)

CAUTION&-------

o

1

Handle with care pressure plate & lever assembly 2 as it is heavy. Ensure that no oil or grease is on clutch disc 3, as a Slipping clutch results . • Reassembly sequence

Reverse the order of disassembly.

18609

Service standards Maintenance item

Location

3

Unit: mm

Clutch disc

-

Replace

Vertical runout

1.0 or less

-

Replace

0.04 to 0.11

0.3

Replace

2.2 to 2.8

0.2

Replace

Tightening torque 1

~

Remedy

1.2 or less

Depth from facing surface to rivet

Location

Limit

Horizontal runout

Play in spline turning direction

o

Standard value

Unit: N· m {kgf· m}

Parts to be tightened Bolt (securing pressure plate & lever assembly)

Tightening torque 32 to 49 {3.3 to 5.0}

Remarks

-

Lubricant

Location

3

21-18

Points of application Clutch disc splines

Specified lubricant Molybdenum disulfide grease [NLGI No.2 (Li soap)]

Quantity 0.7 to 0.8 g

21 lQ Special tools

Unit: mm Tool name and shape

Location

2

Stopper Bolt Washer

3

Clutch Alignment Arbor

49

Part No.

Application

43402-09200 (Stopper bolt) MH005024 (Washer)

Removal and installation of pressure plate & lever assembly

MH061959

Holding clutch disc in position

• Service procedure ~ Removal and installation of pressure plate & lever assembly • Insert ~a Clutch Alignment Arbor in pilot bearing A of the flywheel and support clutch disc 3. • Using ~b Stopper Bolt and ~c Washer, compress pressure spring B and then remove bolts 1. • To reinstall, reverse the order of removal. • Mount the clutch disc so that part no. 0 is visible. • Tighten bolts in diagonal order, gradually up to the specified torque.

CAUTION~--------------

o

3

18605

• If bolts 1 are removed without using ~b Stopper Bolt and ~c Washer, pressure plate & lever assembly 2 is raised by the tension of pressure spring B, damaging the strap plate and coming off positioning pin C of the flywheel. • Do not tighten ~b Stopper Bolt excessively, as doing so damages the boss of pressure plate & lever assembly 2. • Before reinstallation, clean the surface of the flywheel in contact with the clutch disc. • After reinstallation, be sure to remove ~a Stopper Bolt and ~b Washer (at 4 places). If they are left attached, the clutch will not be engaged. • To prevent clutch disc 3 from becoming off-center, pull out ~a Clutch Alignment Arbor after ~b Stopper Bolt and ~c Washer have been removed.

21-19

CLUTCH BODY @] 3

Clutch disc

(1) Facing height Measure dimension A of clutch disc 3 and, if the measurement falls short of the limit, replace the clutch disc.

rn 18606

(2) Play in spline turning direction • Machine feeler gauge B to a width with which it can be inserted into splines C of the drive pinion. Take a measurement with this feeler gauge and, if the measurement exceeds the limit, replace clutch disc 3 or drive pinion. • Take the same measurement from new clutch disc 3 and, if the measurement exceeds the limit, replace the drive pinion.

C

B

18607

(3) Grease application Evenly coat the entire tooth surfaces of splines D of clutch disc 3 with grease. Apply the specified amount of grease to the grease groove in the splines up to the larger diameter of the splines.

D

CAUTION.&.------------An excessive amount of grease results in grease leaking from splines D, causing the clutch to slip.

18608

21-20

21

MEMO

21-21

CLUTCH BODY Pressure Plate & Cover Assembly

18611

• Jobs before disassembly

CD P.21-24 • Disassembly sequence

1 2 3 4 5 6 7 8 9

Strap bolt Washer Bolt Lock plate Support nut Clutch cover Pressure spring Release lever pin Release lever assembly

10 11 12 13 14 15 16

Support lever pin Return spring Support lever Bushing Release lever Bushing Pressure plate

* : Strut plate

CAUTION~----------------------------------------------------­ Remove bushings 13 and 15 only when defects are evident. • Reassembly sequence

Reverse the order of disassembly. Repair kit: Clutch Release Lever Kit • Inspection and adjustments after reassembly

CD P.21-24

21-22

21 Service standards Maintenance item

Location

1,

*

Unit: mm

Clearance between strap bolt and strap plate

Standard value (Basic diameter in [ ])

Limit

Remedy

o to 0.15

0.3

Replace Replace

Installed load (installed length 58.2)

Wire diameter <1>5

760 to 840 N {77.43 to 85.57 kgf}

680 N {69.5 kgf}

Installed load (installed length 63.8)

Wire diameter <1>6

1090 to 1210 N {111.2 to 123.0 kgf}

975 N {99.5 kgf}

Squareness

Wire diameter <1>5

3.66

5.5

Wire diameter <1>6

3.3

5

8,15

Clearance between release lever pin and bushing

[10] 0.06 to 0.16

0.4

Replace

10, 13 14

Clearance between support lever pin and bushing

[10] 0.06 to 0.16

0.4

Replace

7

16

o

Pressure spring

Release lever height Pressure plate

65.6 ± 0.5

Adjust

-

34 ± 0.1

31

Replace

Flatness

0.05 or less

0.2

Correct or replace.

Strap bolt hole 1.0.

10.2

+g.1

10.5

Replace

Thickness

Tightening torque

Location

Replace

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Remarks

1

Strap bolt (securing strap plate)

39 to 49 {4.0 to 5.0}

-

3

Bolt (securing lock plate)

9.8 to 15 {1.0 to 1.5}

-

~ Lubricant Location

Points of application

Specified lubricant

Quantity

Threads and spherical surfaces of support nut

Anti-seizure compound

As required

8,15

Sliding surfaces of release lever pin and bushing

Molybdenum disulfide grease

As required

10,13 12,14

Sliding surfaces of support lever and bushing

Molybdenum disulfide grease

As required

Sliding surfaces of support lever and release lever

Molybdenum disulfide grease

As required

12,16

Sliding surfaces of support lever and pressure plate

Molybdenum disulfide grease

As required

Tip of release lever assembly

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

5

9

21-23

CLUTCH BODY I.&J

Special tools

Unit: mm

Stopper Bolt Washer

6

Part No.

Tool name and shape

Location

43402-09200

Application

MH005024

Removal and installation of pressure plate & lever assembly

Clutch Alignment Arbor

MH061959

Holding clutch disc in position

Clutch Installer

MH061331

Removal and installation of clutch cover

43490-00200

Release lever height adjustment

49

01306

27

15

Clutch Release Lever Aligner

19635

• Service procedure • Jobs before disassembly Make alignment marks on parts before disassembly.

• Inspection and adjustments after reassembly (1) Measurement of release lever height Install a new clutch disc and the pressure plate & lever assembly on the flywheel. P.21-19 When ~ Clutch Release Lever Aligner is applied against clutch cover 6 and clutch release lever 14, make sure that an even clearance is obtained between the aligner and the lever. If there is something wrong, make adjustment of release lever height.

en

14

19636

21-24

21 (2) Adjustment of release lever height 4

5

3

W

• Remove bolt 3 and lock plate 4 and turn support nut 5 to adjust the height of the release lever. • After the adjustment has been made, mount lock plate 4 and secure support nut 5; then, check the height of release lever 14.

14 01314

OJ [!] Clearance between strap bolt and strap plate If the measurement exceeds the limit, replace the defective part.

* 01279

[§J

Removal and installation of clutch cover

• Using [.ga Stopper Bolt and [.gb Washer, hold clutch cover 6 and pressure plate 16 in position. In this condition, remove the following parts: Strap bolt 1, washer 2, bolt 3, lock plate 4, and support nut 5.

• Using [.gc Clutch Installer, compress pressure spring 7 and remove [.ga Stopper Bolt and [.gb Washer. • Gradually loosen [.gc Clutch Installer until pressure spring 7 is inactive and then remove clutch cover 6. • To install, reverse the order of removal.

6

01309

21-25

CLUTCH BODY

o

='l!

7~

• If pressure plate 16 has been reground, insert adjusting washer A corresponding to the amount of regrind in the space between the pressure plate and pressure spring 7.

!\Io

~\b

A~ 16

Installation of pressure spring

Regrind amount

19639

Type and no. of washers

Less than 1 mm

Not required

1 mm or more to less than 2 mm

One 1.2-mm

2 mm or more to less than 3 mm Two 1.2-mm or one 2.3-mm

• Note that the pressure spring comes in two types. Fit them as shown on the left. B: Wire diameter 5 mm C: Wire diameter 6 mm

18162

[!] ~

Clearance between release lever pin and bushing

If the measurement exceeds the limit, replace the defective part.

CAUTION~--------------------------Check bushing 15 where it is press-fitted into release lever 14.

01311

[!Q] ~

Clearance between support lever pin and bushing

If the measurement exceeds the limit, replace the defective part.

CAUTION~--------------------------­ Check bushing 13 where it is press-fitted into release lever 14.

01310

21-26

21 ~ Pressure plate (1) Thickness

JB

~ --------

=-:t:=~ C

For pressure plate 16 thickness, use the following procedure to measure the thickness on friction surface A. If the measurement is below the limit, replace the pressure plate. • Measure reference dimension B (part 0 which is not in contact with clutch disc C) as follows:

0 18613

• Measure the friction amount of friction surface A (indicated in fig.) and subtract the amount from the reference dimension B. The result is the thickness of pressure plate 16.

17166 Measurement direction

16

®

(2) Flatness Measure the clearance between pressure plate 16 and straightedge E over the entire surface (assuming that the pressure plate is flat). If the measurement exceeds the limit, correct or replace the pressure plate.

E

18024

(3) Strap bolt hole 1.0. If the measurement exceeds the limit, replace pressure plate 16.

18614

21-27

BEARING CASE • Removal sequence 1 Bearing case assembly

j

*

*: Flywheel housing

CO P.21-30

CO Gr.11

• Installation sequence Reverse the order of removal.

\) ~ 18625

rG

Lubricant

Location 1

Specified lubricant

Points of application

Molybdenum disulfide grease [NLGI No.2 (U soap)]

Clutch shaft splines

[!]

Quantity As required

Bearing case assembly

[Removal] Move bearing case assembly 1 straight to the rear until the clutch shaft splines come off the clutch.

CAUTION~--------------------------­ Be sure to pull bearing case assembly 1 straight out. Rocking it hard could damage the splines between the clutch shaft and clutch.

[Reinstallation] • Check the drive pinion splines for rust. • If rust gathers on the drive pinion, remove it using a wire brush. • Rub the surfaces of the drive pinion, over which the clutch disc slides, with grease.

CAUTION~--------------------------Do not apply an excessive amount of grease, as a grease drop could cause the clutch to slip.

21-28

21

MEMO

21-29

BEARING CASE Bearing Case Assembly 5

3

2

24

rG 0

18618

• Disassembly sequence

1 2 3 4 5 6 7 8 9

Return spring Clutch shifter Release bearing Set screw Stopper Set screw Grease nipple Key Key

10 11 12 13 14 15 16 17 18

Release fork shaft Release fork Lock sheet Lock plate Snap ring Key Snap ring Roller bearing Clutch shaft

19 Bolt 20 Grease nipple 21 Oil seal 22 Bearing case 23 Needle roller bearing 24 Clutch housing

.., : Non-reusable part

CAUTION~----------------------------------------------------Do not remove release bearing 3 and needle roller bearing 23 unless defects are evident.

• Reassembly sequence

Reverse the order of disassembly.

CAUTION~--------------------------------------------------Use care not to apply an excessive amount grease through grease nipple 7. Excess grease could result in a slipping clutch.

21-30

21 Service standards

Unit: mm Maintenance item

Location

10,23

o

Release fork shaft to needle roller bearing clearance

Standard value (Basic diameter in [ ])

Limit

Remedy

[23) 0.03 to 0.08

0.12

Replace

Tightening torque

Unit: N . m {kgf· m} Tightening torque

Parts to be tightened

Location

6

Set screw (securing release fork)

19

Bolt (securing bearing case)

Remarks

17 {1.7}

-

140 {14.2}

-

~ Lubricant Location

Specified lubricant

Points of application

Quantity

2

Pack clutch shifter.

Wheel bearing grease [NLGI No.2 (Li soap))

As required

7

Through grease nipple

Wheel bearing grease [NLGI No.2 (Li soap))

As required

20

Through grease nipple

Wheel bearing grease [NLGI No.2 (Li soap))

As required

21

Coat oil seal lip

Wheel bearing grease [NLGI No.2 (Li soap))

As required

!:Q Special tools

Unit: mm Tool name and shape

Location

Part No.

Application

21

Oil Seal Insta"er

ME624241

Driving of oil seal into bearing case

23

Needle Roller Bearing Insta"er

03726-83000

Press-fitting of needle roller bearing

01320

21-31

BEARING CASE • Service procedure ~ Installation of oil seal • Face oil seal 21 as shown and fit it into bearing case 22. A: Press ~ : Oil Seal Installer

18619

~ Installation of needle roller bearing Mount needle roller bearing 23 with yellow seal end A facing outside.

23

~-A

CAUTION.&.-------------Do not directly hammer needle roller bearing 23 at installation. ~: Needle Roller Bearing Installer

01322

21-32

an MEMO

21-33

BEARING CASE • Removal sequence 1 Inspection plug Gasket Drain plug Gasket Bearing case assembly P.21-36

2 3 4 5

*

20

~'~10 '-

m

*: Flywheel housing

~-40

~'30

• Installation sequence Reverse the order of removal.

18627

o

Tightening torque

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

Remarks

1

Inspection plug

49 {5}

-

3

Drain plug

49 {5}

-

~ Lubricant Points of application

Location

5

Clutch shaft splines

Specified lubricant Molybdenum disulfide grease [NLGI No.2 (Li soap)]

Quantity As required

• Service procedure • Oil change [Discharge] • When discharging oil, check for quantity and quality of oil, and particularly for metal chips and powders.

01116

21-34

[Pouring] • Check that drain plug 3 has been tightened to specification on the flywheel housing. • Through the inspection port, pour oil until it overflows. (See specifications for the quantity of oil.)

21 []] Bearing case assembly [Removal] Move bearing case assembly 5 straight to the rear until the clutch shaft splines come off the clutch.

CAUTION&-------------Be sure to pull bearing case assembly 5 straight out. Rocking it hard could damage the splines between the clutch shaft and clutch. 01117

[Reinstallation] • Check the clutch shaft splines for rust. • If rust gathers on the clutch shaft, remove it using a wire brush. • Rub the surfaces of the clutch shaft, over which the clutch disc slides, with grease.

CAUTION&-------------------------Do not apply an excessive amount of grease, as a grease drop could cause the clutch to slip.

21-35

BEARING CASE Bearing Case Assembly

5

4

17

31

18620

• Disassembly sequence

1 Return spring Clutch shifter Release bearing Set screw Stopper Set screw 7 Grease nipple 8 Key 9 Key 10 Release fork shaft 11 Release fork

2 3 4 5 6

Lock sheet Lock plate Oil seal Rear cover Gasket Roller bearing (outer) Oil filler plug Bearing case B 20 Gasket 21 Key 22 Roller bearing (inner) 12 13 14 15 16 17 18 19

23 Snap ring 24 Roller bearing (inner) 25 Clutch shaft 26 Roller bearing (outer) 27 Bolt 28 Oil seal 29 Bearing case A 30 Needle roller bearing 31 Clutch housing

o :Non-reusable part

CAUTION~----------------------------------------------------­ Do not remove release bearing 3 and needle roller bearing 30 unless defects are evident.

• Reassembly sequence

Reverse the order of disassembly.

CAUTION~--------------------------------------------------Use care not to apply an excessive amount grease through grease nipple 7. Excess grease could result in a slipping clutch.

21-36

21 Service standards

Unit: mm

Location

10,30

o

Maintenance item

Limit

Remedy

[23] 0.03 to 0.08

0.12

Replace

Clearance between release fork shaft and needle roller bearing

Tightening torque

Location

6 27 ~

Standard value (Basic diameter in [ ])

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened Set screw (securing release fork) Bolt (securing bearing case A)

Remarks

17{1.7}

-

140 {14.2}

-

Lubricant and/or sealant

Location

Points of application

Specified lubricant and/or sealant

Quantity

2

Pack clutch shifter

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

7

Through grease nipple

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

14,28

Coat oil seal lip inner surface

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

16,20

To both sides of gasket

ThreeBond 11 02C

As required

~ Special tools

Unit: mm

Location

Tool name and shape

Part No.

Application

Oil Seal Installer 4459040100

ME624241

X

106

62

Y

80

40

14

28

30

a

14

10

b

24

20

Needle Roller Bearing Installer

44590-40100

Driving of oil seal into rear cover

ME624241

Driving of oil seal into bearing case A

03726-83000

Press-fitting of needle roller bearing

01320

21-37

BEARING CASE • Service procedure

+A

~ ~ Installation of oil seal

~

~/?V~.28 ;;;;;;;;;;:J:!.8"""":'V~

-J_I'T!:z::,-,

• Face oil seals 14 and 28 as shown and fit them into rear cover 15 and bearing case A 28, respectively. A: Press ~: Oil Seal Installer

15, 29 18619

~ Installation of needle roller bearing Mount needle roller bearing 30 with yellow seal end A facing outside.

30

~--A

CAUTION.&.-------------Do not directly hammer needle roller bearing 30 at installation. ~ : Needle Roller Bearing Installer

01322

21-38

21

MEMO

21-39

BEARING CASE • Removal sequence 1 2 3 4 5

Inspection plug Gasket Drain plug Gasket Bearing case assembly

CD P.21-42

* : Flywheel housing CD Gr.11 0: Non-reusable parts

18661

o

Tightening torque

Location

Unit: N· m {kgf· m}

Parts to be tightened

1

Inspection plug

3

Drain plug

Tightening torque

Remarks

49 {5}

-

23 {2.36}

-

~ Sealant Location

5

Points of application Clutch shaft splines

Specified sealant Molybdenum disulfide grease [NLGI No.2 (Li soap)]

Quantity As required

• Service procedure • Oil change [Discharge] • When discharging oil, check for quantity and quality of oil, and particularly for metal chips and powders.

01_1---116

L...-_ _ _ _ _ _ _ _ _ _ _ _ _

21-40

[Pouring] • Check that drain plug 3 has been tightened to specification on the bearing case assembly 5. • Through the inspection port, pour oil until it overflows. (See specifications for the quantity of oil.)

21

rn

Bearing case assembly

[Removal] Move bearing case assembly 5 straight to the rear until the clutch shaft splines come off the clutch.

CAUTION.&.-------------Be sure to pull bearing case assembly 5 straight out. Rocking it hard could damage the splines between the clutch shaft and clutch.

[Reinstallation] • Check the clutch shaft splines for rust. • If rust gathers on the clutch shaft, remove it using a wire brush. • Rub the surfaces of the clutch shaft, over which the clutch disc slides, with grease.

CAUTION.&.-------------Do not apply an excessive amount of grease, as a grease drop could cause the clutch to slip.

21-41

BEARING CASE Bearing Case Assembly

17

,-('\=~...-

~,~~\\ T

16

15 140

~

25

24

34

18712

• Disassembly sequence

1 2 3 4 5 6 7 8 9 10 11 12 13

Return spring Release bearing Grease nipple Grease nipple joint Clutch shifter Set screw Grease nipple Key Release fork shaft Release fork Bolt Bearing retainer Oil seal

14 Bolt 15 Lock sheet 16 17 18 19

20 21 22

23 24 25 26

Lock plate Key Adjust screw cover Gasket Bolt Spacer Oil seal Cover Gasket Taper roller bearing (inner) Adjust screw

27 Taper roller bearing (outer) 28 Bearing case B 29 Gasket 30 Spacer 31 Taper roller bearing (outer) 32 Bearing case A 33 Taper roller bearing (inner) 34 Clutch shaft 35 Gasket 36 Bushing 37 Clutch housing

0: Non-reusable parts

CAUTION~----------------------------------------------------Do not remove release bearing 2 and needle roller bearing 36 unless defects are evident.

21-42

21 • Reassembly order Reverse the order of disassembly.

• Adjustments after reassembly

CD P.21-44

CAUTIONLl----------------------------------------------------Use care not to apply an excessive amount grease through grease nipple 3 or 7. Excess grease could result in a slipping clutch.

Service standards Maintenance item

Location

9,37

o

Clearance between clutch release fork shaft and needle roller bearing

Standard value (Basic diameter in [ ])

Limit

Remedy

[25] 0.14 to 0.21

0.4

Replace

Tightening torque

Unit: N· m {kgf· m}

Parts to be tightened

Location

~

Unit: mm

Remarks

Tightening torque

6

Set screw (securing release fork)

17{1.7}

-

11

Bolt (securing bearing retainer)

17{1.7}

14

Bolt (securing lock plate)

78 {8}

-

20

Bolt (securing bearing case)

93 {9.5}

-

Lubricant and/or sealant Points of application

Location

Specified lubricant and/or sealant

Quantity

Through grease nipple

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

Faying surfaces of bearing retainer and clutch housing

ThreeBond 1104

As required

13,22

Coat oil seal inner surface; pack lip.

Wheel bearing grease [NLGI No.2 (Li soap)]

As required

24,29, 35

To both sides of gasket

ThreeBond 11 02C

As required

3, 7

12

~ Special tools Location

36

Unit: mm Tool name and shape

Bushing Installer

#

Part No.

44490-30100

Application

Press-fitting of bushing

<1>32

18715

21-43

BEARING CASE • Service procedures • Adjustments after reassembly • Using a screwdriver, turn adjust screw 26 in the direction of A and then back it off 2.5 to 3 threads. • Check that there is no thrust play in clutch shaft 34 and that the clutch shaft turns smoothly. • Lock the adjust screw with adjust screw cover 18.

CAUTION~---------------------------At adjustment, spacer B must be fully tightened.

~ ~ Installation of oil seal • Face oil seals 13 and 22 as shown and fit them into bearing retainer 12 and cover 23, respectively. Install jig A so that it makes contact with the side on which an oil seal is installed. B: Press

18713

~ Installation of bushing • With its groove A directed outward, install bushing 36 so that it aligns with the outside end of clutch housing 37. ~: Bushing Installer

21-44

54

GROUP 54 ELECTRICAL SYSTEM SPECIFICATIONS ....................................... .

54-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5. 6. 7. 8.

Circuit Diagram ............................•................... Alternator ..................................................... . Charging Circuit ............................................... . Starter ........................................................ . Preheating Circuit ............................................. . Engine Starter Circuit .......................................... . Safety Relay .................................................. . Automatic Stop System ........................................ .

TROUBLESHOOTING .................................... .

54-4 54-7 54-16 54-18 54-21 54-22 54-23 54-24

54-32

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Preheater System ................................ . 2. Inspection of Safety Relay ..................................... . 3. Automatic Stop System ........................................ .

54-34 54-34 54-39

ALTERNATOR <24V-35A> ...................................................... . 54-46 <24V-80A (with brush» .......................................... . 54-54 <12V-60A> ...................................................... . 54-62 <24V-40A (with vacuum pump» .................................. . 54-70 <24V-40A (without vacuum pump» ............................... . 54-78 <24V-50A> ...................................................... . 54-84 <24V-80A (brush less» ........................................... . 54-90 <24V-90A> ...................................................... . 54-96 <12V-80A> ...................................................... . 54-102

STARTER <24V-5kW> ...................................................... . 54-108 <24V-6kW> ...................................................... . 54-121 <12V-5kW> ...................................................... . 54-132

PREHEATER CIRCUIT ................................... . 54-146 ENGINE STARTER CIRCUIT .............................. . 54-149 AUTOMATIC STOP SYSTEM • Shutdown ..................................................... . 54-150 • Run-on ........................................................ . 54-154

54-1

SPECIFICATIONS Specifications

Item Alternator

MITSUBISHI ELECTRIC CORP.

Manufacturer Type

Alternator with built-in regulator, fan externally mounted type

Alternator with built-in regulator, fan internal contact type

Brushless

With brush Vacuum pump Model Output (V-A) Starter

A3TN 5379

IA3TN 5386

24-35

A6T7 6086

A2T3 2386

2480

1260

M8T60071

Output (V-kW)

Heater relay

A4T41 A4T4 0286 0299

A4T41 A4T41 A4T4 0379 0386 0399

A4T7 0099

A4T7 0199

A4TU 0286

24-50

2480

2490

1280

24-40

M5T50179

M9T50071

24-6

12-5

24-5 16 or less

Model

8 or less

U1T35383

U1X15076

Exciting current (V-A)

24-2.3

12-4

Closed magnetic voltage (V)

16 or less

8 or less

Opened magnetic voltage (V)

4 or less

3.5 or less

Allowable breaking voltage (V)

200

200

Manufacturer

Hiyoshi Denso

Voltage - capacity (V-kW)

22-1.83

22-2.9

11-1.83

Fuse capacity (A)

-

127

-

Manufacturer Model

MITSUBISHI ELECTRIC CORP. U1T31382

Voltage - current (V-A) Fuse capacity (A)

54-2

A4TU 3186

M8T60073

Magnet switch operating voltage (V)

Intake air heater

Not provided

MITSUBISHI ELECTRIC CORP.

Manufacturer Model

Starter relay

Provided

Not provided

U1T31383

U1T31384

24-2.3 91

127

U1T11373 12-4

164

127

54 --------------

Specifications

Item Glow plug

Type

Glow relay

Model

Sheathed type 23-3

Voltage - current (V-A)

UH06670

Voltage - current (V-A)

24-2.3

Fuse capacity (A)

127

Safety relay

Model

Stop solenoid

Manufacturer

R8T30174

R8T30175

Kimura Yoko

DENSO

Shut-down type

Kind

Solenoid relay

Nikko Denki

Manufacturer Kind Model

Run-on type Electromagnetic type

Type Shut-down type

Run-on type

24V

0-25000-5592

0-25000-6720

12V

0-25000-6361

0-25000-6990

54-3

STRUCTURE AND OPERATION 1. Circuit Diagram <24V (Air Heater) Specification> 13 Wire symbol

QJlli

~

Wire conductor sectional area (0.85 mm or more)

15

7

~

C BR

OFF

0

HEAT

ON START

5

3

2

1

18458

54-4

1 Starter switch 2 Heater relay 3 Air heater 4 Heater indicator 5 Battery 6 Battery relay 7 Tachometer sensor 8 Ammeter 9 Lamp switch 10 Tachometer 11 Fuse box 12 Safety relay 13 Alternator 14 Starter relay 15 Starter 16 Thermometer (for oil) 17 Thermo sending unit 18 Thermometer (for coolant) 19 Thermo sending unit 20 Oil pressure gauge 21 Oil pressure gauge unit 22 Warning lamp 23 Oil bypass alarm switch B: Terminal E: Terminal L: Terminal M : Terminal P: Terminal R : Terminal S: Terminal SW: Terminal

B E L M P R S SW

54 <24V (Glow Plug) Specification> 13 Wire symbol ~

f--

Wire conductor sectional area (0.85 mm or more)

15

11

23 -=

22 A

8

B: Terminal E: Terminal L: Terminal M: Terminal P: Terminal R: Terminal S: Terminal SW: Terminal

0.85

+

6 7 60

OFF

1 Starter switch 2 Glow relay 3 Glow plug 4 Glow indicator 5 Battery 6 Battery relay 7 Tachometer sensor 8 Ammeter 9 Lamp switch 10 Tachometer 11 Fuse box 12 Safety relay 13 Alternator 14 Starter relay 15 Starter 16 Thermometer (for oil) 17 Thermo sending unit 18 Thermometer (for coolant) 19 Thermo sending unit 20 Oil pressure gauge 21 Oil pressure gauge unit 22 Warning lamp 23 Oil bypass alarm switch

0

B E L M P R S SW

HEAT

ON

5

3

2

1

18459

54-5

STRUCTURE AND OPERATION <12V Specification> 1 2 3 4 5 6 7 8 9 10

13

11 12 13 14 15 16

15

17

18 19 20 21

11

B: Terminal E: Terminal L: Terminal M: Terminal R: Terminal S: Terminal SW: Terminal

+

8 2

5

3

2

1 18460

54-6

Starter switch Heater relay Air heater Heater indicator Battery Battery switch Tachometer sensor Ammeter Lamp switch Tachometer Fuse box Hour meter Alternator Starter relay Starter Thermometer (for coolant) Thermo sending unit Oil pressure gauge Oil pressure gauge unit Warning lamp Oil bypass alarm switch B E L M R S SW

54 2. Alternator <24V-3SA>

E

B

L)I R 2

1

12

11

10 4 9

8

7

16742

1 Rectifier 2 Stator assembly

3 4 5 6

Rotor assembly Pulley Front bearing Front bracket

7 8 9 10 11 12

Fan Rear bracket Brush spring Regulator & brush, holder Brush Rear bearing

B: Terminal E: Terminal L: Terminal P: Terminal R: Terminal

B E L P R

54-7

STRUCTURE AND OPERATION <24V-80A (with brush)>

p

R~ L

2

9

3

8

4

5

7 10625

1 2 3 4 5 6

54-8

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

7 8 9 10

Front bracket Field coil Rear bracket Regulator 11 Rear bearing 12 Brush

B: Terminal E: Terminal L: Terminal P: Terminal R: Terminal

B E L P R

54 <12V-60A>

9

8

7

16743

1 Rectifier 2 Stator assembly 3 Rotor assembly 4 Pulley 5 Front bearing 6 Fan

7 Front bracket 8 Brush 9 Brush spring 10 Rear bracket 11 Regular & brush holder 12 Rear bearing

B: Terminal E: Terminal L: Terminal R: Terminal

B E L R

54-9

STRUCTURE AND OPERATION <24V-40A (with vacuum pump»

R

L

2

3

4

5

1

11

7 09431

1 2 3 4 5 6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

54-10

7 8 9 10

Front bracket Field coil Rear bracket Regulator 11 Vacuum pump 12 Rear bearing

B: Terminal E: Terminal L: Terminal P: Terminal R: Terminal

B E L P R

54 <24V-40A (without vacuum pump), 12V-80A>

p

B

E

~

R

L

2

3

4

1

11

10

8

7

08644

1 2 3 4

Rectifier Rotor assembly Stator assembly Fan 5 Pulley 6 Front bearing

7 Front bracket 8 Field coil 9 Rear bracket 10 Regulator 11 Rear bearing

B: Terminal E: Terminal L: Terminal P: Terminal R: Terminal

8 E L P R

54-11

STRUCTURE AND OPERATION <24V-50A>

5

B

~

R

L

1

10

8

7 ®34192

1 2 3 4 5 6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

54-12

7 8 9 10 11

Front bracket Field coil Rear bracket Regulator Rear bearing

A: Neutral point diode B: Terminal B E: Terminal E L: Terminal L R: Terminal R

54 <24V-80A (brush less), gOA>

4

3

5

2

A

11

1

1 10

9

8

16744

1 Rectifier Regulator Stator assembly Field coil Fan Pulley

2 3 4 5 6

7 Front bearing 8 Front bracket 9 Rotor assembly 10 Rear bracket 11 Rear bearing

A: Neutral point diode B: Terminal B E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54-13

STRUCTURE AND OPERATION • Alternator with neutral point diode

o

.-1

,

Effectiveness of alternator with neutral pOint diode The point where three stator coils A are coupled is called the neutral point C. Addition of two diodes 0 to the current alternator which uses six diodes makes it possible to provide a higher DC output than an alternator without neutral point diodes.

B

,

A

B: Alternator terminal E: Alternator terminal F: IC regulator L: Alternator terminal R: Alternator terminal

E

B E L R

F

07033

(V) 28 -----

---------------. K

L -_ _ _ _ _ _~~--------~+_--

M

Voltage 0 Turning angle

Variations in potential at neutral pOint, and operation of neutral point diode • The potential at the neutral point C varies up and down as shown with the neutral point DC voltage (one half of the output voltage) as the center. When the alternator rotates at a very high speed, the peak values of the potential by far exceed the output voltage. (28V or more, OV or less) G: During high speed rotation H: During low speed rotation J: Neutral point voltage waveform K: Output voltage L: Mean voltage at neutral point M: Ground potential

07400

In each of the voltage and potential conditions, the neutral point diode operates as described below. • When the neutral point voltage is more than OV and less than 28V, the six conventional diodes operate.

54-14

54 • When the neutral point voltage is more than 28V

B

-'-,:1

The positive side diode N conducts to add to the conventional DC output, so a higher DC voltage is output to each equipment.

:1

,

+'

1

t t

l

R

---" E

07034

B

• When the neutral point voltage is less than OV The negative side diode P conducts, and the neutral point output is supplied via the three conventional diodes.

R

E

p 07035

54-15

STRUCTURE AND OPERATION 3. Charging Circuit

2

1

3 A

5

OFF HEAT ON START

7 <With charge lamp>

8

L - - -- - . . . J

6

<Without charge lamp> 16739

1 2 3 4 5 6 7 8

Battery Battery relay Ammeter Fuse box Alternator Safety relay Charge lamp Starter switch

54-16

A: To starter relay terminal B B: Terminal B E: Terminal E L: Terminal L R: Terminal R

54 When engine is stationary 3

2

Position of starter switch 8: ON • To improve the performance of the alternator 5 in starting power generation at a low speed immediately after the engine has been started, current is set flowing to terminal R. 1

---7

2

---7

8

-r

5 (R ---7 E) ~ 6 (R ---7 L) ---7 Earth

7 <With charge

8

lamp>

<Without charge lamp>

16740

---7 ---7

Earth 5 (L ---7 E)

• In the circuit with A charge lamp 7, current flows as shown below. 1

---7

2

---7

8

-r 5 (R ---7 E) ---7 Earth ~ 7

---7

5 (L

---7

E)

---7

Earth

After engine has been started 3

2

Position of starter switch 8: ON • The alternator 5 starts generating power. • The output voltage at terminal B of the alternator 5 becomes higher than the voltage of the battery 1. • The alternator 5 starts charging the battery

1. L

OFF HEAT

ON

8

R

5 (B)

---7

4

---7

3

---7

8 ---7 2 ---7 1

7 <With charge lamp>

<Without charge lamp>

16741

• In the case of the circuit with the charge lamp 7, the charge lamp goes out, as there is no potential difference between the voltage at terminal L of the alternator 5 and the battery voltage.

54-17

STRUCTURE AND OPERATION 4. Starter <24V-SkW>

5

5

M

6

9 10

21

17

20

19

18 17

16

15 14 13

18987

1 2 3 4 5 6 7 8 9 10 11 12 13

Rear bracket Brush Brush spring Brush holder assembly Magnet switch Lever Guide Center bracket Front bracket Sleeve bearing Stopper ring Overrunning clutch Gear bracket

54-18

14 15 16 17 18 19 20 21 22

Gearshaft Gearshaft bearing Internal gear Rubber packing Front bearing Armature Yoke assembly Rear bearing Starter relay

B: Terminal B M: Terminal M 5: Terminal S

54 <24V-SkW>

16 19

13

17 10739

10 11 12 13 14 15 16

1 Rear bracket 2 Brush 3 Brush spring 4 Brush holder assembly 5 Magnet switch 6 Ball 7 Lever 8 Front bracket 9 Spring

Pinion stopper Pinion Front bearing Overrunning clutch Washer Gearshaft assembly Internal gear assembly 17 Planetary gear 18 Packing

19 20 21 22

Yoke assembly Armature assembly Packing Rear bearing

B: Terminal B M : Terminal M S: Terminal S

This starter uses planetary gear 17 in the reduction gear mechanism.

17 13501

54-19

STRUCTURE AND OPERATION <12V-SkW> 7

6

5

8

11

~

SW (0.85-YL)

22 21

L (0.85-BY)

20

19 18 17 16 15

14 ®26396

1 Rear bracket Brush Brush spring Brush holder Magnetic switch Ball Starter relay Lever Front bracket 10 Spring

11 12 13 14 15 16 17 18 19 20

2 3 4 5 6 7 8 9

Pinion stopper Pinion Front bearing Overrunning clutch Washer Gear shaft Internal gear assembly Planetary gear assembly Rubber packing Yoke assembly

21 Armature assembly 22 Rubber packing 23 Rear bearing B: Terminal L: Terminal M: Terminal S: Terminal SW: Terminal

B L M S SW

This starter uses planetary gear 18 for the reduction gear system.

18 ®26397

54-20

54 5. Preheating Circuit

1

1 2 3 4 5 6

Starter switch Battery relay Battery Heater relay Heater indicator Intake air heater

1 2 3 4 5 6

Starter switch Battery relay Battery Heater relay Glow indicator Glow plug

5

18461



1 5

18462

54-21

STRUCTURE AND OPERATION 6. Engine Starter Circuit

3

2

1

4 ST

OFF HEAT ON START

6

5 16757

1 2 3 4 5 6

Battery Battery relay Starter relay Starter Safety relay Starter switch

54-22

------~/

54 7. Safety Relay The safety relay detects the rotating speed of the alternator. When the rotating speed exceeds the reference value, the safety relay keeps the starter inoperative even if the starter switch is accidentally set to ON while the engine is running.

p E

s

17530

P: Terminal R: Terminal L: Terminal S: Terminal E: Terminal

P R L S E

2

1

r

14

1 17531

1 Alternator 2 Starter switch 3 Battery switch 4 Battery 5 Starter relay

6 Safety relay 7 Ie regulator A: To starter terminal B

• When the starter switch 2 is set to ON, current flows from the starter relay 5 through terminal S of the safety relay 6 to terminal E, and contact P 1 closes. • When rotation of the starter causes the engine to start running, pulses with a frequency of a tenth of the alternator speed are generated at terminal P of the alternator 1. • When the pulse frequency at terminal P of the alternator 1 exceeds the reference value, the continuity between terminals Sand E is lost, and the starter remains inoperative even if the starter switch 2 is set to ON while the engine is running.

54-23

STRUCTURE AND OPERATION 8. Automatic Stop System 1 Battery 2 Starter switch 3 Battery relay 4 Stop switch 5 Solenoid relay 6 Solenoid 7 Engine oil pressure switch 8 Stop lever 9 Injection pump governor 10 Water temperature sensor

® : Engine stop signal ® : Hydraulic pressure detection signal © : Solenoid drive signal @ : Coolant temperature detection signal

5

10

9

7

18736

When the oil pressure becomes abnormal or when the coolant temperature abnormally rises while the engine is running, the automatic stop system automatically stops the engine. When anything wrong occurs in the oil pressure or coolant temperature, it is detected by the engine oil pressure switch 7 or water temperature sensor 10 which operates the solenoid relay 5. As a result, the solenoid 6 moves the stop lever 8 of the injection pump governor 9 in the direction A that the engine stops, thereby stopping the engine. The system comes in two types; the shutdown type and run-on type.

54-24

54 <Shutdown> 1

1 Solenoid relay 2 Alternator 3 Solenoid 4 Starter 5 Battery relay 6 Battery 7 Starter switch 8 Ammeter 9 Stop switch 10 Fuse box 11 Engine oil pressure switch 12 Coolant temperature sensor

~

3

4

11 10 5

6

7 18737

• On normal condition, solenoid 3 is not energized and the stop lever A of the injector pump governor is at the drive side B to keep the engine in running condition. • When a trouble occurs, solenoid 3 is energized and pulls the stop lever A to the stop side C to stop the engine.

18738

54-25

STRUCTURE AND OPERATION Before engine starts

• Position of starter switch 7: ON 6

4

~

5 -r 7 (B ~ BR) ~ 5 (coil) ~ Earth ~ 4 (B) ~ 1 (B) ~ 11 ~ 1 (W) ~ Earth

• Since no generated voltage from the alternator 2 is available at terminal A of the solenoid relay, the solenoid relay 1 remains inoperative, and no current is supplied to the solenoid 3. Therefore, the stop lever A of the injection pump governor stays at the position C where the engine can be started.

B Rl AC R2 C BR OFF 0 HEAT

ON START

7

6 18739

18740

When engine starts

• Position of starter switch 7: START

4

7

54-26

18741

When the engine is started, the generated voltage from the alternator 2 is applied to terminal A of the solenoid relay 1. At this point, the oil pressure is still low. Therefore, the contact of the oil pressure switch 11 remains closed, and current flows to terminal W of the solenoid relay 1 to actuate the solenoid relay. In the solenoid relay, however, the voltage applied to terminal A is accumulated in the capacitor, so the current does not immediately flow to the operating circuit in the relay, thereby delaying the time the solenoid relay is actuated. During the period, the engine oil pressure rises, and the contact of the oil pressure switch opens to stop the supply of current to terminal W of the solenoid relay, making the solenoid relay completely inactive.

54 When engine is automatically stopped

• When the oil pressure abnormally falls or the coolant temperature abnormally rises while the engine is running, engine oil pressure switch 11 or coolant temperature sensor (thermo switch) 12 turns on and current flows as described below. 6

~

5

--p 7 (B

~ BR) ~ 5 (coil) ~ Earth ~ 4 (B) ~ 1 (B) --p 11 ~ 1 (W) ~ Earth

~12~

4

• At this point, the current from terminal A of the solenoid relay 1 is flowing the internal circuit, the switch in the relay is activated and the current flows as follows: 1 (B) B Rl AC R2 C BR OFF 0 HEAT

6

Internal switch of the relay

~

1 (C)

~

3

~

Earth

• As a result, solenoid 3 is activated and pulls the stop lever A in direction o to stop the engine. • Even after losing the generating voltage from the alternator 2, the internal capacitor of the solenoid relay 1 keeps the solenoid 3 in position.

ON

7

~

18742

18743

When engine is manually stopped

1

• Position of stop switch 9: ON Irrespective of the generating voltage of the alternator 2, current from stop switch 9 flows to the internal circuit via ST-terminal of the solenoid relay 1 to activate the internal switch of the relay, and the current flows as follows: 1 (B)

~

Internal switch of the relay

~

1 (C)

~

3

~

Earth

• As a result, engine is stopped in the same way as the automatic stop.

B Rl AC R2 C BR OFF 0 HEAT

6

ON START

7

18744

54-27

STRUCTURE AND OPERATION

2 11

3

Solenoid relay Solenoid Stop switch Battery switch Battery Heater relay Starter switch Alternator Ammeter 10 Engine oil pressure switch 11 Coolant temperature sensor

1 2 3 4 5 6 7 8 9

B: Terminal C: Terminal H: Terminal S: Terminal

B C H S

* When the stop switch is set to ON, the contact opens. When

the switch is set to OFF, the contact closes.

7

6

5 18745

A

18746

54-28

• On normal condition, solenoid 2 is energized and the stop lever A of the injection pump governor is at the drive side B to keep the engine in running condition. • When a trouble occurs, current to activate the solenoid is cut off and solenoid 3 loses its pulling force. Then the stop lever A is pulled to the stop side C by its return spring and the engine is stopped.

54 Before engine starts Battery switch 4: ON

5 -7 4 -7 6 -7 7 (B) -7 9 -7 3 -7 1 (B) As the voltage is applied to terminal B of the solenoid relay 1, but is not applied to terminal S, the solenoid relay is not energized. Therefore, current does not flow to the solenoid relay 2 and solenoid relay 2 does not operate.

4

ON START

5

6

7

18747

When engine starts • Position of starter switch 7: START 5 -7 4 -76 -7 7 (B) -7 7 (C) -7 1 (5) -7 earth 2

1 (B)

3 10

• At this point, internal switch of the solenoid relay 1 turns on and the current flows as follows:

--p Internal coil of relay -7 Earth ~ Internal switch of relay -7 1 (C) -7 2 -7 Earth

9

• Due to the activation of the solenoid 2, the stop lever A of the injection pump governor is pulled to the position B and the engine starts.

4

7

6

5 18748

18749

54-29

STRUCTURE AND OPERATION After engine has started • Position of starter switch 7: ON The current from the starter switch (terminal C) to the solenoid relay 1 (terminal S) is cut off. However, solenoid 2 remains activated as the internal switch is kept in the ON position by the capacitor in the relay. • During this period, engine oil pressure increases to close the engine oil pressure switch 10, and the current flows as follows:

3 10

8

7 (SR) ~ 10 ~ 11 ~ 1 (H) ~ Internal coil of relay ~ Earth

9

• In this way, internal switch of relay is held ON to keep the engine running irrespective of the discontinuation of the current to the terminal S of the solenoid relay 1.

7

5

6

18750

When engine is automatically stopped When the oil pressure abnormally falls or the coolant temperature abnormally rises while the engine is running, the contact of the engine oil pressure switch 10 or coolant temperature sensor (thermo switch) 11 turns OFF to stop the supply of current to the solenoid relay, so the solenoid relay stops operating. Accordingly, the solenoid 2 also stops operating, and the stop lever A of the governor is moved to the stop position by the return spring and the engine is stopped.

3

9

4

7

6

5 18751

A

18752

54-30

54 When engine is manually stopped • Position of stop switch 3: ON (ON: Contact is opened; OFF: Contact is closed) When the current to the solenoid relay 1 (terminal 8) is cut off, the current from the solenoid (terminal C) to the solenoid 2 is also lost, and the engine is stopped in the same way as the automatic stop.

11

3 10

8

9

4

7

6

5

18753

54-31

TROUBLESHOOTING Alternator Defective conditions

-0 0)

Q)

0) .....

E :;::::; t:: 0

.s:: !/) ro c !/) 0) !/) ro 0) ..... u 0) "0 "0

.::; ;;:::

~

::::l

ro ..... 0)

0..

E 0)

~

Probable causes

0)

.s:: E .:!::-ro

>

0 .!:Q

0..

~a;

0) ro ..... c o ro .s:: :; .Cil u .0 0) C
.!:Q

O)Cilo

~ £.s::c 0) .s:: U !/)

0 0 0 0

Connector incorrectly connected, harness open-circuited, defective grounding Blown fuse Weak tension of V belt Broken V belt

0

0

Defective battery Stator coil open-circuited Stator coil and core short-circuited Field coil defective Rectifier defective Regulator defective Brush worn (if brush is provided) Sagging brush spring (if brush is provided) Defective wiring

54-32

'9.....

0)

.!:Q

~

0)

:::: ro

-

.0 ::::l

.0

.....

Q)

Remarks

"0 ..... 0"0

cO) 0) !/) ..... ._ ro ..... .s:: OU -!/) ro·c"o

.-

..... ..!.. 0)0) :::: .... :t::! CD ro 1il 1il .- 3: 0 =:> en en en ~ !/)"O C:X:o 0)

Alternator

0)

~iJ 00'

0)

.s:: .Ql .s:: 0) .....

.....

ro .s:: u !/)

0

0 0 0 0 0 0 0 0

0

0 0 0 0 0

CDGr14 CD Gr 14

54 Starter Starter starts but engine does not start

Defective condition

";::

E

£;

Ol

t:

ro

iii

"0 c en

Ol 0 "0 "-

Ol

t:

ro

Possible causes

US

Connector incorrectly connected, harness open-circuited, defective grounding

0

Blown fuse Insufficient capacity of battery Starter

Contact of magnet switch binding or deposited Coil of magnet switch open-circuited

Worn or damaged ring gear of flywheel

c Ol

..c

"~ Ol

"6>

Ol

-

0

u

Ole

E"O

0

"~ C

enro

OlOl

C"-

en en

EO

ro

Ol

00

:::l

Ol 0Ol .0 "-

t:

ro

iii

en Ciit: -ro 0_ "-en

0 c

Ol

"0 en c Ol c

0

"0 "-

ro

..c

OlOl 00l "OOl

0"0

u"5

ai"O

0"-

coO 0,,-

..cen

"- Ol Q..0l

~o lJ.."O

UJ

UJ

UJ

0

0

0

0

c"~

"-..c c_ O:::"~

"c ro

Remarks

iii

- -

.0

0 "0 Ol c

Olc

ro u

Ol c

"~ Ol c

"6> "6> "6>

~Ol

c

c

c

0

0 0

Worn or damaged pinion

Defective starter switch

"0 Ol

..cCii en-

E

-

Ol c

c

0 0 0 0

Overrunning clutch in defective operation

Defective starter relay

Ol c

..c en

0 0

0

CO Gr 11

0

Starter, Preheater Defective condition

-

"0 Ol

ro

Ol

..c

t:

Ol "0Ol .0

Remarks

-ro

en 0

"E

0 c c

ro ..c

u

Ol C

Ol c

ro

"6> "6> c

c

Possible causes

UJ

UJ

Defective heater relay or glow relay wiring

0 0 0 0 0 0

0 0 0 0

Defective battery wiring Defective air heater or glow plug wiring Defective air heater or glow plug Defective coolant temperature sensor Defective coolant temperature sensor wiring

CO Gr 14

54-33

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Preheater System • Set the starter switch to OFF. • Connect the inspection lamp 2 (24V-1.BW or thereabouts) to the glow plug 1. • Set the starter switch to the HEAT position. • If the inspection lamp 2 does not come on, check the glow plug or heater relay.

2

1

08718

2. Inspection of Safety Relay Service standards Location

Unit: mm

Maintenance item

Standard value

Limit

Output voltage at terminal P

When engine is stationary

1V or less

-

Replace alternator or wiring.

While engine is running (at idle, 600 rpm or more)

12 -16V

-

Check and replace wiring.

Output voltage at terminal R

While engine is running

Approx.24V

-

Check and replace wiring.

Output voltage at terminal S

When engine is started (in cranking state)

1V or less

-

• If the output voltage is close to the battery voltage, replace the safety relay. • If the output voltage is OV, check and replace parts

Output voltage at terminal L

While engine is running

5V or less (but not OV)

-

• Replace • If the output voltage is close to the battery voltage, inspect the alternator and herness and replace if necessary.

6

54-34

Remedy

54 (1) Checking output voltage at terminal P • Connect the voltmeter (pointer type) 7 as shown.

3

0

5

6

1 2 3 4 5 6 7

Battery Battery relay Starter switch Fuse Alternator Safety relay Voltmeter (pointer type)

A: To terminal B of starter relay 0: To terminal L of starter relay E: Terminal E L: Terminal L P: Terminal P R: Terminal R S: Terminal S

• 18469

L

5 P E

Measure the voltage between terminal P in the illustration and the ground. • If the reading is out of the standard value, the alternator 5 or wiring is defective. Check all the parts and replace defective ones. • Start the engine and let it run at idle (600 rpm or more) and measure the voltage. • If the reading is OV, the wiring to terminal P is short-circuited. Check the wiring and connector connections. Replace if defective.

S 17534

17535

54-35

ON-VEHICLE INSPECTION AND ADJUSTMENT (2) Checking output voltage at terminal R • Connect the voltmeter 7 as shown. • Place the starter switch 3 in the ON position and measure the voltage. • When the reading is out of the standard value, check the wiring. Replace if defective.

A

6

5

=

18471

L

5

P E

P

S 17534

54-36

17535

54 (3) Checking output voltage at terminal S

o

6

5

• Connect the voltmeter 7 and lamp 8 as shown. • Set the starter switch 3 to the START position and measure the voltage between the safety relay 6 (terminal S) and the earth in the cranking state. • If the reading is out of the standard value, the following points are likely to be defective. Check all the points and replace if defective. • When the reading is close to the battery voltage, the safety relay 6 is defective. • When the reading is OV, the following problems are suspected. Defective wiring Incorrectly connected connector Defective starter relay Defective starter switch

'="

-=-

18470

L

• Start the engine and let it run at idle (600 rpm or more). • Measure the voltage at terminal P. • If the reading is out of the standard value, replace the alternator 5. • In the idling state, check to ensure that the lamp 8 does not come on. When the voltage at terminal P is normal and the lamp comes on, replace the safety relay 6.

5

P E

P

S 17534

17535

54-37

ON-VEHICLE INSPECTION AND ADJUSTMENT ®

(4) Checking output voltage at terminal L (where no charge lamp is provided)

3

erminal Q~ In\ C\Q Key. B ~'<:'9~ \SJ~

o

o

6

5

=:=

18472

L

5 p

E

p

S 17534

54-38

17535

• Connect the voltmeter 7 as shown. • Place the starter switch 3 at the ON position and measure the voltage. • If the reading is out of the standard value, replace the safety relay 6. If the reading is close to the battery voltage, check the alternator 5 and wiring, and replace if defective.

54 3. Automatic Stop System <Shutdown> 1 2 3 4 5 6 7 8

1

9

4

10 11 12

11

Solenoid relay Alternator Solenoid Starter Battery relay Battery Starter switch Ammeter Stop switch Fuse box Engine oil pressure switch Water temperature sensor

10

7

18737

Measure the voltages at the terminals of the solenoid relay 1. Perform checks as described below and replace defective parts.

When starter switch 7 is placed at ON pOSition, solenoid 3 operates.

Measure voltage at terminal A. (24V available?)

Yes- - 1 Alternator 2. defective

No Measure voltage at terminal ST.

>-----1 24V

Stop switch 9 defective

I

O_V___ Solenoid relay 1 defective

L - -_ _ _ _ _ _ _

54-39

ON-VEHICLE INSPECTION AND ADJUSTMENT Even when stop switch 9 is set to ON, engine does not stop.

Measure voltage at terminal ST.

I . . .. OV ~---- Stop sWitch 9 defective

24V Measure voltage at terminal C.

-~-I

Solenoid relay 1 defective

____________2_4\,,' __ 1 Solenoid 3 defective

When oil pressure is abnormally low or coolant temperature abnormally high, engine does not stop.

* Measure while engine is running.

OV

Measure voltage at terminal w.*

Engine oil pressure switch 11 or water temperature sensor 12 defective

24V No

Measure voltage at terminal A. (28 to 29V available)*

~

1

Alternator 2 defective

Yes Measure voltage at terminal C. *

OV

I Solenoid relay 1 defective

24V

I Solenoid 3 defective

After engine has stopped, solenoid 3 is not caused to be OFF.

Measure voltage at terminal C.

,>--_O_V__ I Solenoid 3 defective

24V Measure voltage at terminal ST.

I

) -24V - - - - Stop switch 9 defective

Yes Measure voltage at terminal A. (24Vavailable?)

'>-----1 No

Yes

54-40

Solenoid relay 1 defective

.. 1 Alternator 2 defective

54 While engine is running, solenoid 3 is operated and engine stops.

Measure voltage at terminal C.*

* Measure while engine is running.

... OV__ I Solenoid 3 defective .

24V Measure voltage at terminal ST. *

24V-. .- I Stop switch 9 defective

OV Measure voltage at terminal W. *

O~ ____ I Solenoid relay 1 defective 24V ......... Engine oil pressure switch 11 or water temperature sensor 12 defective

~-.-~. ----------~-----~-----.--

~

If in order

Oil pressure or coolant temperature abnormal

54-41

ON-VEHICLE INSPECTION AND ADJUSTMENT 1

2 11

3

10

1 Solenoid relay 2 Solenoid 3 Stop switch 4 Battery switch 5 Battery 6 Heater relay 7 Starter switch 8 Alternator 9 Ammeter 10 Oil pressure switch 11 Water temperature sensor

9

8

ON START

7

6

5 18745

Measure the voltages at the terminals of the solenoid relay 1. Perform checks as described below and replace defective parts.

When the battery switch 4 is set to ON, the solenoid 2 is operated. Or when the starter switch 7 is set to the ON position with the battery switch at ON, the solenoid is operated.

~ Measure voltage at terminal S.

I

54-42

OV

24V

I Solenoid relay 1 defective Starter switch 7 defective or incorrect wiring

I

54 Even when starter switch 7 is set to ON position, solenoid 2 does not operate. (Battery switch 4: ON)

Check battery.

Defective I - - - - Battery 5 defective

Good Measure voltage at terminal B

OV

~ 24V Place starter switch 7 at START position and measure voltage at terminal S. (18V or more available?)

>--_N~O_ Battery 5 defective (Capacity insufficient when loads are placed)

Yes Measure voltage at terminal C. (Battery voltage available)

--~~I

Solenoid relay 1 defective

~

Yes I Solenoid 2 defective ~----------------------~

Is there continuity between terminals of stop switch 3?

)--_~N~o_1

Stop switch 3 defective

.. - Yes II ncorrect wiring

When starter switch 7 is returned from START position to ON pOSition, solenoid 2 operates.

Place starter switch 7 at START position and measure voltage at terminal S. (18V or more available?)

Yes

r-------j~

I

Solenoid relay 1 defective

'-----____________~N __ o ___ ·1 Battery 5 defective

54-43

ON-VEHICLE INSPECTION AND ADJUSTMENT When oil pressure is abnormally low or coolant temperature abnormally high, engine does not stop.

Measure voltage at terminal H.*

* Measure while engine is running.

24V

Engine oil pressure switch 10 or water temperature sensor 11 defective

OV

Measure voltage at terminal S. *

24V

~ I Starter switch 7 defective

OV

Measure voltage at terminal C.*

24V 1

OV

--I

Solenoid 2 defective

Solenoid relay 1 defective

Even when stop switch 3 is set to OFF, engine does not stop.

~ Measure voltage at terminal B. I

24V

I Stop switch 3 defective

OV

I Solenoid 2 defective·

While engine is running, solenoid 2 is operated, and engine stops.

* Measure while engine is running.

~ Measure voltage at terminal C. *

24V 1

Solenoid 2 defective 1

~ OV Measure voltage at terminal B. *

~

I Stop switch 3 defective

24V

I Solenoid relay 1 defective

OV

Engine oil pressure switch 10 or water temperature sensor 11 defective

~

If in order

Oil pressure or coolant temperature abnormal

54-44

I

24V

Measure voltage at terminal H.* I

OV

1

54

MEMO

ALTERNATOR <24V-3SA> • Removal sequence



1 Adjust bolt 2 Adjust shaft 3 V belt 4 Alternator assembly CD P.54-48 5 Adjust plate

* :Alternator bracket WARNING~ - - - - - - -

®16745



Before removing the alternator 4, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative 8 terminal is not disconnected, the battery voltage is always available at terminal Band is dangerous. • Installation sequence

5

Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 3.

CD Gr 14

®46895

Service standards Location

4

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

20A or more

-

2500 rpm

29A or more

-

5000 rpm

33A or more

-

28.5 ± 0.5V

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-46

54 • Service procedure

[i] DC24V

Inspection of alternator

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 4 as shown.

NOTE C

4

E

F

®16753

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch 0: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch 0 to ON. • Operate the alternator 4 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-35A I • Measure the current with the alternator 4 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 4. CD P.54-48 A

v

(2) Inspection of performance of regulator (Inspection by test bench) DC24V

G

®16755

• Wire the alternator 4 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 4 rotate at a low speed. • Increase the rotating speed of the alternator 4 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-47

ALTERNATOR <24V-35A> Alternator Assembly

9

1

16197

• Disassembly sequence 1 Rotor and front bracket assembly 2 Nut 3 4 5 6

Pulley Rear bearing Rotor assembly Cover

7 Front bearing

8 Front bracket 9 10 11 12

Stator and rear bracket assembly Stator assembly Cover Brush

NOTE Do not remove parts 4, 7,10 and 12 unless they are found to be defective . • Reassembly sequence

9:

54-48

1:

13 Regulator and brush holder CO P.54-47 14 Slinger 15 Rectifier 16 Rear bracket

54 Service standards

Unit: mm Maintenance item

Location Rotor assembly

5

Standard value

Field coil resistance (at 20°C) Slip ring outside diameter

12

o

Brush length

9 to 10.5 Q

t3

2

Replace

32.4

21.5

8

Replace

Unit: N· m {kgf· m}

-----'--~--

----------

Parts to be tightened

---.--

Remedy

-

33

Tightening torques

L.ocation

Limit

Nut {to mount pulley)

Tightening torque 132 to 162 {13.5 to 16.5}

Remarks -

• Service procedure

OJ Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 8 and stator assembly 10. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 9.

CAUTION&-------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 10 might be damaged and short-circuited.

9

1 16198

12 13

16199

[I nstallation] If the brush 12 is protruding from the regulator & brush holder 13, the rotor assembly 5 cannot be mounted on the rear bracket 16. Therefore, perform the following steps. • Push the brush 12 into the regulator & brush holder 13. • Insert the pin C from the rear of the rear bracket 16 and press the pin C against the pin hole D to hold the brush 12. If the brush 12 is worn and the pin hole D gone, hold the end of the brush 12 with the pin C. • After installation, slowly remove the pin C.

54-49

ALTERNATOR <24V-3SA> [Disassembly1

CAUTION~--------------------------­ When the rotor assembly 5 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they will be broken or damaged.

5

16223

W Removal of rear bearing

A

CAUTION~--------------------------When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush will fail to make good contact.

16224

[1]

Inspection of rotor assembly

(1) Resistance of field coil

A

• Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly

5.

04757

(2) Continuity between slip ring and core

• Check to ensure that there is no continuity between slip ring A and core B. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 5.

A

04758

(3) Outside diameter of slip ring

• If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 5. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION~-------------­

-$:59 54-50

Do corrective grinding within the extent that the outside diameter of the slip ring A does not exceed the limit.

54 [Q]

Stator assembly

[Removal] • Disconnect the leads A and remove the stator assembly 10 from the rectifier 15. The leads are soldered to the diode leads B of the rectifier. (Three places)

15

CAUTION~--------------------------­ De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

16746

[I nspection]

(1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 10.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 10.

®02337

[gI 13

Brush

[Removal] After removing the cover A, de-solder the leads of the brush 12 and remove the brush from the regulator & brush holder 13.

54-51

ALTERNATOR <24V-3SA>

13

12

[Installation] • Install the brush 12 in the regulator & brush holder 13 in the direction shown. • After installation, solder the leads of the brush 12 to the regulator & brush holder 13. Thereafter, fit the cover A as before.

16231

[I nspection] If the length of the brush 12 is near the wear limit

e,

replace.

e 04786

~ Removal of regulator & brush holder • Remove the regulator & brush holder 13 by de-soldering the two i"ustrated points A. • For installation, reverse the order of removal.

15

16232

~ Inspection of rectifier

,-----E

• Check the rectifier 15 to see if the internal diodes function properly. Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

A---~-+--+--*-'

C ---+---------+--*-+-- F D-----+--~--~

'------G G

A

A, e, C, 0: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

__~~

c

®13084

• Exchange the cases.

o

EB and e sides of the tester and perform checks in both

CAUTIONA-------------When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 15, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

F

54-52

E

16233

54

MEMO

54-53

ALTERNATOR <24V-80A (with brush» • Removal sequence 1 Adjust bolt 2 V-belt 3 Alternator assembly 4 Adjust plate

3

mP.54-56

* :Alternator bracket

WARNING~----------------------------------------------------

e

Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous .

e

• Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2.

mGr 14

Service standards Location

3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

Standard value

Limit

1500 rpm

32A or more

-

2500 rpm

64A or more

-

5000 rpm

78A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-54

54 • Service procedure

WInspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

3

E

®16753

A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at SOOO rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-80A I • Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.S4-S6 (2) Inspection of performance of regulator (Inspection by test bench)

m

A

~e ®

v

DC24V

®16755

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G : Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to SOOO rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-55

ALTERNATOR <24V-80A (with brush» Alternator Assembly

02

~

17 10699

• Disassembly sequence 1 2 3 4 5 6 7 8

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing Rotor assembly Cover

9 10 11 12 13 14 15

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Stator assembly Brush

16 Brush spring 17 Regulator & brush holder

OJ P.54-55 18 Rectifier 19 Rear bracket

o :Non-reusable part

NOTE Do not remove parts 6, 10 and 14 unless they are found to be defective. • Reassembly sequence

13

~

54-56

1

13: I 19 ~ 18 ~ 17 ~ 16

~ 15 ~ 14 I

12~11 ~10---79 I ,

1:

7~ 8~ 6 ~ 5~4~3~2

54 Service standards

Unit: mm

Location 7

Maintenance item Rotor assembly

Standard value

Field coil resistance (at 20°C) Slip ring outside diameter

o

15

Brush length

16

Spring pressure of brush spring

7.2Q

2

Remedy Replace

-

41

40.4

23

8

3.1 to 4.3 N {0.32 to 0.44 kgf}

2 N {0.2 kgf}

Tightening torques

Location

Limit

Replace

Unit: N· m {kgf' m}

Parts to be tightened Nut (to mount pulley)

Tightening torque 132 to 162 {13.5 to 16.5}

Remarks -

• Service procedure

OJ Rotor & front bracket assembly A

[Removal] • Insert a plain screwdriver A between the front bracket 12 and stator assembly 14. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 13.

CAUTION&-------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 14 might be damaged and short-circuited.

13

1 10700

15 17

16199

[I nstallation] If the brush 15 is protruding from the regulator & brush holder 17, the rotor assembly 7 cannot be mounted on the rear bracket 19. Therefore, perform the following steps. • Push the brush 15 into the regulator & brush holder 17. • Insert the pin C from the rear of the rear bracket 19 and press the pin C against the pin hole 0 to hold the brush 15. If the brush 15 is worn and the pin hole 0 gone, hold the end of the brush 15 with the pin C. • After installation, slowly remove the pin C.

54-57

ALTERNATOR <24V-80A (with brush» [Disassembly]

CAUTION~--------------------------­ When the rotor assembly 7 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they will be broken or damaged.

E

10825

[!]

Removal of rear bearing

CAUTION~---------------------------

A

When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush will fail to make good contact.

13530

[2]

A

Inspection of rotor assembly

(1) Resistance of field coil • Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly 7.

13531

B

(2) Continuity between slip ring and core

A

• Check to ensure that there is no continuity between slip ring A and core B. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 7.

13532

A

(3) Outside diameter of slip ring • If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 7. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION~ --------------------Do corrective grinding within the extent that the outside diameter of the slip ring A does not exceed the limit.

54-58

54 B]

Stator assembly

[Removal] • Disconnect the leads A and remove the stator assembly 14 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Six places)

CAUTION~--------------------------­ De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. 18

®02366

• For installation, reverse the order of removal.

[I nspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 14.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 14.

®02337

~ Brush [Removal] De-solder the illustrated points A and remove the brush 15 from the regulator & brush holder 17.

17

CAUTION~--------------------------De-soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time. 15

02353

54-59

ALTERNATOR <24V-80A (with brush» [I nstallation] • Install the brush 15 in the regulator & brush holder 17 in the direction shown. • Mountthe pin C in the hole B of the brush 15 to make sure that the brush does not protrude from the regulator & brush holder 17. • After installation, solder the leads of the brush 15 to the illustrated points A.

CAUTION~--------------------------­ Soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time.

B

• After soldering, remove the pin C.

15

11021

[Inspection] If the length of the brush 15 is less than the limit, replace. D : Length when new E: Service limit length

DE

02355

~ Rectifier [Removal] • Remove the rectifier 18 by de-soldering the illustrated portion A.

CAUTION~ --------------------------De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal. 02357

54-60

54 [Inspection] • Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

E

B C

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

F

D

G

B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

®13084

E

•

Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION&' When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. B

C

G

D

®13083

54-61

ALTERNATOR <12V-60A> • Removal sequence

1 Adjust bolt 2 V-belt 3 Alternator assembly IT] P.54-64 4 Adjust plate

* :Alternator bracket

16748

*

WARNING~---------------------------------------------------­ Before removing the alternator 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with

a tape or something else. If the negative e terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous .

• Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2. IT] Gr 14

Service standards Location

3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

26A or more

-

2500 rpm

45A or more

-

5000 rpm

53A or more

-

14.4 ± 0.3V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-62

54 • Service procedure

[II DC12V

Inspection of alternator

(1) Inspection of performance of alternator (Inspection by test bench)

• Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

3

B

F

R 16749

A: Ammeter B: Alternator terminal B C: Switch 0: Switch E: Alternator terminal E F: Load resistance (variable resistance) G : Alternator drive motor R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch 0 to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 12V-60A I • Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. CO P.54-64

A

(2) Inspection of performance of regulator (Inspection by test bench)

DC12V

5J

EEl

8

B G

16750

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-63

ALTERNATOR <12V-60A> Alternator Assembly

• Disassembly sequence 1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan 5 Spacer 6 Spring 7 Rear bearing 8 Rotor assembly 9 Cover

10 11 12 13 14 15 16 17

Cover Front bearing Cover Oil seal Front bracket Stator & rear bracket assembly Stator assembly Connector

NOTE Do not remove parts 7,11 and 16 unless they are found to be defective . • Reassembly sequence

15 -7 1

54-64

15:

20

-7

19 -7 18 ~ 21-716~22-717

1:

18 Brush 19 Brush spring 20 Regulator & brush holder CD P.54-63 21 Rectifier 22 Rear bracket

0: Non-reusable part

54 Service standards

Unit: mm

Location Rotor assembly

8

Standard value

Maintenance item Field coil resistance (at 20°C) Slip ring outside diameter

o

18

Brush length

19

Spring pressure of brush spring

2.4

Q

Replace

-

40.4

23

8

Replace

3.1 to 4.3 N {0.32 to 0.44 kgf}

2 N {0.2 kgf}

Replace

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

132 to 162 {13.5 to 16.5}

Nut (to mount pulley)

2

Remedy

40.8 to 41.2

Tightening torques

Location

Limit

Remarks -

• Service procedure

[I] A

Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 14 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 15.

CAUTION&-------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

B

15

1 10700

o

18 20

16199

[Installation] If the brush 18 is protruding from the regulator & brush holder 20, the rotor assembly 8 cannot be mounted on the rear bracket 22. Therefore, perform the following steps. • Push the brush 18 into the regulator & brush holder 20. • Insert the pin C from the rear of the rear bracket 22 and press the pin C against the pin hole 0 to hold the brush 18. Ifthe brush 18 is worn and the pin hole 0 gone, hold the end ofthe brush 18 with the pin C. • After installation, slowly remove the pin C.

54-65

ALTERNATOR <12V-60A> [Disassembly]

CAUTION&-------------When the rotor assembly 8 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they will be broken or damaged.

E

10825

WRemoval of rear bearing A

CAUTION&-------------When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush will fail to make good con- . tact.

13530

[[] Inspection of rotor assembly A

(1) Resistance of field coil • Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly 8.

13531

B

(2) Continuity between slip ring and core

A

• Check to ensure that there is no continuity between slip ring A and core B. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 8.

13532

A

(3) Outside diameter of slip ring • If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 8. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION&------------Do corrective grinding within the extent that the outside diameter of the slip ring A does not exceed the limit.

54-66

54 ~ Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 21. The leads are soldered to the diode leads B of the rectifier. (Six places)

CAUTION&-------------De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. 16

®02335

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads

• Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

(2) Continuity between each lead and core

• Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 16.

®02337

~ Brush [Removal] De-solder the illustrated points A and remove the brush 18 from the regulator & brush holder 20.

20

CAUTION&-------------De-soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time. 18

02353

54-67

ALTERNATOR <12V-60A> [I nstallation] • Install the brush 18 in the regulator & brush holder 20 in the direction shown. • Mountthe pin C in the hole B of the brush 18 to make sure that the brush does not protrude from the regulator & brush holder 20. • After installation, solder the leads of the brush 18 to the illustrated points A.

CAUTIONLt.-------------Soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time.

B

• After soldering, remove the pin C.

18

11021

[Inspection] If the length of the brush 18 is less than the limit, replace. D : Length when new E: Service limit length

DE

02355

~ Inspection of rectifier

.-----D

• Check the rectifier 21 to see if the internal diodes function properly, and replace if defective. A-----+--~--+---~~

B ----+-+---11--___+-+_- E c---+-1-~~

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

__~~

'------- F

®13084

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected • Exchange the EB and cases.

e sides of the tester and perform checks in both

CAUTIONLt.-------------When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 21, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

54-68

54

MEMO

54-69

ALTERNATOR <24V-40A (with vacuum pump» • Removal sequence

1 2 3 4 5 6 7

Vacuum pipe Oil return hose Oil inlet hose Adjust plate V-belt Alternator assembly CD P.54-72 Adjust plate

* :Alternator bracket

*

16752

WARNING~---------------------------------------------------­

e

Before removing the alternator 6, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous .

e

• Installation sequence

Reverse the order of removal. • Adjustment after installation

Adjust the tension of the V-belt 5.

CD Gr 14

Service standards Location

6

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less) *;

Standard value

Limit

1500 rpm

24A or more

-

2500 rpm

33A or more

-

5000 rpm

37A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

"When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-70

54 • Service procedure

[§J DC24V

Inspection of alternator

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 6 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

6

E

®16753

A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 6 at SOOO rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-40A I • Measure the current with the alternator 6 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check P.S4-72 the alternator 6.

m

(2) Inspection of performance of regulator A

EEl

~8

v

(Inspection by test bench) DC24V

®16755

• Wire the alternator 6 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V : Voltmeter • Set the switch C to ON. • Let the alternator 6 rotate at a low speed. • Increase the rotating speed of the alternator 6 to SOOO rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-71

ALTERNATOR <24V-40A (with vacuum pump» Alternator Assembly

14 10114

• Disassembly sequence 1 Vacuum pump assembly P.54-76 2 a-ring 3 Rotor & front bracket assembly 4 Nut 5 Pulley 6 Fan 7 Spacer

m

8 9 10 11 12 13 14

Rear bearing Rotor assembly Cover Front bearing Front bracket Stator & rear bracket assembly Stator assembly

NOTE Do not remove parts 8, 11 and 14 unless they are found to be defective. • Reassembly sequence

13:

54-72

19--+18

16Y17~15~14

I

15 16 17 18 19

Field coil Regulator P.54-71 Rectifier Oil seal Rear bracket

m

0: Non-reusable part

54 Service standards Location

Standard value

Field coil resistance (at 20°C)

15

o

Maintenance item

Approx. 6.2

Q

Tightening torques

Location

-

Remedy Replace

Unit: N· m {kgf' m}

Parts to be tightened

Tightening torque

Nut (to mount pulley)

4

Limit

132 to 162 {13.5 to 16.5}

Remarks

-

• Service procedure

@]

18

Rotor & front bracket assembly

[Removal]

CAUTION~--------------------------Wind a tape around the spline portion A of the shaft of the rotor & front bracket assembly 3 to prevent damage to the oil seal 18 at the time of removal.

10116

• Insert a plain screwdriver A between the front bracket 12 and stator assembly 14. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 3 from the stator & rear bracket assembly 13.

CAUTION~--------------------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 14 might be damaged and short-circuited.

13

3 10701

54-73

ALTERNATOR <24V-40A (with vacuum pump» [Disassembly]

C

CAUTION~--------------------------When the rotor assembly 9 is held in a vice, make sure that the base B of the lugs of the core is held. If the lugs C of the core are held, they will be broken or damaged.

10819

~ Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 14 from the rectifier 17. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION~--------------------------­ 14 ®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

[I nspection]

(1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 14.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 14.

®02337

54-74

54 ~ Field coil [Removal] • Remove the two screws A.

CAUTION.&-------------If the screws B are removed fi rst, the weight of the field coil 15 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first.

A

16118

• Remove the three screws B.

CAUTION.&-------------When the screws B are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 15.

CAUTION.&-------------When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between the terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

[IZllnspection of rectifier

r-----D

• Check the rectifier 17 to see if the internal diodes function properly, and replace if defective.

A-----+--~--+---~~

B------+--------+---~--..-E

L------F

®13084

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected • Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION.&-------------When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 17, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. A

B

F

c

®13083

54-75

ALTERNATOR <24V-40A (with vacuum pump» Vacuum Pump Assembly • Disassembly sequence 1 2 3 4 5 6

Vacuum housing O-ring Vane Rotor Plate O-ring

* :Alternator CO P.54-72

o :Non-reusable part

• Reassembly sequence Reverse the order of removal. 5

00359

Service standards Location

-

54-76

Maintenance item Attainable vacuum pressure (when alternator speed is 1500 rpm)

Standard value 93 kPa {700 mmHg or more}

Limit -

Remedy -

54

MEMO

54-77

ALTERNATOR <24V-40A (without vacuum pump» • Removal sequence

1 2 3 4

3

Adjust bolt V-belt Alternator assembly Adjust plate

CO P.54-80

* :Alternator bracket

WARNING~---------------------------------------------------Before removing the alternator 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative 8 terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous . • Installation sequence

Reverse the order of removal. • Adjustment after installation

Adjust the tension of the V-belt 2.

CO Gr 14

Service standards Location

3

Standard value

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

Limit

1500 rpm

24A or more

-

2500 rpm

33A or more

-

5000 rpm

37A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-78

54 • Service procedure []] Inspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

3

E

F

®16753

A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current !24V-40A!

A

®

~e

v

• Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. OJ P.54-80 (2) Inspection of performance of regulator (Inspection by test bench) DC24V

®16755

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V : Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-79

ALTERNATOR <24V-40A (without vacuum pump» Alternator Assembly

~

~

12

'~

1

~

17

1)1>$

~

15

16

14

16754

• Disassembly sequence

1 2 3 4 5 6 7

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing Rotor assembly

8 9 10 11 12 13

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Stator assembly

NOTE Do not remove parts 6, 9 and 13 unless they are found to be defective . • Reassembly sequence

12

~

54-80

1

12:

17--+16 15

Y

14~13

I

1:

14 15 16 17

Field coil Regulator CD P.54-79 Rectifier Rear bracket

0: Non-reusable part

54 Service standards Location 14

o

Maintenance item

Standard value

Field coil resistance (at 20°C)

5.8 to 6.6

Q

Tightening torques

Location

2

Limit -

Remedy Replace

Unit: N· m {kgf· m}

Parts to be tightened Nut (to mount pulley)

Tightening torque

Remarks

132 to 162 {13.5 to 16.5}

-

• Service procedure

OJ Rotor & front bracket assembly

A

[Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 13. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION~---------------------------­ If the plain screwdriver A is inserted too far, the coil B of the stator assembly 13 might be damaged and short-circuited.

12

1

09525

[Disassembly]

CAUTION~ ----------------------When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

7

c

02319

54-81

ALTERNATOR <24V-40A (without vacuum pump» ~ Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 13 from the rectifier 16. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION~--------------------------­ 13

®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads

• Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 13.

®02336

(2) Continuity between each lead and core

• Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 13.

®02337

54-82

54 B]

Field coil

[Removal] • Remove the two screws A.

CAUTION&,-------------If the screws B are removed first, the weight of the field coil 14 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first.

A

16118

• Remove the three screws B.

CAUTION&,---------------------------When the screws B are removed, the field coil will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 14.

CAUTION&,-------------When the field coil is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

02325

[!§]

D

Inspection of rectifier

• Check the rectifier 16 to see if the internal diodes function properly, and replace if defective. A B

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

E

C

F

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected

®13084

D

•

Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION&' When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 16, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. A

B

F

C

®13083

54-83

ALTERNATOR <24V-50A> • Removal sequence

1 Adjust bolt 2 V-belt 3 Alternator assembly 4 Adjust plate

CO

P.S4-86

* :Alternator bracket

*

®46896

WARNING~----------------------------------------------------­

e

Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous .

e

• Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2.

CO Gr 14

Service standards Location

3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

24A or more

-

2500 rpm

38A or more

5000 rpm

45A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-84

54 • Service procedure

WInspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

3

E

F

®16753

A: Ammeter B: Alternator terminal B C: Switch 0: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch 0 to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current [24V-50A [ • Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.54-86

m

A

v

(2) Inspection of performance of regulator (Inspection by test bench) DC24V

®16755

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-85

ALTERNATOR <24V-50A> Alternator Assembly

®42355

• Disassembly sequence 1 2 3 4 5 6

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing

7 Rotor assembly 8 Cover 9 Front bearing 10 Front bracket 11 Stator & rear bracket assembly 12 Screw

NOTE Do not remove parts 6, 9 and 15 unless they are found to be defective . • Reassembly sequence

11

~

54-86

1

11:

18--+17 16

Y

15 ~ 14 ~ 13 ~ 12 I

1:

13 14 15 16 17 18

Screw Field coil Stator assembly Regulator P.54-85 Rectifier Rear bracket

m

54 Service standards 14

o

Standard value

Maintenance item

Location

5.1 to 6.0

Field coil resistance (at 20°C)

Q

Tightening torques 2

-

Remedy Replace

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Location

Limit

132 to 162 {13.5 to 16.5}

Nut (to mount pulley)

Remarks

-

• Service procedure

[IJ

A

Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 10 and stator assembly 15. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 11.

CAUTION~--------------------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 15 might be damaged and short-circuited.

1

11

®42356

[Disassembly]

CAUTION~---------------------------­ When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs 0 of the core are held, they will be broken or damaged.

c

®4241 0

54-87

ALTERNATOR <24V-50A> ~ Field coil [Removal] • Remove the two screws 12.

CAUTION~---------------------------­ If the screws 13 are removed first, the weight of the field coil 14 will act on the portion connected to the regulator 16 and secured by the screws 12, and damage to the connected portion may result. Therefore, make sure that the screws 13 are removed first. ®19134

• Remove the three screws 13.

CAUTION~--------------------------­ When the screws 13 are removed, the field coil 14 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 14.

CAUTION~--------------------------­ ®30765

When the field coil 14 is taken out, the portion connected to the regulator 16 may be caught by the stator coil. Don't pull it out with undue force.

[I nspection] • Measure the resistance between terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

®16636

~ Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 15 from the rectifier 17. The leads are soldered to the diode B of the rectifier. (four places)

CAUTION~--------------------------De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

15 ®02335

• For installation, reverse the order of removal.

54-88

--_/~

54 [I nspection 1 (1) Continuity between leads

• Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 15.

®02336

'----------------

(2) Continuity between each lead and core

• Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 15.

®O2337

[IZJ E

Inspection of rectifier

• Check the rectifier 17 to see if the internal diodes function properly, and replace if defective.

A

B

C

F

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

D G ®15270

E

B

A, B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

• Exchange the cases.

EB and e sides of the tester and perform checks in both

CAUTION&-------------When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 17, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. ®15271

54-89

ALTERNATOR <24V-80A (brush less» • Removal sequence 1 Adjust bolt 2 Adjust shaft 3 V-belt 4 Alternator assembly 5 Adjust plate

CD P.54-92

* :Alternator bracket

®46897

WARNING~---------------------------------------------------­ Before removing the alternator 4, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative 8 terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous . • Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 3.

CD Gr 14

Service standards Maintenance item

Location

4

Alternator output current (When 27V is generated)

Alternator speed

When cold

* When hot

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

56A or more

-

2500 rpm

86A or more

-

5000 rpm

77A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-90

54 • Service procedure

[I] DC24V

Inspection of alternator

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 4 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

4

E

F

®16753

A: Ammeter B: Alternator terminal B C: Switch 0: Switch E: Alternator terminal E F: Load resistance (variable resistance) G : Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch 0 to ON. • Operate the alternator 4 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-80A I

A

v

• Measure the current with the alternator 4 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 4. CD P.54-92 (2) Inspection of performance of regulator (Inspection by test bench) DC24V

®16755

• Wire the alternator 4 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 4 rotate at a low speed. • Increase the rotating speed of the alternator 4 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-91

ALTERNATOR <24V-80A (brush less» Alternator Assembly

16 16756

• Disassembly sequence

1 2 3 4 5 6 7

Rotor & front bracket assembly Nut Pulley Fan Nut Rear bearing Rotor assembly

8 9 10 11 12 13 14

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Screw Screw

NOTE Do not remove parts 6, 9 and 16 unless they are found to be defective . • Reassembly sequence

12

~

54-92

1

12:

19-->18 17

Y

16

~ 15 ~ 14 ~ 13

I

15 16 17 18 19

Field coil Stator assembly Regulator P.54-91 Rectifier Rear bracket

m

., : Non-reusable part

54 Service standards 15

Standard value

Maintenance item

Location

Limit

Field coil resistance (at 20°C)

(; Tightening torques Location

2 ~

Remedy

-

2.6 to 3.4 1'2

Replace Unit: N· m {kgf· m}

Tightening torque

Parts to be tightened

132 to 162 {13.5 to 16.5}

Nut (to mount pulley)

Remarks -

Lubricants Points of application

Location

10

Kinds Supplied with the service part oil seal

Apply to the oil seal lip

Quantity As required

• Service procedure

[I]

A

Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION&-------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

1

12

09525

[Disassembly]

o

CAUTION&-------------When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs 0 of the core are held, they will be broken or damaged.

7

C

02319

54-93

ALTERNATOR <24V-80A (brush less» ~ Field coil [Removal] • Remove the two screws 13.

CAUTION~--------------------------­

14

If the screws 14 are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws 13, and damage to the lead portion may result. Therefore, make sure that the screws 13 are removed first. 19140

• Remove the three screws 14.

CAUTION~--------------------------When the screws 14 are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 15.

CAUTION~--------------------------When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

[!§]

Stator assembly

[Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION~---------------------------­ 16 ®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

54-94

54 [I nspection1 (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 16.

®O2337

~ Inspection of rectifier

D

• Check the rectifier 18 to see if the internal diodes function properly, and replace if defective. A B

E

Resistance infinite in both cases .... Open Resistance close to n in both cases ... Short

®13084

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected

C

F D

•

Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION'& When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. A

B

F

C

®13083

54-95

ALTERNATOR <24V-90A> • Removal sequence 1 Adjust bolt 2 V-belt 3 Alternator assembly 4 Adjust plate

3

mP.54-98

* :Alternator bracket A: B: C: E:

Connect to Connect to Connect to Connect to

terminals Land R. terminal B. terminal C. terminal E.

®16747

WARNING&' - - - - - - - - - - - - - - - - - - - - - - - - - -

e

Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative e terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous . • Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2.

mGr 14

Service standards Location

3

Maintenance item Alternator output current (When 27V is generated)

Alternator speed

When cold

*When hot

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

53A or more

-

2500 rpm

82A or more

-

5000 rpm

86A or more

-

28.5 ± 0.5V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-96

54 • Service procedure

WInspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

3

E

F

®16753

A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-90A I • Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.54-98

m

(2) Inspection of performance of regulator A

~e ®

v

(Inspection by test bench) DC24V

®16755

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-97

ALTERNATOR <24V-90A> Alternator Assembly

16 16756

• Disassembly sequence

1 2 3 4 5 6 7

Rotor & front bracket assembly Nut Pulley Fan Nut Rear bearing Rotor assembly

8 9 10 11 12 13 14

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Screw Screw

NOTE Do not remove parts 6, 9 and 16 unless they are found to be defective . • Reassembly sequence

12 -71

12:

19-->18

17

54-98

Y

16 -715 -714

-71~

I

15 16 17 18 19

Field coil Stator assembly Regulator CD P.54-97 Rectifier Rear bracket

0: Non-reusable part

54 Service standards Maintenance item

Location 15

o

2.6 to 3.4

Field coil resistance (at 20°C)

n

2

Remedy Replace

-

Tightening torques

Unit: N· m {kgf· m}

Parts to be tightened

Location

rG

Limit

Standard value

Tightening torque 132 to 162 {13.5 to 16.5}

Nut (to mount pulley)

Remarks -

Lubricants

Location

10

Points of application

Kinds

Apply to the oil seal lip

Supplied with the service part oil seal

Quantity As required

• Service procedure

OJ Rotor & front bracket assembly

A

[Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION~---------------------------­ If the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

12

1

09525

[Disassembly]

CAUTION~----------------------------

D

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

7

c

02319

54-99

ALTERNATOR <24V-90A> ~ Field coil [Removal] • Remove the two screws 13.

CAUTION~--------------------------­ If the screws 14 are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws 13, and damage to the lead portion may result. Therefore, make sure that the screws 13 are removed first. 19140

• Remove the three screws 14.

CAUTION~ --------------------------When the screws 14 are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 15.

CAUTION~---------------------------­ When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

II§]

Stator assembly

[Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION~--------------------------16 ®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

54-100

54 [I nspection1

(1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 16.

®O2337

B] E

Inspection of rectifier

• Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

A

B

C

F

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

0 G ®15270

E

B

A, B, C, 0: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected • Exchange the cases.

EB and e sides of the tester and perform checks in both

CAUTION.&.-------------When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. ®15271

54-101

ALTERNATOR <12V-80A> • Removal sequence

1 Adjust bolt 2 3 4 5

3

V-belt Alternator assembly Adjust plate Alternator bracket

CD P.54-104

®16747

WARNING~---------------------------------------------------­

e

Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

e

• Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2.

CD Gr 14

Service standards Location

3

Maintenance item Alternator output current (* When hot, when 13.5V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

Standard value

Limit

1500 rpm

38A or more

-

2500 rpm

65A or more

-

5000 rpm

76A or more

-

14.7 ± 0.3V

-

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-102

54 • Service procedure

[ill DC12V

Inspection of alternator

(1) Inspection of performance of alternator (Inspection by test bench)

• Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured.

C

3

E

®16753

A: Ammeter B: Alternator terminal B C: Switch 0: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch 0 to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current 112V-80A I • Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.54-104 (2) Inspection of performance of regulator (Inspection by test bench)

m

A

v

DC12V

G

®16755

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G : Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-103

ALTERNATOR <12V-80A> Alternator Assembly ~

o 10

13

~

1

14

1

19

.J

17 18

16758

• Disassembly sequence

1 2 3 4 5 6 7

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing Rotor assembly

8 9 10 11 12 13 14

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Screw Screw

NOTE Do not remove parts 6, 9 and 16 unless they are found to be defective . • Reassembly sequence

12

~

1

54-104

12:

19--+18 17

Y

16

~ 15 ~ 14 ~ 13

I

15 16 17 18 19

Field coil Stator assembly Regulator CD P.54-103 Rectifier Rear bracket

o :Non-reusable part

54 Service standards 15

o

Standard value

Maintenance item

Location

2.6 to 3.4 12

Field coil resistance (at 20°C)

Tightening torques

Location 2

Limit

Remedy Replace

-

Unit: N· m {kgf· m}

Parts to be tightened

Tightening torque

Nut (to mount pulley)

132 to 162 {13.5 to 16.5}

Remarks -

r0, Lubricant Points of application

Location

10

Specified lubricant

Apply to the oil seal lip

Supplied with the service part oil seal

Quantity As required

• Service procedure

[I]

A

Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION&-------------If the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

1

12

09525

[Disassembly]

CAUTION&-------------When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

7

c

02319

54-105

ALTERNATOR <12V-80A> ~ Field coil [Removal] • Remove the two screws 13.

14

CAUTION~--------------------------­ If the screws 14 are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws 13, and damage to the lead portion may result. Therefore, make sure that the screws 13 are removed first. 20015

• Remove the three screws 14.

CAUTION~--------------------When the screws 14 are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 15.

CAUTION~------------------------­ When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

~ Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION~--------------------------­ 16 ®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

54-106

54 [I nspection1 (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 16.

®O2337

~ Inspection of rectifier

D

• Check the rectifier 18 to see if the internal diodes function properly, and replace if defective. A B

E

Resistance infinite in both cases .... Open Resistance close to Q in both cases ... Short

®13084

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected

C

F D

•

Exchange the cases.

EB and e sides of the tester and perform checks in both

CAUTION& When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. A

B

F

C

®13083

54-107

STARTER <24V-SkW> • Removal sequence 1 2 3 4

1

Starter relay CD P.54-149 Battery cable EB Earth strap Starter assembly CD P.54-11 0

B: Terminal B S: Terminal S

WARNING'& - - - - - - - - - - Before removing the starter assembly 4, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative 8 terminal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous . • Installation sequence Reverse the order of removal.

16759

54-J08

[ 54

I

MEMO

54-109

STARTER <24V-SkW> Starter Assembly

Ii

Ii

29

27

I\~~

~

21

7

36

\~ 19

Ii 4

20

17 18 15

®47262

• Disassembly sequence

1 Stopper ring 2 Pinion stopper 3 Pinion 4 Spring 5 Magnet switch 6 Shim 7 Rear bracket 8 Packing 9 Yoke & brush holder assembly 10 Brush spring 11 Brush e 12 Brush holder assembly 13 Yoke assembly 14 Brush EEl

54-110

15 16 17 18 19

20 21

22 23 24 25 26 27

Yoke Armature assembly Rear bearing Armature Ball Front bracket assembly Cover Packing Planetary gear Packing Plate Gearshaft & overrunning clutch assembly E-ring

28 Gearshaft & Internal gear assembly 29 Gearshaft assembly 30 Washer 31 Internal gear 32 Overrunning clutch 33 Lever assembly 34 Front bearing 35 Oil seal 36 Front bracket

0: Non-reusable part

54 CAUTION~----------------------------------------------------• Do not remove the bearings 17 and 34 unless defects are evident. • When the armature assembly 16 is removed, the ball 19 might come out with it. Take care not to lose the ball. • It is not necessary to remove the pinion 3 when only the motor should be removed and inspected for inspection of the brushes and the related parts. • Be sure to remove the pinion 3 before disassembling any other parts.

• Assembly sequence Follow the disassembly sequence in reverse.

CAUTION~----------------------------------------------------­ Whenever the magnetic switch 5 is replaced, the pinion gap must be adjusted. • Inspection after reassembly

CD P.54-112 Service standards Location

10 11,14

Unit: mm Maintenance item

Standard value

During 23V supply

-

Adjust

85A or less

-

Check

3300 rpm or more

-

Current Rotating speed

Spring pressure of brush spring

Remedy

0.5 to 2.0

Pinion gap No-load characteristics

Limit

29 to 39 N {3 to 4 kgf}

20 N {2 kgf}

Replace

Brush length

18

11

Replace

Outside diameter of commutator

32

31.4

Replace

Commutator outer circumferential runout

-

0.05 or more

Depth of mica between segments

-

0.2 or less

--

16

Ii

Repair or replace

Lubricant

Location

Points of application

Specified lubricant

Quantity

5

Lever contact surface of magnetic switch

Multipurpose grease [NLGI No.2 (Li soap))

16

Teeth of armature assembly gear

MOLYKOTE

® AG650

As required

Sliding surfaces of armature assembly and gear shaft assembly

MOLYKOTE

® AG650

As required

Ball

MOLYKOTE

® AG650

As required

23,31

Teeth of planetary gear and internal gear

MOLYKOTE

® AG650

As required

29,32

Sliding surfaces of gear shaft assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap))

30

Washer

MOLYKOTE

32

Splines of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap))

As required

33

Sliding surfaces of lever assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap))

As required

16,29 19

® AG650

As required

As required As required

54-Ill

STARTER <24V-SkW> • Service procedure • Inspection after reassembly After reassembly, check the starter by supplying current.

WARNING&' - - - - - - - - - - - - - - • When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it.

®14266

CAUTION&.------------------------• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

®14257

(1) Performance test • Wire the starter as shown.

B

A: Ammeter B: Starter terminal B C: Switch

D: DC power supply S: Starter terminal S V: Voltmeter

• Set the voltage at 23V DC.

CAUTION&.----------------------The voltage that is applied should be limited to 24V maximum. ®10767

A

v

• The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations ranging from measuring the current that flows through the starter to measuring the rotating speed are completed in less than 30 seconds. • Set the switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

o

CAUTION&.--------------

®14258

When the switch C is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply D is supplied from terminal B of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. • Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion 3 with a stroboscope. • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-112

54 (2) Pinion gap [Inspection] • Wire the starter as shown.

10768

C: Switch 0: Switch E: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch C and switch 0 to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC24V

®14259

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch 0 to OFF to stop rotation of the pinion.

DC24V

CAUTION&------------When the switch C and switch 0 are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch E is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. ®14260

• Pull out the overrunning clutch 32 by hand, then push back its end lightly and measure the amount F the clutch moves in the axial direction (pinion gap). • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, replace the lever assembly 33.

F

ill

,

32 ®10769

54-1I3

STARTER <24V-SkW> [i]

Pinion

[Removal] To remove the pinion 3, it is necessary to supply current to the starter and let the pinion spring out.

WARNING& - - - - - - - - - - - - - -

®14267

• When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch assembly 5 may be very hot after the end of inspection. Be careful when you touch it.

CAUTION&--------------

®14257

• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever assembly 33 without supplying current to the starter, the front bracket 36 and lever could be damaged by the impact produced when the stopper ring 1 is removed. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

• Wire the starter as shown. A: Switch C: Switch 0: Cable M: Starter terminal M S: Starter terminal S 10768

DC24V

®14259

54-114

• The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. • Set the switch A and switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

54 • Immediately (in less than 5 seconds) after the pinion 3 has started rotating, set the switch C to OFF to stop rotation of the pinion.

DC24V

CAUTION.&.--------------

®14260

When the switch A and switch C are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch C is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. • Set the pipe-like tool E on the pinion stopper 2. • Lightly strike the tool E with a hammer to remove the stopper ring 1 from the ring groove F of the pinion stopper 2. • Remove the stopper ring 1 and remove the pinion 3. • Set the switch A to OFF to stop supplying current to the starter.

CAUTION.&.-------------®10779

When the power supply to the starter is stopped, the pinion 3 may move in and the stopper ring 1 may fit in the ring groove F of the pinion stopper 2 again. In this case, repeat the operations by supplying current to the starter.

[I nstallation1 To install the pinion 3, it is not necessary to supply current to the starter. • Install the pinion stopper 2 and pinion 3 on the overrunning clutch 32 in the direction shown. • Set the stopper ring 1 in the ring groove F of the overrunning clutch 32.

®10781

• Pull the pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2.

®10782

54-115

STARTER <24V-SkW>

WMagnet switch [I nstallation] Install the magnet switch 5 on the lever assembly 33 with terminal S in the direction shown.

®10771

[Inspection]

(1) Open circuit test on coil • Check to ensure that there is continuity between terminals Sand M. • If there is no continuity, replace the magnet switch 5.

M

®10773

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 5.

A

M ®10774

(2) Contact fusion check • Check to ensure that there is no continuity between terminals Band M. • If there is continuity, replace the magnet switch 5.

M ®10775

(3) Contact contacting check

B

•

----l~

1@"--------L-i

• Push the end of the magnet switch 5 in to close the internal contact. In this state, check to ensure that there is continuity between terminals Band M. • If there is no continuity, replace the magnet switch 5. ..

M ®10776

54-116

54 []] Removal of yoke & brush holder assembly To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14. • Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 10 alongside the brushes.

®16083

• Remove the yoke & brush holder assembly 9 from the front bracket assembly 20.

CAUTION&-------------When the yoke & brush holder assembly 9 is removed, do not tilt it downward. Otherwise, the armature assembly 16 may fall down. • For installation, reverse the order of removal.

20017

[Q]

10

Inspection of brush spring

• Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown. • If the reading is less than the limit, replace the brush spring 10.

11,14

02466

[!!] B] 12

Inspection of brush

(1) Length of brush If the reading is less than the limit, replace the brushes 11 and 14.

CAUTION&-------------

To replace the brush e 11, replace the brush holder assembly 12.

(2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500).

[g]

Inspection of brush holder assembly

• Check to ensure that there is no continuity between the EB side brush holder and e side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 12.

e

®02467

54-117

STARTER <24V-SkW> [3]]

Inspection of yoke assembly

(1) Open circuit test on coil

• Check to ensure that there is continuity between cable A and brush

EB 14. • If there is no continuity, it means an open circuit. Replace the brush EB 14 or yoke assembly 13.

®02477

(2) Earth test on coil

• Check to ensure that there is no continuity between the yoke assembly 13 and brush EB 14. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush EB 14 or yoke assembly 13.

/13

CAUTION&------------The coil may be short-circuited to the yoke assembly 13 due to the accumulation of worn-off metal particles from the brushes and/or armature. ®02478

[!§] A

Inspection of armature assembly

(1) Short circuit test on coil 16

• Bring the iron piece A close to the armature assembly 16, keeping it in parallel.

B: Armature tester

®02471

• Slowly rotate the armature assembly 16 by hand. • If the iron piece A is attracted or vibrates, it means a short circuit. Replace the armature assembly 16. (2) Earth test on coil

• Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 16.

D

E ®13329

(3) Runout of commutator

If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 16 within the limit. (4) Condition of commutator surface

C

54-118

• If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator portion C. ®13330

54 (5) Outside diameter of commutator

If the reading is more than the limit, replace the armature assembly 16.

®02474

(6) Depth of mold between segments Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 16. F: Depth of mold • Make repairs by grinding the illustrated portion G. ®16078

• If the mold portion is as shown, repair or replace the armature assembly 16. No good

Good

~ ®02476

28

~ Removal of gear shaft and internal gear assembly Remove the E-rings 27 and then the gear shaft and internal gear assembly 28 from the overrunning clutch 32. Proceed as follows if the assembly 28 cannot be removed due to interference of the splined section A of gear shaft assembly 29 with internal parts of the overrunning clutch. • Press the gear shaft assembly 29 against the overrunning clutch 32 . • Turn the gear shaft assembly 29 approx. 1/8 of a turn to change the position of splined section A.

®16917

32

28

29

m

.-

®16915

54-119

STARTER <24V-SkW> ~ Inspection of overrunning clutch

c~ B

Perform the following checks. If there is anything wrong, replace the overrunning clutch 32. • Check to ensure that when the shaft A is made to rotate in the direction B, it rotates smoothly. • Check to ensure that when the shaft A is made to rotate in the direction C, it is locked.

\ A ®13328

~ Installation of lever assembly Install the lever assembly 33 in the illustrated direction on the overrunning clutch 32.

®10778

~ Installation of front bearing A

• Before the front bearing 34 is press-fitted, install the oil seal 35. • Press-fit the front bearing 34 in the front bracket 36 with a press, using the pipe-like tool A.

35 ®13325

• Stake the front bracket 36 side.

CAUTION&.-------------Avoid staking the previously staked points B. C: Staking points (4 places)

®13326

54-120

54

STARTER <24V-SkW> ~--------------~---------

• Removal sequence 1 Starter cable EB 2 Starter relay P.54-149 3 Starter assembly P.54-124

ru

S \

B

B: Terminal B S: Terminal S

WARNING& - - - - - - - - - - Before removing the starter assembly 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative 8 terminal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous . • Installation sequence Reverse the order of removal.

2

16891

54-121

STARTER <24V-SkW> Starter Assembly ~

rG 4 5

~ 78~~CJ~

23

15\~\

3~~O 19 16892

• Inspection before disassembly

CD P.54-124 • Disassembly sequence

1 2 3 4 5 6 7 8 9 10

Magnet switch Cover Front bracket assembly Center bracket Packing Adjusting washer Stopper ring Pinion stopper Pin Lever

11 12 13 14 15 16

17 18 19 20

Overrunning clutch Gear bracket Gearshaft bearing Gearshaft Cover Sleeve bearing Front bracket Armature assembly Front bearing Rear bearing

21 22 23 24 25 26 27 28 29 30

Armature Packing Yoke & rear bracket assembly Rear bracket Brush holder assembly Brush spring Brush 8 Brush ED Packing Yoke assembly

CAUTION~ • Do not remove the bearings 13, 16, 19 and 20 unless they are found to be defective. • When the yoke & rear bracket assembly 23 is removed from the front bracket assembly 3, be careful not to allow the armature assembly 18 to fall.

54-122

54 • Reassembly sequence Reverse the order of disassembly.

NOTE When the magnet switch 1 was replaced, be sure to adjust the pinion gap . • Inspection after reassembly

CD P.54-124 Service standards Maintenance item

Location

18

26 27,28

Unit: mm Standard value

Limit

Remedy

Thrust gap of gearshaft assembly

0.1 to 0.5

-

Adjust

Pinion gap

0.5 to 4.0

-

Adjust

110A or less

-

Check

3,300 rpm or more

-

No-load characteristics (During 23.5V supply) Armature assembly

Current Rotating speed

Outside diameter of commutator

43.2

42.6

Replace

Runout of outer circumference of commutator

o to 0.03

0.1

Replace

Depth of mica between segments

0.4 to 0.6

0.2 or less

Replace

25 to 34 N {2.55 to 3.45 kgf}

18 N {1.8 kgf}

Replace

23

14

Replace

Spring pressure of brush spring Brush length

~ Lubricant Location

Points of application

1

Apply to lever contacting portion of magnet switch.

Multipurpose grease [NLGI No.2 (Li soap)]

As required

4

Apply to gear shaft mounting section of center bracket

Multipurpose grease [NLGI No.2 (Li soap)]

As required

6

Apply to adjusting washer

Multipurpose grease [NLGI No.2 (Li soap)]

As required

11

Apply to lever sliding surfaces of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

14

Apply to clutch splined portion of gear shaft

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Apply to internal gear of gearshaft

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Greasing portion at end of front bracket

Multipurpose grease [NLGI No.2 (Li soap)]

As required

17

Specified lubricant

Quantity

54-123

STARTER <24V-SkW> • Service procedure • Inspection before disassembly Thrust gap of gearshaft 14 [I nspection] • Measure the thrust gap of the gearshaft 14. • If the reading is out of the standard value, adjust by the following procedures.

20035

[Adjustment] • Remove the center bracket 4 from the front bracket assembly 3. • Adjust by changing the thickness of adjust washer 6. Types of adjust washers: 0.25, 0.5 mm

6

4 11958

• Inspection after reassembly

1

After reassembly of the starter, check the starter by supplying current.

WARNING& - - - - - - - - - - - - - • When current is supplied to the starter, the pinion C will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 1 may become very hot during inspection. Be careful when you touch it.

C

20036

CAUTION&-------------• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

20037

54-124

54 (1) Performance test

s

8

• Wire the starter as shown. A: Ammeter 8: Starter terminal B D: Switch E: DC power supply S: Starter terminal S V: Voltmeter

C 20038

E -

--$lS. /' v Cf( ====E= (~ )

A

'

DI

20039

• Set the voltage at 23.5V DC.

CAUTION&.------------The voltage that is applied should be limited to 24V maximum. • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations ranging from measuring the current that flows through the starter to measuring the rotating speed are completed in less than 30 seconds. • Set the switch D to ON to supply current to the starter. At the time, the pinion C will spring out and rotate.

CAUTION&.------------When the switch D is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply E is supplied from terminal 8 ofthe starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. • Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion C with a stroboscope. • Set the switch D to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-125

STARTER <24V-SkW> (2) Pinion gap

G

[Inspection] • Wire the starter as shown.

S M

C 20040

0: Switch E:24V DC F: Switch G: Connector M : Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch 0 and switch F to ON to supply current to the starter. At the time, the pinion C will spring out and rotate.

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch F to OFF stop rotation of the pinion.

CAUTION&.------------When the switch 0 and switch F are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion C. To prevent baking the pull-in coil, therefore, it is necessary that the switch is set to OFF immediately (in less than 5 seconds). 20042

• Lightly push the end of the pinion C in and measure the amount J

the clutch moves in the axial direction (pinion gap).

NOTE When the pinion is strongly pushed, the pinion moves back, while compressing the spring. • Set the switch 0 to OFF to stop supplying current to the starter. • If the reading is out of the standard value, it means that the starter has been incorrectly reassembled. Therefore, repeat disassembly and reassembly.

J

10

12413

OJ Magnet switch

~s

[I nstallation] Install the magnet switch 1 in the illustrated direction on the lever 10. S: Terminal S

12414

54-126

54 [Inspection]

(1) Open circuit test on coil • Check to ensure that there is continuity between terminals Sand M. • If there is no continuity, replace the magnet switch 1.

M

11960

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 1. M

A~ 11961

(2) Contact fusion check • Check to ensure that there is no continuity between terminals Band

M. M

• If there is continuity, replace the magnet switch 1.

11962

(3) Contact contacting check B

• Strongly push the end of the magnet switch 1 in to close the internal contact. In this state, check to ensure that there is continuity between terminals Band M. • If there is no continuity, replace the magnet switch 1.

M

11963

[!QIlnstaliation of lever Install the lever 10 in the illustrated direction on the overrunning clutch 11. 10 11

20043

54-127

STARTER <24V-6kW> [TI]

Overrunning clutch

[Removal] • Set the pipe-like tool A on the pinion stopper 8. • Lightly strike the tool A with a hammer to remove the pinion stopper 8 from the stopper ring 7. • Remove the stopper ring 7 from the gearshaft 14 and withdraw the pinion stopper 8.

11965

[Inspection] • Check to ensure that the pinion B of the overrunning clutch 11 rotates in the direction C and does not rotate in the direction D. • If there is anything wrong, replace the overrunning clutch 11.

11966

[Installation] • Install the pinion stopper 8 in the illustrated direction on the gearshaft

8-[] ~~--- 8

-=-r

14.

--14

12416

• Install the stopper ring 7 in the ring groove E of the gearshaft 14.

1~o-7

14--i E 12417

• Strongly pull the pinion gear F to securely mount the pinion stopper 8 in the stopper ring 8.

F 12418

54-128

54 ~ Inspection of armature assembly (1) Short circuit test on coil • Bring the iron piece B close to the armature assembly 18, keeping it in parallel.

A: Armature tester

®02471

• Slowly rotate the armature assembly 18 by hand. • If the iron piece B is attracted or vibrates, it means a short circuit. Replace the armature assembly 18.

(2) Earth test on coil • Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 18.

E

02472

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 18 within the limit.

(4) Roughness of commutator surface • If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator portion C. 02473

(5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 18.

®02474

(6) Depth of mold between segments Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 18. F: Depth of mold • Make repairs by grinding the illustrated portion G. ®16078

54-129

STARTER <24V-SkW> • If the mold portion is as shown, repair or replace the armature assembly 18.

No good

Good

~

~~.'C3l€lp

~ ®02476

~ Inspection of brush holder assembly • After thoroughly cleaning the brush holder assembly, check to ensure that there is no continuity between the E9 side brush holder and e side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 25.

~ Inspection of brush spring • Use new brushes 27 and 28 and measure the load at the moment the brush spring 26 leaves the brushes as shown. • If the reading is below the limit, replace the brush spring 26.

26

~ 27,28

14833

~ ~ Inspection of brush (1) Length of brush If the reading is less than the limit, replace the brushes 27 and 28. A: Brush length

CAUTION&-------------

To replace the brush e 27, replace the brush holder assembly 25.

14832

(2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500).

54-130

54 @Q]

Inspection of yoke assembly

(1) Open circuit test on coil • Check to ensure that there is continuity between connector A and brush EB 28. • If there is no continuity, it means an open circuit. Replace the yoke assembly 30.

®0247

(2) Earth test on coil

28

• Check to ensure that there is no continuity between the yoke assembly 30 and brush EB 28. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush EB 28 or yoke assembly 30.

CAUTION.&,------------The coil may be short-circuited to the yoke assembly 30 due to the accumulation of worn-off metal particles from the brushes and/or armature. ®02478

54-131

STARTER <12V-SkW> • Removal sequence 1 2 3 4

Starter relay elJ P.54-149 Battery cable EEl Earth strap Starter assembly lIJ P.54-134

B: Terminal B S: Terminal S

WARNING'&' - - - - - - - - - - Before removing the starter assembly 4, be sure to disconnect the negative e terminal of the battery and insulate it with a tape or something else. If the negative e terminal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous . • Installation sequence

4

Reverse the order of removal. ®47209

54-132

54

MEMO

54-133

STARTER <12V-5kW> Starter Assembly

®47182

• Disassembly sequence

1 Stopper ring 2 Pinion stopper 3 Pinion 4 Spring 5 Magnet switch 6 Shim 7 Rear bracket 8 Packing 9 Yoke & brush holder assembly 10 Brush spring 11 Brush 12 Brush holder assembly 13 Yoke assembly 14 Brush EB

e

54-134

15 16 17 18 19

20 21

22 23 24 25 26

Yoke Armature assembly Rear bearing Armature Ball Front bracket assembly Cover Packing Planetary gear Packing Plate Gearshaft & overrunning clutch assembly

27 E-ring 28 Gearshaft & Internal gear assembly 29 Gear shaft assembly 30 Washer 31 Internal gear 32 Overrunning clutch 33 Lever assembly 34 Front bearing 35 Oil seal 36 Front bracket

0: Non-reusable parts

54 CAUTION~----------------------------------------------------• Do not remove the bearings 17 and 34 unless defects are evident. • When the armature assembly 16 is removed, the ball 19 might come out with it. Take care not to lose the ball. • It is not necessary to remove the pinion 3 when only the motor should be removed and inspected for inspection of the brushes and the related parts. • Be sure to remove the pinion 3 before disassembling any other parts.

• Assembly sequence Follow the disassembly sequence in reverse.

CAUTION~----------------------------------------------------­ Whenever the magnetic switch 5 is replaced, the pinion gap must be adjusted.

• Inspection after reassembly

en P.54-136

Service standards Location

10 11,14 16

rC'i

Unit: mm Standard value

Maintenance item

During 11V supply

-

Adjust

230A or less

-

Check

3400 rpm or more

-

Current Rotating speed

Remedy

O.S to 2.0

Pinion gap No-load characteristics

Limit

29 to 39 N {3 to 4 kgf}

20 N {2 kgf}

Replace

Brush length

18

11

Replace

Outside diameter of commutator

32

31.4

Replace

Commutator outer circumferential runout

-

Depth of mica between segments

O.S

Spring pressure of brush spring

O.OS or more 0.2 or less

Repair or replace

Lubricant

Location -5

Points of application

Specified lubricant

Quantity

Lever contact surface of magnetic switch

Multipurpose grease [NLGI No.2 (Li soap)]

Teeth of armature assembly gear

MOLYKOTE

® AG6S0

As required

Sliding surfaces of armature assembly and gear shaft assembly

MOLYKOTE

® AG6S0

As required

Ball

MOLYKOTE

® AG6S0

As required

23,31

Teeth of planetary gear and internal gear

MOLYKOTE

® AG6S0

As required

29,32

Sliding surfaces of gear shaft assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

30

Washer

MOLYKOTE

32

Splines of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

33

Sliding surfaces of lever assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

16 16,29 19

® AG6S0

As required

As required As required

54-135

STARTER <12V-SkW> • Service procedure • Inspection after reassembly After reassembly, check the starter by supplying current.

WARNING'& - - - - - - - - - - - - - • When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it.

®39615

CAUTION.&------------------------• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

®14257

(1) Performance test • Wire the starter as shown. A: Ammeter B: Starter terminal B C: Switch

0: DC power supply 5: Starter terminal S V: Voltmeter

• Set the voltage at 11 V DC.

CAUTION.&-------------The voltage that is applied should be limited to 12V maximum. ®26379

A

v

• The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations ranging from measuring the current that flows through the starter to measuring the rotating speed are completed in less than 30 seconds. • Set the switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

D

CAUTION.&-------------

®14258

When the switch C is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply 0 is supplied from terminal B of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. • Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion 3 with a stroboscope. • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-136

54 ----------._--

(2) Pinion gap [Inspection] • Wire the starter as shown. C: Switch E: Switch F: Cable M : Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter, It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch C and switch E to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC 12V

®14259

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch E to OFF to stop rotation of the pinion.

DC 12V

CAUTION&------------When the switch C and switch E are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch E is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating.

:€1 ®14260

G

• Pull out the overrunning clutch 32 by hand, then push back its end lightly and measure the amount G the clutch moves in the axial direction (pinion gap). • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, replace the lever assembly33.

R~ 32

®28766

54-137

STARTER <12V-SkW> [II

Pinion

[Removal] To remove the pinion 3, it is necessary to supply current to the starter and let the pinion spring out.

WARNING&' - - - - - - - - - - - - - • When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it.

CAUTION&.--------------

®14257

• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever assembly 33 without supplying current to the starter, the front bracket 36 and lever could be damaged by the impact produced when the stopper ring 1 is removed. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

• Wire the starter as shown. A: Switch C: Switch D: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. • Set the switch A and switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC 12V

®14259

54-138

54 • Immediately (in less than 5 seconds) after the pinion 3 has started rotating, set the switch C to OFF to stop rotation of the pinion.

DC 12V

CAUTION~---------------------------­

®14260

When the switch A and switch C are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch C is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. • Set the pipe-like tool E on the pinion stopper 2. • Lightly strike the tool E with a hammerto remove the stopper ring 1 from the ring groove F of the pinion stopper 2. • Remove the stopper ring 1 and remove the pinion 3. • Set the switch A to OFF to stop supplying current to the starter.

CAUTION~ ---------------------------®10779

When the power supply to the starter is stopped, the pinion 3 may move in and the stopper ring 1 may fit in the ring groove F of the pinion stopper 2 again. In this case, repeat the operations by supplying current to the starter.

[Installation] To install the pinion 3, it is not necessary to supply current to the starter. • Install the pinion stopper 2 and pinion 3 on the overrunning clutch 32 in the direction shown. • Set the stopper ring 1 in the ring groove F of the overrunning clutch 32.

®10781

• Pull the pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2.

54-139

STARTER <12V-SkW> ~ Magnet switch [Installation] Install the magnet switch 5 on the lever assembly 33 with terminal S in the direction shown.

33 ®47194

[Inspection]

(1) Open circuit test on coil • Check to ensure that there is continuity between terminals Sand M. • If there is no continuity, replace the magnet switch 5.

®28628

:QII

•

~

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 5 .

M ®28629

(2) Contact fusion check • Check to ensure that there is no continuity between terminals Band

B

• ~~~II_~

M. • If there is continuity, replace the magnet switch 5.

M ®28630

(3) Contact contacting check

• ~"----"---~II_~+ M ®28631

54-140

• Push the end of the magnet switch 5 in to close the internal contact. In this state, check to ensure that there is continuity between terminals Band M. • If there is no continuity, replace the magnet switch 5.

54 []] Removal of yoke & brush holder assembly

To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14. • Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 10 alongside the brushes.

11,14

®16083

~

• Remove the yoke & brush holder assembly 9 from the front bracket assembly 20.

14

CAUTION&.-------------When the yoke & brush holder assembly 9 is removed, do not tilt it downward. Otherwise, the armature assembly 16 may fall down.

10 11

• For installation, reverse the order of removal.

®26390

[!.QIlnspection of brush spring

u

• Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown. • If the reading is less than the limit, replace the brush spring 10.

~~.~ ~~10 11,14

®14833

54-141

STARTER <12V-SkW> [EJ G]

Inspection of brush

(1) Length of brush If the reading is less than the limit, replace the brushes 11 and 14. A

A: Brush length

CAUTION&-------------

To replace the brush e 11, replace the brush holder assembly 12.

(2) Commutator contacting surfaces ®36023

If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500).

[g] 12

Inspection of brush holder assembly

• Check to ensure that there is no continuity between the E9 side brush holder and e side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 12.

~ Inspection of yoke assembly (1) Open circuit test on coil • Check to ensure that there is continuity between cable A and brush E9 14. • If there is no continuity, it means an open circuit. Replace the brush E9 14 or yoke assembly 13.

®02477

(2) Earth test on coil 14

• Check to ensure that there is no continuity between the yoke assembly 13 and brush E9 14. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush E9 14 or yoke assembly 13.

CAUTION&------------The coil may be short-circuited to the yoke assembly 13 due to the accumulation of worn-off metal particles from the brushes and/or armature. ®02478

~ Inspection of armature assembly (1) Short circuit test on coil • Bring the iron piece A close to the armature assembly 16, keeping it in parallel. B: Armature tester • Slowly rotate the armature assembly 16 by hand. • If the iron piece A is attracted or vibrates, it means a short circuit. Replace the armature assembly 16. ®02471

54-142

54 (2) Earth test on coil • Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 16.

®13329

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 16 within the limit.

(4) Condition of commutator surface

C

• If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator portion C. ®13330

(5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 16.

®02474

(6) Depth of mold between segments Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 16. F: Depth of mold • Make repairs by grinding the illustrated portion G. ®16078

• If the mold portion is as shown, repair or replace the armature assembly 16.

Good

No good

~ ®02476

54-143

STARTER <12V-SkW> 28

~ Removal of gear shaft and internal gear assembly Remove the E-rings 27 and then the gear shaft and internal gear assembly 28 from the overrunning clutch 32. Proceed as follows if the assembly 28 cannot be removed due to interference of the splined section A of gear shaft assembly 29 with internal parts of the overrunning clutch 32. • Press the gear shaft assembly 29 against the overrunning clutch 32. • Turn the gear shaft assembly 29 approx. 1/8 of a turn to change the position of splined section A.

®16917

28

32

29

-m

'-

®16915

~ Inspection of overrunning clutch Perform the following checks. If there is anything wrong, replace the overrunning clutch 32. • Check to ensure that when the shaft A is made to rotate in the direction B, it rotates smoothly. • Check to ensure that when the shaft A is made to rotate in the direction C, it is locked.

c~ B

A ®13328

~ Installation of lever assembly Install the lever assembly 33 in the illustrated direction on the overrunning clutch 32.

®10778

54-144

54 ~ Installation of front bearing A

• Before the front bearing 34 is press-fitted, install the oil seal 35. • Press-fit the front bearing 34 in the front bracket 36 with a press, using the pipe-like tool A.

®13325

• Stake the front bracket 36 side.

CAUTION.&-------------Avoid staking the previously staked points B. C: Staking points (4 places)

®13326

54-145

PREHEATER CIRCUIT 1 Starter switch 2 Heater relay (or glow relay) 3 Heater indicator (vehicles with air heater) Glow plug indicator (vehicles with glow plugs) 4 Intake air heater 5 Glow plug 6 Battery relay (24V specification) Battery switch (12V specification) 7 Battery

<24V (air heater) specification> 1

®®

7 18461

18462

7 <12V specification>

7

54-146

18463

54 Service standards 5

Standard value

Maintenance item

Location

Resistance of glow plug at normal temperature

Limit

Remedy

-

3.80

Replace

• Service procedure

!1J Inspection of heater relay (or glow relay) (1) Inspection of heater If the fuse A is blown, replace it with one having the same amperage stamped on the fuse.

EB

(2) Inspection of main body

(4)

• Perform continuity checks according to the following table.

A

rrn

(5)

(0 (2)(3) (4)

~

When no current is supplied When current is supplied

o---D ®---8

(2)

(3)

@

0 D 0- --0

D

0 ®-

G)

@ (Body earth)

D

-e

There is continuity between terminals. Terminals to which battery voltage is applied: DC24V <24V system> DC12V <12V system>

A: Fuse ®29090

• If there is anything wrong, replace the heater relay (or glow relay) 2.

54-147

PREHEATER CIRCUIT [}] Inspection of intake air heater (1) Inspection of fuse If there is anything wrong, replace the fuse A (127A).

--4

A: Fuse (127A)

(2) Inspection of main body

18465

Check the terminals for looseness, and the heater element for damage and loose contact with the glass. • If there is anything wrong, replace the intake air heater 4.

[§J

Inspection of glow plug

• Measure the resistance of the glow plug 5 as shown. • If the reading is out of the standard value, replace the glow plug 7. Gr 11

m

02513

54-148

54

ENGINE STARTER CIRCUIT 1 2 3 4

Alternator Starter relay Starter Battery relay (24V) Battery switch (12V) 5 Battery 6 Starter switch 7 Safety relay

18466

Service standards Location

Standard value

Maintenance item Safety relay

7

Limit

Approx. 2000

Remedy Replace

-

• Service procedure ~ Inspection of starter relay • Perform continuity checks according to the following table.

2

s

~

B

S

When current is supplied

0

{)

0----0 EB-----G

18017

L

0-- f------()

When no current is supplied

B

SW

8)

"-

\J

There is continuity between terminals. Terminals to which battery voltage is applied DC24V <24V system> DC12V <12V system>

• If there is anything wrong, replace the starter relay 2.

[I]

Inspection of safety relay

Measure the resistance value between terminals R-L. If the reading is out of the standard value, replace the safety relay 7.

p E

s

L 17530

54-149

AUTOMATIC STOP SYSTEM (SHUTDOWN)

A

B Rl AC R2 C BR

13

18

OFF 0

6

HEAT

ON STAR

7

18737

View A

8 Ammeter 9 Stop switch

1 Solenoid relay 2 Alternator 3 Solenoid 4 Starter 5 Battery relay 6 Battery 7 Starter switch

10 11 12 13

Fuse box Engine oil pressure switch Coolant temperature sensor Lock nut

18819

14 Rod 15 Swivel joint 16 Ball joint 17 Base lever 18 Stop lever 19 Flange bolt

Service standards Maintenance item

Location

1

3

Unit: mm

Solenoid relay

Solenoid

Limit

Remedy

Delay time at start (after application of 28.5V to terminal B, and 28.5V to terminal A)

18 ± 5 secs.

-

Replace

Delay time at stop (after application of 24V to terminal B and OV to terminal A)

30 ± 5 secs.

-

Replace

1.2 ± 0.2

-

Adjust

0.5A or less

-

Replace

78 ± 20 kPa {0.8 ± 0.2 kgf/cm2}

-

Replace

City water cooling

95 ± 2°C

-

Replace

Radiator cooling

101 ± 2°C

-

Replace

Clearance between base lever and case stopper Holding coil current

11

Engine oil pressure switch operating pressure

12

Coolant temperature sensor operating temperature

54-150

Standard value

54 • Service procedure

IT] aw..---.L,'--;

+-~r-<1

J

Wire as shown at left and perform the following inspections.

B C

F: Power supply G: Switch H: Solenoid (or coil load: 30 ± 3A) J: Switch K: Switch L: Power supply

ST

L

K

~-

Solenoid relay

W

A E '---~

+

18820

(1) Inspection of oil pressure timer • Connect 28.5V DC power supplies to F and L. • Set the switch G to ON. • Set the switch K to ON and simultaneously measure the time required before the solenoid H operates. • If the reading is out of the standard value, replace defective parts.

NOTE When the timer is to be re-tested, allow a recovery time of five minutes as the discharge finishing time of the capacitor in the solenoid relay 1. (2) Inspection of stop timer • Connect 24V DC power supply to F and 28.5V DC power supply to

L. • Set the switches G and K to ON. • Set the switch K to OFF 5 seconds after the solenoid H has operated. (It takes 5 seconds for the generating voltage of alternator 2 to disappear after the activation of the solenoid.) At the same time, measure the time required before the solenoid returns. • If the reading is out of the standard value, replace defective parts.

NOTE When the timer is to be re-tested, allow a recovery time of five minutes as the discharge finishing time of the capacitor in the solenoid relay. (3) Manual stop timer • Connect 24 V DC power supply to F. • Set the switch J to ON to operate the solenoid H. • Measure the time required for the solenoid H to return after setting the switch J to OFF. • If the reading is out of the standard value, replace defective parts.

54-151

AUTOMATIC STOP SYSTEM (SHUTDOWN)

rn

Solenoid

[I nstallation] • Temporarily tighten the ball joint 16 to the rod 14 and thread the other end six to nine times into the swivel joint 15 and secure it with lock nuts

13.

A

• Check to ensure that the rotating portions of the swivel joint 15 and ball joint 16 smoothly rotate. • Mount the solenoid 3 on the engine. • Rotate the ball joint 16 to adjust the length of rod 14, place the stop lever 18 in the normal use position, and install the ball joint with the flange bolt 19.

13

18 17

View A

18819

[Adjustment] • Adjust the length of the rod 14 so that the clearance B between the base lever 17 and case stopper A will have the standard value with the solenoid 3 in operation.

3

18_,,-_ _~ 14 .. C

17~~A

C: Solenoid moving direction • Firmly tighten the lock nuts 13 at both ends of the rod 14 and stop operation of the solenoid. 18824

CAUTION~--------------------------Do not continue to supply current to the solenoid 3 for more than 20 seconds. Otherwise the solenoid may be burned.

• Switch the switch of the circuit between ON and OFF repeatedly two or three times and check the following items.

CAUTION~ --------------------------Do not switch the switch rapidly between ON and OFF.

• Check to ensure that the stop lever 18, rod 14 and solenoid 3 move smoothly. • Check to ensure that the clearance B between the base lever 17 and case stopper A have the standard value.

54-152

54 [Inspection] Wire as shown at left and perform the following checks.

3

AUX

NOTE The checks can be performed by use of either the ammeter C or lampD.

<-&i (+)

18821

3

A: Power supply B: Switch C: Ammeter • Set the switch B to ON. • If the reading of the ammeter C after activation of solenoid 3 is out of the standard value or the lamp D does not light, replace the solenoid.

CAUTION&--------------

D

When the check lamp does not light, do not continue to supply current to the solenoid 3 for more than 20 seconds. Otherwise the solenoid may be burned.

18822

[!] 11

A¢

~ (2) 18825

Inspection of engine oil pressure switch

Perform the following checks. If defective, replace the engine oil pressure switch 11. • Under the condition where no air pressure A is applied to the engine oil pressure switch 11, check to ensure that there is continuity between the terminals (1) and (:~). • Slowly apply the air pressure A to the engine oil pressure switch 11, beginning at 0 kPa (0 kgf/cm2). When there is no more continuity between the terminals (1) and (2), measure the air pressure and check to ensure that the air pressure has the standard value. B: Air pressure gauge

~ Inspection of coolant temperature sensor

(2)

~(1)

~ ~

\l

e

~

e

• Put the coolant temperature sensor 12 in a container filled with engine oil. • Before raising the oil temperature, check to ensure that there is no continuity between the terminals CD and ®. • Slowly raise the oil temperature and stir the engine oil well. • Measure the temperature at the time when there is continuity between the terminals CD and ®. • If the reading is out of the standard value, replace defective parts. 18826

NOTE When the oil temperature is near the operating temperature, slowly heat the oil. (When the operating temperature -SoC is reached, leave it alone for five minutes, and then raise the oil temperature at a rate of 1°C in two or three minutes.)

54-153

AUTOMATIC STOP SYSTEM

14

12

12

13

14

2 00

15

3 9

8

4

HEAT

14

ON

12

13

START

7

6

5

View A 18827

18745

7 Starter switch 8 Alternator 9 Ammeter 10 Engine oil pressure switch 11 Coolant temperature sensor

1 Solenoid relay 2 Solenoid 3 Stop switch 4 Battery switch 5 Battery 6 Heater relay

12 13 14 15 16

Lock nut Rod Ball joint Stop lever Base lever

Service Standards Location

Unit: mm Maintenance item

1

Solenoid relay delay time

2

Solenoid

30

± 4 sees.

Limit

Remedy

-

Replace

Pointer clearance

0.8 to 1.5

-

Replace

Clearance between stop lever and external stopper

0.4 to 0.5

-

Replace

Holding coil current

24V system

1A or less

-

Replace

12V system

5A or less

-

Replace

-

Replace

-

Replace

-

Replace

11

Engine oil pressure switch operating pressure

12

Coolant temperature sensor operating temperature

54-154

Standard value

City water cooling Radiator cooling

78

± 20 kPa {0.8 ± 0.2 ± 2°C 101 ± 2°C 95

kgf/cm 2 }

54 • Service procedure []] Solenoid relay F

G

1

Wire as shown at left and perform the following checks.

B C H

S E L 18828

F: Power supply G: Switch J: Solenoid (or coil load: 30 ± 3A) K: Switch L: Switch

(1) Inspection of operation of solenoid relay 1 and delay time • Check to ensure that when the switches G and L are set to ON, the solenoid J operates. • Set the switch L to OFF and simultaneously measure the time required before the solenoid J is deactivated. (2) Inspection of relay holding time • Set the switches G and L to ON. After the solenoid J has operated, set the switch K to ON. • Set the switch L to OFF and check to ensure that the solenoid J stays in the operating state for more than 30 seconds. • After checking that the solenoid J is in the operating state, set the switch K to OFF to check that the solenoid is deactivated.

rn 13

! 15

12 14

2

~ ~

Solenoid

[Installation] • Install the ball joint 14 to the rod 13 and temporary tighten with lock nut 12. • Check to ensure that the ball joint 14 moves smoothly. • Install the solenoid 2 to the engine. • With the stop lever 15 in the stop position, install the rod 13. Adjust the rod length by turning it.

View A 14

12 13

18827

[Adjustment] • Remove the cover of the solenoid 2. • Apply the specified voltage to solenoid 2 and energize the solenoid. • Check that the clearance A between the pointers of the solenoid is within the standard value.

A 2

1 18831

54-155

AUTOMATIC STOP SYSTEM • With the solenoid 2 kept energized, adjust the clearance C between the base lever 16 and the case stopper B to the standard value by turning the rod 13. 0: Solenoid moving direction 2

18832

• Deenergize the solenoid 2. • Firmly tighten the lock nut 12. • Switch the solenoid 2 between ON and OFF repeatedly two or three times (with approx. 10 seconds of internal) and check the following items.

CAUTION~--------------------------­ DO not switch the solenoid rapidly between ON and OFF. • Check to ensure that the stop lever 15, rod 13 and solenoid 2 operate smoothly. • Check to ensure that the clearances A and C fall within the standard limits. • Mount the cover of solenoid 2.

[I nspection] Wire as shown at left and perform the following checks. A: Power supply B: Switch C:Ammeter

2

18829

B8

• Set the switch B to ON. • If the reading of the ammeter C after the activation of solenoid 1 is out of the standard value, replace the solenoid.

[!Q] 10

A¢

CD

~®

18833

Inspection of engine oil pressure switch

Perform the following checks. If defective, replace the engine oil pressure switch 10. • Under the condition where no air pressure A is applied to the engine oil pressure switch 10, check to ensure that there is no continuity between the terminals CD and ®. • Slowly apply the air pressure A to the engine oil pressure switch 10, beginning at 0 kPa (0 kgf/cm 2 ). When there is continuity between the terminals CD and ®, measure the air pressure and check to ensure that the air pressure has the standard value. B: Air pressure gauge

54-156

54 [TI]

Inspection of coolant temperature sensor

• Put the coolant temperature sensor in a container filled with engine oil. • Before raising the oil temperature, check to ensure that there is continuity between the terminals C1J and \2. • Slowly raise the oil temperature and stir the engine oil well. • Measure the temperature at the time when there is no more continuity between the terminals (1.: and (2). • If the reading is out of the standard value, replace defective parts. 18826

NOTE When the oil temperature is near the operating temperature, slowly heat the oil. (When the operating temperature -SoC is reached, leave it alone for five minutes, and then raise the oil temperature at a rate of 1°C in two or three minutes.)

54-157

61

GROUP 61 SPECIAL EQUIPMENT SPECIFICATIONS ........................................

61-2

STRUCTURE AND OPERATION 1. Air Compressor ................................................ 2. Air Pressure Governor ...................................... " . .

61-3 61-7

ON-VEHICLE INSPECTION AND ADJUSTMENTS 1. Checking Air Pressure Governor Valve Opening Pressure. . . . . . . . .

61-8

AIR COMPRESSOR
AIR PRESSURE GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61-10 61-18 61-26 61-34

61-40

61-1

SPECIFICATIONS Item Air compressor

Type

Air-cooled, single-cylinder

Cylinder bore x stroke mm



Cylinder displacement dm 3 {mL}

201 {201}

Manufacturer

61-2

Specifications

80 x 40

Air-cooled, single-cylinder

80 x 60

301 {301}

Water-cooled, single-cylinder

80 x 60

301 {301}

SANWA SEIKI MFG. CO., LTD

Water-cooled, single-cylinder

85 x 60

340 {340}

61

STRUCTURE AND OPERATION 1. Air Compressor



1

1

4

15

15

8

10

13

11

10

®18392

1 2 3 4 5

6 7 8

9 10

Delivery valve Cylinder head Unloader valve Unloader valve spring Suction valve Suction valve spring Cylinder liner Compressor gear Crankshaft Crankcase

11 12 13 14 15

®47000

Bearing holder Coupling Connecting rod Piston Delivery valve spring

A: From air cleaner B: To air tank C: From air pressure governor

• The air compressor is driven by compressor gear 8 which is in mesh with the timing gear of the engine. • Cylinder head 3 is provided with fins that prevent it from being overheated by the compression heat generated by the air compressor.

When air is taken in

• When compressor gear 8 is turned, crankshaft 9 in mesh with the compressor gear lowers piston 14. • The vacuum generated at this time opens suction valve 5, allowing air A from the air cleaner to be drawn into cylinder liner 7.

5 14

7

12791

61-3

STRUCTURE AND OPERATION When air is sent under pressure • When piston 14 goes up on the compression stroke, suction valve spring 6 closes suction valve 5. • The compressed-air pressure overcomes the force of delivery valve spring 15, pushing to open delivery valve 1, which results in the air B being sent under pressure to the air tank.

5

15

6

B

12792

When the unloader valve operates

12793

• When the pressure of the air in the air tank builds up to exceed the predetermined level, the air pressure governor operates and compressed air C is sent to unloader valve 3, pushing down the unloader valve. At the same time, the air keeps suction valve 5 open, which means that the air in cylinder liner7 is not compressed and the air compressor runs under no load. • As the air pressure of the air tank drops below the predetermined level, the air pressure governor is operated again to discharge compressed air C above unloader valve 3. As a result, the unloader valve is returned to its original position by unloader valve spring 4.

<Water-cooled type (Oldham's coupling type» 1 2 3 4 5 6 7

1 15

8 9

10

10 11 12 13 14 15

Delivery valve Cylinder head Unloader valve Unloader valve spring Suction valve Suction valve spring Piston Cylinder liner Crankcase Compressor gear Bearing Crankshaft Coupling Connecting rod Delivery valve spring

A: From air cleaner B: To air tank C: From air pressure governor P18393

• The air compressor is driven by compressor gear 10 which is in mesh with the timing gear of the engine. • To prevent cylinder head 2 from being overheated by the compression heat generated by the air compressor, coolant is introduced from the oil cooler to cool down each valve of the cylinder head. It is then returned to the rear end of the engine cylinder head.

61-4

61 When air is taken in • When compressor gear 10 is turned, crankshaft 12 in mesh with the compressor gear lowers piston 7. • The vacuum generated at this time opens suction valve 5, allowing air A from the air cleaner to be drawn into cylinder liner 8.

18394

When air is sent under pressure • When piston 7 goes up on the compression stroke, suction valve spring 6 closes suction valve 5. • The compressed-air pressure overcomes the force of delivery valve spring 15, pushing to open delivery valve 1, which results in air B being sent under pressure to the air tank.

18395

When the unloader valve operates

3 C

8

18396

When the pressure of the air in the air tank builds up to exceed the predetermined level, the air pressure governor operates and compressed air C is sent to unloader valve 3, pushing down the unloader valve. At the same time, the air keeps suction valve 5 open, which means that the air in cylinder liner 8 is not compressed and the air compressor runs under no load. As the air pressure of the air tank drops below the predetermined level, the air pressure governor is operated again to discharge compressed air C above unloader valve 3. As a result, the unloader valve is returned to its original position by unloader valve spring 4.

61-5

STRUCTURE AND OPERATION <Water-cooled type (Laminated coupling type» 11

B

t

Delivery valve Suction valve Compressor gear Crankshaft Crankcase Bearing holder Connecting rod Piston Cylinder liner Valve seat assembly 11 Cylinder head assembly

1 2 3 4 5 6 7 8 9 10

1 2

10

9

A: From air cleaner B: To air tank

3

7

6 ®47001

When air is taken in

• As compressor gear 3 is driven, crankshaft 4 which is meshed with the compressor gear is also driven. As a result, piston 8 moves down. • This creates vacuum which then opens suction valve 2. As a result, air A is sucked from the air cleaner and flows into cylinder liner 9.

When air is sent out under pressure

• As piston 8 moves up in the compression stroke, suction valve 2 is closed by compressed air B. • Air B compressed by piston 8 opens delivery valve 1 and flows to the air tank.

61-6

61 2. Air Pressure Governor 1 Vent hole 2 Low-pressure valve 3 High-pressure valve 4 Filter 5 Diaphragm 6 Valve body 7 Adjusting spring

1

7

B+

A: From air tank B: To air compressor unloader valve

2

6 5

4

t A 18397

The air pressure governor makes the air compressor operate under load or idly to keep the air tank pressure constant.

When the high-pressure valve is operated • The high-pressure valve 3 of diaphragm 5 receives at all times air pressure A which is equal to that in the air tank through filter 4, balancing with the force of adjusting spring 7. • When the air tank inside pressure becomes greater than the high-pressure valve opening pressure, air pressure A pushes up high-pressure valve 3 of diaphragm 5. As the area to which this pressure is applied increases, the diaphragm quickly goes up, closing the seat of low-pressure valve 2 of the diaphragm. • When low-pressure valve 2 closes, air pressure A moves through valve body 6 to push down the unloader valve to open the suction valve, thereby stopping the charge of air pressure A into the air tank.

When the low-pressure valve is operated • When the air pressure in the air tank gradually drops causing adjusting spring 7 to push down diaphragm 5, low-pressure valve 2 opens and high-pressure valve 3 closes. • As high-pressure valve 3 closes, the air pressure to the unloadervalve side is discharged through vent hole 1, which again starts the charging of air into the air tank.

61-7

ON-VEHICLE INSPECTION AND ADJUSTMENTS 1. Checking Air Pressure Governor Valve Opening Pressure Service standards Maintenance item

Location

1

Standard value

Valve opening pressure on high-pressure valve end

715

kgfl em 2 }

-

Valve opening pressure on low-pressure valve end

625 ~~: kPa {6.4 ~:~~ kgf/em 2 }

-

1

2

3 18398

4 7

5 6

18399

61-8

Limit

+34 -4.9

kPa { 7. 3

+0.35 -0.05

Remedy Adjust

[I nspection] • Install air gauge A between air pressure governor 1 and air tank 2. • Start the engine and, observing air gauge A, gradually increase the air pressure. • Measure the pressure (valve opening pressure on high-pressure valve end) when the needle of air gauge A stops deflecting. • Watching air gauge A, gradually decrease the air pressure. • Measure the pressure (valve opening pressure on low-pressure valve end) when the needle of air gauge A starts deflecting again. • If the measurements do not fall within the standard value range, adjust as follows. [Adjustment] • Remove cover 4. • Loosen lock nut 5 and lightly tighten sleeve 6 until it can no longer be tightened. From that point, loosen sleeve 61/2 to 3/4 turns. • Start the engine and gradually increase the air pressure of air tank 2. • Check that charging of air into air tank 2 is stopped. • Gradually decrease the air tank 2 air pressure and adjust the amount of tightening of adjusting screw 7 to obtain the specified valve opening pressure on the low-pressure valve end. • Tighten adjusting screw 7 if the valve opening pressure on the low-pressure valve end is too low and loosen it if the pressure is too high. • Fill air tank 2 with air again and tighten sleeve 6 so that the valve opening pressure on the high-pressure valve end will be adjusted to the standard pressure. • If the valve opening pressure on the high-pressure valve end is too low, tighten sleeve 6; if the pressure is high, loosen sleeve 6. • After the adjustments have been made, tighten lock nuts 5 and 8 securely. • After the lock nuts have been tightened, make the checks again and, if the standard values are not met, make re-adjustments again. • Reinstall the cover and seal the governor.

61

MEMO

61-9

AIR COMPRESSOR
1 2 3 4 5 6 7 8

Unloader pipe Connector Eye bolt Air outlet pipe Eye bolt Air inlet pipe Air compressor assembly O-ring

P61-12

*a: Injection pump assembly 11l Gr. 13A *b: Oil pipe lIJ Gr. 13A *c: Flywheel housing

mGr. 11

0: Non-reusable parts • Installation sequence

Reverse the order of removal.

®46992

o

Tightening torque

Location

~

Unit: N· m {kgf· m} Tightening torque

Parts to be tightened

Remarks

20 to 25 {2.0 to 2.5}

-

14.7 to 21.5 {1.5 to 2.2}

-

Eye bolt (for air outlet pipe installation)

130 {13}

-

Eye bolt (for air inlet pipe installation)

110 {11}

-

1

Unloader pipe

2

Connector

3

5

Lubricant

Location

8

61-10

Points of application O-ring

Specified lubricant Engine oil

Quantity As required

61 • Service procedur

o Installation of' e air compre • Set cylinder No 1 ssor assembly ~lJ Gr. 11. • After 1 .

asse~~fnrng

of the engine at TOG' In the com inscribed lines A . pression stroke. y 7 to flywheel houslng . with *c . each other' Install . air compressor

*c

.

• pOinter Rem . oveC.Inspectio . n plug B and check" . • If not aligned II Inscnbed line A is al , remove and ref't . Igned with I air com pressor assembly 7.

61-11

AIR COMPRESSOR
<

1

34

35

47

440 ®46993

61-12

61 • Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Nut Lock washer Compressor gear Spacer Bolt Coupling Bolt Connector Gasket Snap ring Unloader valve Unloader valve spring Unloader valve guide Suction valve holder Suction valve spring Suction valve Suction valve seat

18 19 20 21 22 23 24 25 26 27 28 29 30, 31 32 33 34

Suction valve gasket Nut Delivery valve holder Suction valve gasket Delivery valve Delivery valve spring Spring holder Gasket Cylinder head Bolt Cylinder liner a-ring 1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring

35 36 37 38 39 40 41 42 43 44 45 46 47

Piston pin Piston Nut Lock washer Connecting rod Bearing Bolt Connecting-rod cap Crankshaft Bolt Plate Bearing Crankcase

o :Non-reusable parts ~ : Locating pin

• Reassembly sequence Reverse the order of disassembly.

Service standards Location

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Limit

Remedy

15

Suction valve spring load (Installed length 9)

2.3 N {0.23 kgf}

1.3 N {0.13 kgf}

Replace

23

Suction valve spring load (Installed length 5)

3.2 N {0.33 kgf}

2.4 N {0.24 kgf}

Replace

Clearance between piston and cylinder liner

Top

[80] 0.27 to 0.33

0.35

Skirt

[80] 0.11 to 0.17

0.19

Replace cylinder liner Replace

28,36

30 to 33

30 to 33,36

Piston ring gap (as measured inside cylinder liner) Clearance between piston ring and piston groove

Compression ring

-

1.0

Oil ring

-

1.0

Compression ring

-

0.08

Oil ring

-

0.08

Replace

35,36

Clearance between piston pin and piston

[16]

0.08

Replace piston pin

35,39

Clearance between piston pin and connecting-rod small end

[16]

0.07

Replace connecting rod

Connecting rod end play

-

0.5

Replace connecting rod

[34]

0.1

Replace

-

1.0

Replace crankshaft

[76.5]

0.12

Replace crankshaft

39

40,43 43 43,47

Clearance between connecting-rod bearing and crankshaft Crankshaft end play Clearance between crankshaft and crankcase bushing I.D.

61-13

AIR COMPRESSOR
o

Tightening torque

Unit: N . m {kgf' m} Remarks

Tightening torque

Parts to be tightened

Location

167 to 211 {17.0 to 21.5}

-

Bolt (for coupling installation)

30 to 36 {3.1 to 3.7}

-

7

Bolt (for cylinder head installation)

25 to 29 {2.5 to 3.0}

-

8

Connector

29 to 34 {3.0 to 3.5}

-

13

Unloader valve guide

98 to 118 {1 0 to 12}

-

14

Suction valve holder

98 to 118 {10 to 12}

-

19

Nut

44 to 58 {4.5 to 6.0}

-

20

Delivery valve holder

98 to 118 {1 0 to 12}

-

27

Bolt (for cylinder liner installation)

25 to 29 {2.5 to 3.0}

-

37

Nut (for installation of connecting rod cap and connecti ng-rod)

23 to 25 {2.3 to 2.6}

-

44

Bolt (for plate installation)

14 to 18 {1.4 to 1.8}

-

1

Nut (for compressor gear installation)

5

~ Special tools Location

14

Part No.

Tool name and shape

Suction Valve Tool

Application

MH062013

For removal and installation of suction valve holder

MH062014

For removal and installation of delivery valve holder

MH060014

For removal and installation of piston rings

01730

20

Delivery Valve Tool

04813

30 to 33 Piston Ring Tool

01732

61-14

61 • Service procedure

W Installation of compressor gear • Install compressor gear 3 to crankshaft 43, ensuring that the "0" mark on the gear is aligned with the "0" mark on the crankshaft. • Insert tab A of lock washer 2 such that the "0" mark on compressor gear 3 remains exposed.

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

~ Suction valve holder [Removal and Installation] ~: Suction Valve Tool

[Staking] Stake cylinder head 26 at pOints not corresponding to O-ring's sealing surface A. B: Punch

~ Removal and installation of delivery valve holder ~: Delivery Valve Tool

61-15

AIR COMPRESSOR
Piston rings

[Removal and Installation]

rg: Piston Ring Tool 30 to 33

01738

[Installation positions] A: Inscription of letters B: Side rail C: Spacer D: Gap in 2nd compression ring 31 E: Gap in 1st compression ring 30 F: Side rail gap in oil ring 33 G: Spacer gap in oil ring 33 H: Gap in 3rd compression ring 32

Approx.

Approx.

120°C

120°C

E

H

®46994

~ Assembling connecting rod • Assemble connecting rod cap 42 onto connecting rod 39 such that inscribed numerical figures A are located on the same side. • Install bolts 41 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 42. • After tightening the nuts, bend lock washers 38.

39 37

38 A

42

61-16

43

41

09645

61

MEMO

61-17

AIR COMPRESSOR
1 2 3 4 5 6 7 8

Unloader pipe Connector Eye bolt Air outlet pipe Eye bolt Air inlet pipe Air compressor assembly O-ring

CO P61-20

*a: Injection pump assembly CO Gr. 13A *b: Oil pipe CO Gr. 13A *c: Flywheel housing CO Gr. 11

0: Non-reusable parts • Installation sequence

Reverse the order of removal.

®46966

o

Tightening torque

Unit: N· m {kgf' m} Tightening torque

Parts to be tightened

Location

Remarks

20 to 25 {2.0 to 2.5}

-

14.7 to 21.5 {1.5 to 2.2}

-

Eye bolt (for air outlet pipe installation)

130 {13}

-

Eye bolt (for air inlet pipe installation)

110 {11}

-

1

Unloader pipe

2

Connector

3

5

!j Lubricant Points of application

Location

8

61-18

O-ring

Specified lubricant Engine oil

Quantity As required

• Service proced

~

ure

I

61 I

Installation of air . compre • Set cylinder N 1 ssor assembly ((, o. of the engine . at TDG in th cJ-J Gr. 11 • After aligning ins'b . e compression stroke cn ed line A . a . mpressor ssembly 7 to flywheel hou:ingW~tch each other, install air co

~

35653

• pointer RemoveCinspection plug B and check if . . • If . Inscribed Ii . nol aligned, rem ne A IS aligned wilh ove and refit air com pressor assembl y 7 .

*c

35654

61-19

AIR COMPRESSOR
06

7~~

8~ 9

tr

1 0------' 011

24

26

~17 0

~J-I ~

@

II

~ I

16~

15 ~ 14--0 13-----9

~I

Gl 'L

23

L22 .,,;r21

~20

~19

O~~O

42

45

430 P46967

61-20

61 • Disassembly sequence 1 Nut

17 Nut

2 Lock washer 3 Compressor gear 4 Collar

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

5 Bolt 6 Connector 7 Gasket 8 Snap ring 9 Un loader valve 10 Unloader valve spring 11 Unloader valve guide 12 Suction valve holder 13 Suction valve spring 14 Suction valve 15 Suction valve seat 16 Suction valve gasket

33 34 35 36 37 38 39 40 41 42 43 44 45 46

Delivery valve holder ~uction valve gasket Delivery valve Delivery valve spring Spring holder Gasket Cylinder head Bolt Cylinder liner O-ring 1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring

Piston pin Piston Nut Lock washer Connecting rod Bolt Connecting-rod cap Bolt Oil seal Bearing holder O-ring Bearing Crankshaft Crankcase

.:. : Non-reusable parts

• Reassembly sequence Reverse the order of disassembly.

Service standards Location

Unit: mm Maintenance item

Standard value (Basic diameter in [ ])

Limit

Remedy

13

Suction valve spring load (Installed length 9)

2.3 N {0.23 kgf}

1.3 N {0.13 kgf}

Replace

21

Suction valve spring load (Installed length 5)

3.2 N {0.33 kgf}

2.4 N {0.24 kgf}

Replace

Cylinder liner to piston clearance

Top

[80] 0.27 to 0.33

0.35

Replace

Skirt

[80] 0.11 to 0.17

0.19

26,34

Piston ring gap (as measured inside cylinder liner)

Compression ring

-

Oil ring

-

1.0

28 to 30,34

Piston ring to piston ring groove clearance

Compression ring

-

0.08

Replace

33,34

Piston pin to piston clearance

[16]

0.08

Replace piston pin

33,37

Piston pin to connecting rod small end clearance

[16]

0.07

Replace connecting rod

0.5

Replace connecting rod

0.1

Replace connecting rod

1.0

Replace bearing and/or crankshaft

28 to 31

37

37,45

45

Connecting rod end play

Connecting rod big end to crankshaft clearance

Crankshaft end play

-

[34]

-

1.0

Replace

61-21

AIR COMPRESSOR
o

Tightening torque

Location

Unit: N· m {kgf' m}

Parts to be tightened

1

Nut (for compressor gear installation)

5

Tightening torque

Remarks

167to211 {17.0to21.5}

-

Bolt (for cylinder head assembly installation)

29 to 34 {3.0 to 3.5}

-

6

Connector

29 to 34 {3.0 to 3.5}

-

11

Unloader valve guide

98 to 118 {1 0 to 12}

-

12

Suction valve holder

98 to 118 {1 0 to 12}

-

17

Nut

44 to 58 {4.5 to 6.0}

-

18

Delivery valve holder

98 to 118 {10 to 12}

-

25

Bolt (for cylinder liner installation)

25 to 29 {2.5 to 3.0}

-

35

Nut (for installation of connecting rod cap and connecting rod)

23 to 26 {2.3 to 2.6}

-

40

Bolt (for bearing holder installation)

14 to 18 {1.4 to 1.8}

-

~ Special tools Location

12

Tool name and shape

Part No.

Suction Valve Tool

Application

MH062013

For removal and installation of suction valve holder

MH062014

For removal and installation of delivery valve holder

MH060014

For removal and installation of piston rings

01730

18

Delivery Valve Tool

04813

28 to 31

Piston Ring Tool

01732

61-22

61 -

"0"

~

• Service procedure

[I]

"0"

Installation of compressor gear

• install compressor gear 3 to crankshaft 45, ensuring that the "0" mark on the gear is aligned with the "0" mark on the crankshaft. • Insert tab A of lock washer 2 such that the "0" mark on compressor gear 3 remains exposed.

45

3 2 1 35656

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

G]]

Suction valve holder

[Removal and Installation] ~: Suction Valve Tool

[Staking] Stake cylinder head 24 at points not corresponding to O-ring's sealing surface A. B: Punch

G]]

Removal and installation of delivery valve holder

~: Delivery Valve Tool

61-23

AIR COMPRESSOR
Piston rings

[Removal and Installation] ~: Piston Ring Tool

(

)

-~

_ _\c.:-'

09643

[Installation positions] A: Inscription of letters B: Side rail C: Spacer D: Gap in 2nd compression ring 29 E: Gap in 1st compression ring 28 F: Side rail gap in oil ring 31 G: Spacer gap in oil ring 31 H: Gap in 3rd compression ring 30

D Approx.

Approx.

120°C

120°C

H ®36519

@Z]

Assembling connecting rod

• Assemble connecting rod cap 39 onto connecting rod 37 such that inscribed numerical figures A are located on the same side. • Install bolts 38 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 39. • After tightening the nuts, bend lock washers 36.

37

35 36

A 39

45

38

09645

~ Installing oil seal Face oil seal 41 as shown in the illustration. Then, fit it in bearing holder 42 by pressing evenly until it is flush with end face A of the holder.

®46829

61-24

61

MEMO

61-25

AIR COMPRESSOR <WATER-COOLED (OLDHAM'S COUPLING TYPE» • Removal sequence 1 2 3 4 5 6 7 8 9 10 11 12

6

*a

Unloader pipe Connector Eye bolt Air outlet pipe Eye bolt Air suction pipe Eye bolt Water inlet pipe Eye bolt Water outlet pipe Air compressor assembly O-ring

CD P.61-28

*a: Injection pump assembly CD Gr.13A *b: Oil pipe CD Gr.13A *c: Flywheel housing CD Gr.11 12 ~O

o :Non-reusable parts ®_46_9-----'9S

L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

•

Installation sequence

Reverse the order of removal.

o

Tightening torque Tightening torque

Parts to be tightened

Location

rG

Unit: N . m {kgf· m} Remarks

20 to 25 {2.0 to 2.5}

-

14.7 to 21.5 {1.5 to 2.2}

-

Eye bolt (for air outlet pipe installation)

98 {1 O}

-

5

Eye bolt (for air suction pipe installation)

180 {18}

-

7

Eye bolt (for water inlet pipe installation)

39 {4}

-

9

Eye bolt (for water outlet pipe installation)

39 {4}

-

1

Unloader pipe

2

Connector

3

lubricant

Location

12

61-26

Points of application a-ring

Specified lubricant Engine oil

Quantity As required

61 • Service procedure

[TIl

Installation of air compressor assembly

• Set cylinder No.1 of the engine at TDC in the compression stroke. Gr. 11. • After aligning inscribed lines A with each other, install air compressor assembly 11 to flywheel housing *c.

35653

• Remove inspection plug B and check if inscribed line A is aligned with pointer C. • If not aligned, remove and refit air compressor assembly 11.

35654

61-27

AIR COMPRESSOR <WATER-COOLED (OLDHAM'S COUPLING TYPE» Air Compressor Assembly

290

~25

23~24 22~

O~

47

®46996

61-28

61 • Disassembly sequence

1 Nut 2 Lock washer 3 Compressor gear 4 Spacer 5 Bolt 6 Coupling 7 Bolt 8 Connector 9 Gasket 10 Snap ring 11 Unloader valve 12 Unloader valve spring 13 Unloader valve guide 14 Delivery valve holder 15 O-ring 16 Spring holder 17 Delivery valve spring

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

35 36 37 38 39 40 41 42 43 44 45 46 47

Delivery valve O-ring Delivery valve seat Suction valve holder Suction valve spring Suction valve Suction valve seat Suction valve gasket Cylinder head Bolt Cylinder liner O-ring 1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring

Piston pin Piston Nut Lock washer Connecting rod Bearing Bolt Connecting-rod cap Crankshaft Bolt Plate Bearing Crankcase

o :Non-reusable parts ~ : Locating

pin

• Reassembly sequence Reverse the order of disassembly.

Service standards Location

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Limit

Remedy

17

Delivery valve spring load (Installed length 9.5)

4.5 N {0.46 kgf}

3.7 N {0.37 kgf}

Replace

22

Suction valve spring load (Installed length 9)

2.3 N {0.23 kgf}

1.3 N {0.13 kgf}

Replace

Clearance between piston and cylinder liner

Top

[80) 0.27 to 0.33

0.35

Skirt

[80) 0.11 to 0.17

0.19

Replace cylinder liner. Replace

28,36

30 to 33 Piston ring gap (as measured inside cylinder liner)

Compression ring

-

1.0

Oil ring

-

1.0

Compression ring

-

0.08

Replace

30 to 32,36

Clearance between piston ring and piston groove

35,36

Clearance between piston pin and piston

[16)

0.08

Replace piston pin

35,39

Clearance between piston pin and connecting-rod small end

[16)

0.07

Replace connecting rod.

0.5

Replace connecting rod.

0.1

Replace

1.0

Replace crankshaft.

0.12

Replace crankcase.

39

40,43 43 43,47

Connecting rod end play

Clearance between connecting-rod bearing and crankshaft Crankshaft end play Clearance between crankshaft and crankcase bushing 1.0.

-

[34) -

[99)

61-29

AIR COMPRESSOR <WATER-COOLED (OLDHAM'S COUPLING TYPE»

o

Tightening torque

Unit: N· m {kgf· m} Remarks

Tightening torque

Parts to be tightened

Location

167 to 211 {17.0 to 21.5}

-

Bolt (for coupling installation)

30 to 36 {3.1 to 3.7}

-

7

Bolt (for installation of cylinder head and cylinder liner)

25 to 29 {2.5 to 3.0}

-

8

Connector

29 to 34 {3.0 to 3.5}

-

13

Unloader valve guide

98 to 118 {10 to 12}

-

14

Delivery valve holder

98 to 118 {1 0 to 12}

-

21

Suction valve holder

98 to 118 {1 0 to 12}

-

27

Bolt (for installation of cylinder liner)

25 to 29 {2.5 to 3.0}

-

37

Nut (for installation of connecting rod cap and connecting-rod)

23 to 25 {2.3 to 2.6}

-

44

Bolt (for plate installation)

14 to 18 {1.4 to 1.8}

-

1

Nut (for compressor gear installation)

5

~ Special tools Tool name and shape

Location

21

Part No.

Suction Valve Tool

Application

MH062013

For removal and installation of suction valve holder

MH060014

For removal and installation of piston rings

01730

Piston Ring

30 to 33 Tool

01732

61-30

61 • Service procedure

[i]

Installation of compressor gear

• Install compressor gear 3 to crankshaft 43, ensuring that the "0" mark on the gear is aligned with the "0" mark on the crankshaft. • Insert tab A of lock washer 2 such that the "0" mark on compressor gear 3 remains exposed.

35656

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

~ Suction valve holder [Removal and Installation]

(.g: Suction Valve Tool

[Staking] Stake cylinder head 26 at points not corresponding to O-ring's sealing surface A. B: Punch

~ to ~

Piston rings

[Removal and installation]

(.g: Piston Ring Tool

61-31

AIR COMPRESSOR <WATER-COOLED (OLDHAM'S COUPLING TYPE» [Installation positions] A: Inscription of letters B: Side rail C: Spacer D: Gap in 2nd compression ring 31 E: Gap in 1st compression ring 30 F: Side rail gap in oil ring 33 G: Spacer gap in oil ring 33 H: Gap in 3rd compression ring 32

D Approx.

Approx.

120°C

120°C

H ®36519

~ Assembling connecting rod • Assemble connecting rod cap 42 onto connecting rod 39 such that inscribed numerical figures A are located on the same side. • Install bolts 41 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 42. • After tightening the nuts, bend lock washers 38.

39

37 38 A

42

61-32

43

41

09645

61

MEMO

61-33

AIR COMPRESSOR <WATER-COOLED (LAMINATED COUPLING TYPE» • Removal sequence

1 2 3 4 5 6 7 8 9 10 11

Eye bolt Water inlet pipe Eye bolt Water outlet pipe Eye bolt Air suction pipe Eye bolt Air outlet pipe Bracket Air compressor assembly O-ring

CO P'61-36

*a: Injection pump assembly CO Gr.13A *b: Oil pipe CO Gr.13A *c: Flywheel housing CO Gr.11

o :Non-reusable parts • Installation sequence

Reverse the order of removal.

®46968

o

Tightening torque

Unit: N . m {kgf· m} ---

Tightening torque

Parts to be tightened

Location

Remarks

1

Eye bolt (for water inlet pipe installation)

39 {4}

-

3

Eye bolt (for water outlet pipe installation)

39 {4}

-

5

Eye bolt (for air suction pipe installation)

180 {18}

-

7

Eye bolt (for air outlet pipe installation)

98 {1 O}

---

~ Lubricant Location 11

61-34

Specified lubricant

Points of application O-ring

Engine oil

Quantity As required

=====~1o~~===l-~.s~e:r~v~ic:e~p:r:o:c:ed:u~r:::-e------_IJ6~r:11 [iQ]

Installation of aIr . com pres • Set cylinder N 1 sor assembly CD Gr. 11. o. of the engine at TDG in th • After aligning. . e compression stroke Inscnbed r . ho. uSing *c.eac h other, install a·Ir compressor assembly 10 to flywheel Ines A with

_ _ _ 35653

• pointer Removec.inspection pIug B and check if insc ·b . A. . • If n ed line IS aligned with not aligned r . comp ressor assembly 10. , emove and refl·t air

*c

35654

61-35

AIR COMPRESSOR <WATER-COOLED (LAMINATED COUPLING TYPE» Air Compressor Assembly

12

~16 / 18

011~

4

28

270 ®46969

61-36

61 • Disassembly sequence 1 Nut 2 Lock washer 3 Compressor gear 4 Collar 5 Bolt 6 Cylinder head assembly 7 Gasket 8 Valve seat assembly 9 Bolt 10 Cylinder liner 11 a-ring

12 13 14 15 16 17

18 19 20 21 22

23 24 25 26 27 28 29 30

1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring Piston pin Piston Nut Lock washer Connecting rod Bolt

Connecting rod cap Bolt Oil seal Bearing holder a-ring Bearing Crankshaft Crankcase

0: Non-reusable parts

• Reassembly sequence Reverse the order of disassembly.

Service standards Location

10,18

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

Top

[85] 0.27 to 0.33

0.35

Replace

Skirt

[85] 0.11 to 0.17

0.19

Maintenance item Cylinder liner to piston clearance

12 to 15 Piston ring gap (as measured inside cylinder liner)

Compression ring

-

1.0

Replace

Oil ring

-

1.5

Compression ring

-

0.08

Replace

12 to 14,18

Piston ring to piston ring groove clearance

17,18

Piston pin to piston clearance

[16]

0.08

Replace piston pin

17,21

Piston pin to connecting rod small end clearance

[16]

0.07

Replace connecting rod

0.5

Replace connecting rod

0.1

Replace connecting rod

1.0

Replace bearing and/or crankshaft

21

21,29

29

o

Connecting rod end play

Connecting rod big end to crankshaft clearance

Crankshaft end play

-

[34]

-

Tightening torque

Location

Parts to be tightened

Unit: N· m {kgf' m} Tightening torque

Remarks

167 to 211 {17.0 to 21.5}

-

Bolt (for cylinder head assembly installation)

29 to 34 {3.0 to 3.5}

-

9

Bolt (for cylinder liner installation)

25 to 29 {2.5 to 3.0}

-

19

Nut (for installation of connecting rod cap and connecting rod)

23 to 25 {2.3 to 2.6}

-

24

Bolt (for bearing holder installation)

14 to 18 {1 .4 to 1.8}

-

1

Nut (for compressor gear installation)

5

61-37

AIR COMPRESSOR <WATER-COOLED (LAMINATED COUPLING TYPE»

r.g

Special tools Tool name and shape

Location

12 to 15

Part No.

Piston Ring Tool

MH060014

Application

For removal and installation of piston rings

01732

• Service procedure

@]

Installation of compressor gear

• Install compressor gear 3 to crankshaft 29, ensuring that the "0" mark on the gear is aligned with the "0" mark on the crankshaft. • Insert tab A of lock washer 2 such that the "0" mark on compressor gear 3 remains exposed.

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

~ to [!§]

Piston rings

[Removal and Installation]

[.g: Piston Ring Tool

Ii

~ 09643

61-38

61 [Installation positions] A: Inscription of letters B: Side rail C: Spacer D: Gap in 2nd compression ring 13 E: Gap in 1st compression ring 12 F: Side rail gap in oil ring 15 G: Spacer gap in oil ring 15 H : Gap in 3rd compression ring 14

D Approx. 120°C

Approx. 120°C

H ®36519

~ Assembling connecting rod • Assemble connecting rod cap 23 onto connecting rod 21 such that inscribed numerical figures A are located on the same side. • Install bolts 22 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 23. • After tightening the nuts, bend lock washers 20.

21 19

20 A 23

29

22

09645

~ Installing oil seal Face oil seal 25 as shown in the illustration. Then, fit it in bearing holder 26 by pressing evenly until it is flush with end face A of the holder.

®46829

61-39

AIR PRESSURE GOVERNOR • Disassembly sequence

1 2 3 4 5 6 7 8 9 10 11 12

Cover Nut Adjusting screw Spring Nut Sleeve O-ring Snap ring Filter Screen Cap Diaphragm

0: Non-reusable parts • Reassembly sequence

Reverse the order of disassembly. • Adjustment after reassembly

OJ P. 61-8

18426

o

Tightening torque

Location

Unit: N· m {kgf' m}

Parts to be tightened

Tightening torque

2

Nut (for tightening of adjusting screw)

9.8 to 15 {1 to 1.5}

-

5

Nut (for tightening of sleeve)

15 to 20 {1 .5 to 2}

-

61-40

Remarks

ISD1 diesel engine

Shop Manual (for industrial use) )... MITSUBISHI FUSO TRUCK & BUS CORP. SEPTEMBER 2004

566

PUb.No.97821-02031, SEPTEMBER 2004

MITSUBISHI FUSO TRUCK & BUS CORPORATION