Mitsubishi 6D22 Engine Service Manual Con Texto Reconocido PDF

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MITSUBISHI
MOTORS
Shop Manual
diesel engine
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6 D 2 (for industrial use)

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Pub. No. 97841-02003

ENGINE
Stop Manual GROUP INDEX

GENERAL ........................................... 0 0
F @ i i W i ENGOME ............................................... 1 1
This shop m anual contains the specification, co n LUBRBCATI0IM .............................. IE 1

struction, operation, a d ju s tm e n t and service proce
dures of the M odel 6D22, diesel e ngine fo r service
FUEL AMP ENGUWECOMTROL ...... 0 0
m echanics engaged in servicing o f th e M itsubishi
diesel engines.
COCLIMG ...................................... 1 4
Please make the m ost o f this shop m anual to p erform
correct servicing and wasteless operations.
DMYABE AMB EXHAUST ............... 1 5
Note that som e o f the contents of this shop m anual
are subject to change o w in g to im p ro v e m e n ts , etc.
that m ay be introduced after p ublication of this shop ENGBME ELECTRBCAL .................. 1 6
manual.
CLUTCH ....................................... ? 1
MAR. 1989
SPECOAL EQUIPMENT .................. 6 1
Applicable Engine M odels
6D22 1
6D22-T [ For industrial use
6D22-TC J
ORGANIZATION - GROUP CLASSIFICATION
1. G R O U P C L A S S IF IC A T IO N
This m anual is organized into several g ro up s classified a ccording to the e ng in e basic elements.
No. G roup nam e D escrip tion
00 General E xternal v ie w , m a jo r s p e cifica tio ns, e n g in e o u tp u ts classifie d by a p p lic a tio n , e ng in e n um b e rs,

ca u tio n plate, general p reca u tio ns fo r s e rv ic in g , general bolts and n uts tig h te n in g to rq u e table
11 Engine Engine p ro p e r (c y lin d e r head, va lve m e cha n ism , ca m sha ft, p is to n , crankshaft, tim in g gear, fly w h e e l),
sp ecifica tio ns, service sta n d ard s, special to o l, tro u b le s h o o tin g
12 Lubrication L u b rica tio n system (oil p um p , o il filte r, o il coole r), s p e cifica tio ns, service standards, special to o l,
tro u b le s h o o tin g
13 Fuel and engine Fuel system (in je ctio n p u m p , in je c tio n nozzle, fuel filte r, p u m p d riv e case, w a te r sepa ra to r), specifica tio ns,
co ntro l service standards, special to o l, tro u b le s h o o tin g
14 C ooling C oo lin g system (w a te r p u m p , th e rm o s ta t, ra d ia to r, c o o lin g system clea n ing p rocedures, fan), specifica tio ns,
service standards, special to o l, tro u b le s h o o tin g
15 Intake and exhaust A ir cleaner, tu rb o c h a rg e r, a fte r co ole r, s p e cifica tio n s, service s ta n d ard s, special to o l, tro u b le s h o o tin g
16 Engine e lectrical S tarter, a lte rn a to r, p re h e a ting syste m , relays, a u to m a tic stop device, s p e cifica tio n s, se rvice standards,
special to o l, tro u b le s h o o tin g
21 Clutch C lutch prop e r, bea rin g case, s p e cifica tio n s, service sta n d ard s, special to o l, tro u b le s h o o tin g
61 Special e q u ip m e n t A ir co m pre sso r, a ir p ressure g o v e rn o r, sp e c ific a tio n , service sta n d ard s, special to o l
MOTE:
Each group starts w ith page i .
2
ORGANIZATION - TERMS AND UNITS, TABLE OF
CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
2. TERM S AMO U N ITS

The fo llo w in g term s and units are used th ro u g h o u t the entire texts of this manual.
(1) Front and Rear
The term s " f r o n t " is the fan side and "r e a r " th e fly w h e e l side o f the engine.
(2) Right and Left
The te rm s " r i g h t " and " le ft" shall be used to indicate the side as vie w e d fr o m the fly w h e e l side o f the engine.
(3) Service Standard Term s
N om ina l value
Show s the n om in a l d im en sion s, d im e n sio n o f an ind ivid u a l part, standard clearance betw een parts in an
assembly, or the standard perform an ce o f an assembly.
Lim it
Sh ow s the value of a part at w h ic h the part is no lo n g e r serviceable fr o m the p erform an ce as w ell as strength
vie w p o in ts, req uirin g replacem ent or repair.
(4) T igh ten ing T orque
Over- or u n d e rtig h te n in g of bolts and nuts has critical effects on p erfo rm a n ce and functions.
T igh ten ing to rq u e is therefore specified fo r som e tig h te n in g points.
All tig h te n in g to rq u e specifications m ay be considered as " d r y " unless " w e t " is specified.
W here no tig h te n in g to rq u e is specified, use a to rq ue value specified in the General Bolts and Nuts T ig h te n in g
T orq ue Table.
(5) Units
For length, w e ig h t, area, and v o lu m e , the SI unit (International System o f Units) is used w ith the m e tric n ota tion
jo in tly s h o w n in parentheses.
Tem p eratu re is sh ow n in centigrade (C).
3. TABLE F OMVERSBQM RATE FOR FO O T-PO UND MAYS OMTQ SO MOTS
U n it S ign o f SI u n it Sign o f fo o t-p o u n d u n it C onversion rate
Mass q u a n tity o f m a tte r kg lb 1 kg = 2.2046 lb

g oz 1 g = 0.035274 oz
D im ension m ft. 1 m = 3.2808 ft.

mm in. 1 m m = 0.03937 in.
Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)

1 lit. = 0.220 gal. (Im p.)
cc OZ 1 cc = 0.033814 oz (U.S.)
1 cc = 0.035195 oz (Im p.)
Force N (N ew ton) Ibf 1 N = 0.2248 Ibf
Pressure kPa (kilopascal) lb f/in .2 1 kPa = 0.145 Ib f/in .2

1 kPa = 0.2953 in.Hg
Stress N /cm 2 Ib f/in .2 1 N /cm 2 = 1.45 Ib f/in .2
M o m e n t o f force N m Ibf. ft 1 N m = 0.7375 Ibf. ft
O u tp u t kW (kilo w a tt) HP 1 kW = 1.34 HP
Tem perature C F tC = d .8 tC + 32)F
3
ORGANIZATION - READING THE ILLUSTRATION
4. R EAPIN G TH E OLLUSTRATO^
(Ex. 1: D isassem bly and Inspection)
NV ... N o m in a l Value
L ... L im it
D am age, a bn o rm a l w e a r
Indicates the
service standards.
Inner or o u te r p e rip h e ry dam aged,

co rro d e d o r peeled
N um b e rs assigned ind ica te a typ ica l d is a s s e m b ly sequence.
1 Connecting rod cap Oil ring

2 Connecting rod bearing 7 Snap ring
Piston 8 Piston pin
1st compression ring 9 Connecting rod
2nd compression ring
l
Indicates th a t th e disa sse m b ly
p roce d u re is e xpla ine d in th e text.
C2337C
4
O R G A N IZ A T IO N R E A D IN G THE IL L U S T R A T IO N
(Ex. 2: Reassembly)
(1) Illustrations (exploded view s and a ssem bly d ra w - identical a m o n g v a riou s typ es of available systems
ings) show a typical service procedures if it is and units.
5
00
CONTENTS
1. EXTER N A L VIE W ....................... . 2 3. E N G IN E N U M B ER S AND

2. M AJO R S P E C IF IC A T IO N S ............ 3 C A U T IO N PLATE ..... ................. 4
2.1 M AJO R S P E C IF IC A T IO N S .......... 3 4. G ENERAL P R E C A U TIO N S
2 .2 EN G IN E O U T P U T S C L A S S IF IE D FOR S E R V IC IN G ..... . 5
BY A P P LIC A TIO N ........................... 3 5. G ENERAL BO LTS AND N U TS
T IG H T E N IN G TO R Q U E TABLE 6
00-1
00 GENERAL E X T E R N A L V IE W
i . E XTER N A L VBEW
N atural-aspirated e n g in e >
A0243A
< T u rb och a rg e d e n g in e >
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS 00
2 M A J O R S P E C IF IC A T IO N S
2.1 M AJO R SPEC0F1CAT1OMS
Engine m odel 6D22-TC (Tu rb och a rg ed , w ith

6D22 6D22-T (Turbocharged)
Item a fte r cooler)
Type Diesel, 4-cycle, Diesel, 4-cycle, Diesel, 4-cycle,

w a te r-co o le d w a te r-c o o le d w a te r-c o o le d
C om b u stio n m e th o d D irect in je c tio n D irect in je c tio n D irect in je c tio n
No. and a rra n g e m e n t o f cylin d e r 6 in-line 6 in -lin e 6 in-line
C ylin de r bore x stroke mm 130 x 140 130 x 140 130 x 140
T o ta l d isp la cem e n t cc 11 149 11 149 11 149
E ngine d im e n sio n
(w ith o u t fan)
O verall length mm 1 390 1 390 1 401
O verall w id th mm 898 872 882
O verall heig h t mm 1 023 1 162 1 209
E m p ty w e ig h t kg* 980 1 010 1 015
* E m pty w e ig h t as m easured a ccording to M its u b is h i M o to rs C o rp o ra tio n sta n d ard .
2.2 E N G IN E O U T P U T S C L A S S IF IE D BY A P P L IC A T IO N
E ngine m o de l 6D22-TC
6D22-T
6D22 (Tu rb och a rg ed , w ith
(Tu rb och a rg ed )
A p p lica tio n a fte r co ole r)
In te rm itte n t rated o u tp u t kW (H P )/rp m 109 (1461/1 500 161 (2161/1 500 179 (2401/1 500
129 (1731/1 800 186 (2491/1 800 207 (2771/1 800
141 (1891/2 000 195 (2611/2 000 219 (2341/2 000
149 (200I/2 200 201 (269I/2 200 227 (3041/2 200
C on tin u ou s rated o u tp u t kW (H P )/rp m 99 (1321/1 500 146 (1961/1 500 163 (2181/1 500
117 (1571/1 800 169 (2261/1 800 188 (2521/1 800
128 (1711/2 000 178 (2381/2 000 199 (2671/2 000
135 (1811/2 200 183 (2451/2 200 206 (2761/2 200
MOTE:
1. Tine o u tp u t {SAE, gross) Is c o rre c te d to
s tan d a rd a m b ie n t c o n d itio n s based on
SAE J 1 3 4 9 .
2. T h e con tinuous ra te d o u tp u t a llo w s
10% tone hour) o ve rlo ad o p e ra tio n .
00-3
00 GENERAL - ENGINE NUMBERS AND CAUTION PLATE
3. E N G IN E N U M B ER S AND CAUYOON
PLATE
(1) Engine N u m b er
V A L V E C L E A R A N C E (COLD)
______ 1
IN L E T 0.4m m (0 .0 l 6 i n U
E X H A U S T 0.6m m ( 0 . 0 2 4 in )
F IR IN G O R D E R 1 - 5 - 3 - 6 2 4 -
------ 2
FUELINJECTION TIMINGEZTBTDC-
3
1 Valve clearance
2 Firing order
3 Fuel injection timing
B9012A
The e ngine n u m b e r is s ta m p e d on the p osition as

illustrated.
Ex: 6 D 2 2 - 0 1 2 3 4 5
------------------------- Engine n u m b e r
----------------Engine m od el
The engine n u m b e r is im p o r ta n t in k n o w in g the

h istory o f th e engine.
(2 ) C a u tio n P la te
E0175
The caution plate is located as illustrated. The caution

plate bears the valve clearance, fuel injection se qu
ence and tim in g .
00-4
GENERAL - GROUP P R E C A U T IO N S FO R S E R V IC IN G
4 . GEMEFAL PRECAUTIONS FOR SER

WOCONG
Before starting the service procedures, check the
vehicle fo r total tim e driven, use co n d itio n s, and
user's co m p la in ts and requests to k n o w exactly the MITSUBISHI MOTORS
GEwuiiE m .m s
engine conditions. Record in fo rm a tio n w h e re neces
sary.
To ensure you are d o ing correct and efficient service
V __ __ _
jobs, observe the fo llo w in g precautions:
A0006A
(7) The oil seals, packings, O-rings, and o th e r rub be r

parts, gaskets, and split pins m ust be replaced w ith a
new one w h e n e v e r they are rem ove d. For replace
m ent, use M itsub ish i G enuine parts.
(1) Before p e rfo rm in g the service p rocedures given

in this manual, kn o w the tro u b le spots and isolate the
possible cause to d ete rm ine w h e th e r the rem oval or
d isassem bly p rocedure is required.
(2) Select a flat surface fo r the service job.
(3) W hen servicing the electrical system, be sure to
disconnect the negative cable fr o m the battery.
(4) Carefully check parts fo r oil leaks before cleaning.
A fte r cleaning, it m ay b ecom e d iffic u lt to s p o t defec (8) A p p ly the specified grease to U-packings, oil
seals, dust seals, and bearings before installation.
tive areas.
(5) Ready and make the m o s t of the special tools (9) W hen w o rk requires an assistant o r tw o , alw ays
required fo r servicing. Use the rig h t tools (specified make sure o f the safety each other. Never play w ith
special tools) in the rig h t place to prevent d a m a g e s to sw itches and levers.
parts and personal injury. (10) Make sure th a t y o u r shoes are free f r o m grease
(6) Make a lig n m e n t marks and keep disassem bled and oil especially w h e n w o r k in g on a heavy item.
parts neatly arranged to ensure th a t th ey are reas (11) W hen checking o r ch a n g in g lubricants, w ip e off
sem bled into the rig ht positions. grease and oil fro m parts im m e d ia te ly w ith a waste.
Special care m u s t be taken fo r assem blies in v o lv (12) Special care m u s t be taken in h a n dling sensors
ing a n u m b e r o f parts, s im ila r parts, or parts and relays w h ich are suspectible to shocks and heat.
identical at right- and left-hand sides to ensure (13) Use care so that hands and fin g e rs are not injured
correct reassembly. by sharp edges o r corners o f the parts.
For a lig n m e n t and p u n ch in g m arkings, select a (14) W e a r safety g og gles w h e n e v e r h a n dling a g rin d e r
position that w o u ld n ot m a r the appearance and or w e ld in g m achine. W e a r g loves as required to

ensure u tm o s t safety.
function.
Clearly d istin g u ish parts to be replaced fro m
those reused.
00-5
G ENERAL - G ENERAL BOLTS A N D N U TS
00 T IG H T E N IN G T O R Q U E T A B L E
5. GEMEI3AL BOLTS AM MUYS T IG H T - MTEs

EMDMG TO RQ UE TABLE 1. T h re a d s and s e a t s u rfa c e s m u st be ire
Unless o th e rw is e specified, th e parts and e q u ip m e n t
dry state
of vehicle m u s t be tig h te n e d by the fo llo w in g stan 2. W hen th e re is a d iffe re n c e b e tw e e n th e
dard bolts and nuts. T ig h te n in g to rq ue s fo r these nut and bolt (stu d ) id e n tific a tio n m arks,
bolts and nuts are s h o w n below . tig h te n to th e to rq u e co rresp o n d in g t
th e b o lt (stu d ) id e n tific a tio n m a rk .
Standard bolts and nuts
U n it: N m (kgfm )
Dia. m m Pitch m m 4T (Head m ark 4 o r O) 7T (Head m ark 7 o r 0 ) 8T (Head m a rk 8 o r )
5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 (0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
10 1.25 18.6 to 27.5 (1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.5 to 6.0)
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
12 1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
14 1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
16 1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 (19 to 26)
Flange bolts and nuts

U n it: N m (kgfm )
Dia. m m Pitch m m 4T (Head m ark 4 o r O) 7T (Head m ark 7 o r ) 8T (Head m ark 8 o r 0 )
6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 (1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
1.5 18.6 to 28.4 (1.9 to 2.9) 35.3 to 53.0 (3.6 to 5.4) 44.1 to 63.7 (4.5 to 6.5)
12 1.25 37.3 to 53.9 (3.8 to 5.5) 78.5 to 108 (8.0 to 11) 88.3 to 118 (9.0 to 12)
1.75 33.3 to 51.0 (3.4 to 5.2) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
00-6
11
ENGINE
CONTENTS
1. G ENERAL ........ 2 5 .3 FLY W H EE L, T IM IN G GEAR AND

2. S P E C IF IC A T IO N S ........ 8 C A M S H A FT .................. ................. 30
3. SE R V IC E STAND AR DS .............. 9 5.3.1 D isassem b ly ................................ 30
3.1 SER VIC E STA N D A R D TABLE ..... 9 5 .3 .2 In s p e c tio n ................................... 34
3 .2 T IG H T E N IN G TO R Q U E TA BLE ... 12 5 .3 .3 D isassem b ly ..... ................. ........ 38
4. SPEC IA L TOOL ..................................... 13 5 .4 C R A N K C A SE AN D M A IN M O V IN G
5. SE R V IC E PRO CEDURES ................... 17 PARTS ............................. . 42
5.1 M E A S U R E M E N T OF C O M P R E S 5.4.1 D isas sem b ly ...... 42
SIO N PRESSURE ........................ 17 5 .4 .2 In s p e c tio n .......... 46
5.2 CYLONDER HEAD AND VA LVE 5 .4 .3 R e asse m b ly ............................ 56
M E C H A N IS M ......... 18 5 .5 IN S P E C T IO N AND A D JU S T M E N T
5.2.1 D isassem b ly ................... 18 OF V A LV E CLEAR AN CE ............ . 62
5 .2 .2 In s p e c tio n ....... 21 6. T R O U B L E S H O O T IN G .................. . 64
5 .2 .3 R easse m b ly ....... 27
11-1
11 E N G IN E - GENERAL
1. Q E I^ E fm iL
(1 ) C o m b u s tio n C h am b er
For m o re effective co o lin g o f the co m b u s tio n c h a m

ber, w a te r directors w h ic h direct c o o la n t f lo w are
pressed into the b o tto m o f the c y lin d e r head.
(2 ) V a lv e M e c h a n is m
The c o m b u s tio n ch a m b e r is m ad e up o f the cylin d e r

head and piston top. The inje ction nozzle as w ell as
the nozzle tube is m o u n te d to th e cylin d e r head. The
nozzle tube holds the nozzle in p osition and protects
the nozzle sheathed by it fr o m coolant. Since the
outside o f the nozzle tu b e is exposed to the w a te r
jacket, the to p end o f the tube is sealed o ff w ith an
O-ring and the b o tto m end staked to pre ven t entrance
o f water.
C o m b u stio n is a ccom plishe d by c o m p re ssin g the fuel
d irectly injected into the c o m b u s tio n cham ber.
The valve m ech an ism is o f overhead valve type and is

co nstructed as s h o w n above.
11-2
E N G IN E - GENERAL 11
(a) Both inlet and exhaust valves are m ade of
surface-treated heat-resistant steel. The valve seat
angle is 45 .
A valve stem seal is p ro vid e d on the stem of valve to
control the q u a n tity o f lub rica nt of the valve and valve
g uide sliding portions.
(b) The valve springs are u ne ven ly-p itche d springs.
Two inn er and o u te r sp ring s d ifferen t in coiled
direction are installed.
(c) The rocker and rocker shaft are s u pp orte d on the
rocker shaft bracket and are in d e p e n d e n tly installed
fo r each cylinder. S o m e rockers are used fo r both inlet B0378A
and exhaust valves, and the end sliding p ortion is

quenched. (b) The c o olan t fed in fr o m the w a te r p u m p at the left
The rocker shaft is a h o llo w rou nd rod sealed o ff by fro n t end o f th e crankcase cools the oil cooler, then
th ru st plates at both ends. The inside o f the shaft flo w s th ro u g h the w a te r jacket holes and around all
constitutes an engine oil passage. the cylinders to cool th e m before reaching the
(d) A steel ball and concave piece are respectively cylin d e r head.
w eld e d to the b o tto m and to p ends o f the push rod (c) The c y lin d e r liner is o f rem ova ble w e t type and its
and both ends are case-hardened. to p and b o tto m are press-fitted at the to p of the
(e) The ta pp et is o f cylind rica l shape and its m ating crankcase and th e w a te r jacket in crankcase, respec
surfaces w ith the ca m sh aft are spherical. The ta ppet tively.
is rem ova ble th ro u g h the side of the crankcase. Rubber rings and O-rings are installed at the top and
(f) The cam profile of the ca m sh a ft has a special b o tto m o f c y lin d e r liner to prevent e ntry o f coolant.
curve. The surface is in d u ctio n -h a rd e n e d to im p ro v e The w a te r jacket has a coolant th ro ttlin g shelf for
the p erform an ce of the valve m e ch a n ism at high h ig he r cooling p erform ance.
speed o p e ra tion and im p ro v e w e a r resistance. (4 ) Pastora asid Pastora Rarag
(3) C ra n k c a s e and C y lin d er Liner (a ) Pastora
(a) Seven ca m sh a ft b ush in gs are installed to the The piston, m ade of a lu m in u m alloy casting, has a
ca m shaft bearing p o rtio n of th e crankcase. To facili to ro id a l type c o m b u s tio n ch a m b e r at its top.
tate insertion and rem oval o f the ca m sh a ft fr o m the
rear end of the case, the bearing I.D. is n a rro w e r
to w a rd th e front.
11-3
11 ENGINE - GENERAL
A N iresist piston ring insert is cast into the 1st piston (5 ) C o n n e c tin g Rod a n d C o n n e c tin g Rod
ring g ro o v e to increase d u ra b ility. B e a rin g
S tam pe d on the top surface o f the piston are a size
m ark (or oversize d im e n s io n on oversize pistons) for
selection fit w ith the c y lin d e r liner, a piston w e ig h t
mark, part n um be r, id e n tifica tion mark, and the "F "
w ith an a rr o w fo r the fro n t m ark s h o w in g the piston
installing direction.
Piston pin fo r co nn ectin g piston to co nnecting rod is
of fu ll-flo a tin g type and is pre ven te d fr o m m o v in g out
by means of a snap ring installed on each end of the
pin ends.
On the piston fo r the 6D22-TC, a co o lin g ca vity is
provided.
(b ) P is to n rin g
The co nn ectin g rod is a die fo rg in g o f I cross section

p ro v id in g high rig idity. A lead bronze bushing is
press-fitted o n to the small end. The co nnecting rod
bearing o f the big end is a split type plain bearing.
There are three piston rings installed: tw o c o m p re s
T h ro u g h the stem o f co nnecting rod, an oil passage is
sion rings and one oil ring. The sliding surface of each
p ro vid e d o b liq u e ly to lubricate the small end bushing.
ring is hard c h ro m e plated to im p r o v e d urability.
On the to p o f co nn ectin g rod fo r the 6D22-TC, an oil
The piston rings are shaped as s h o w n in th e figure.
hole is p ro vid e d fo r co o lin g th e piston.
The co nn ectin g rod and co nnecting rod cap are
co up le d w ith fo u r bolts.
11-4
E N G IN E - GENERAL m
(6) C ra n k s h a ft and M ain B earing
(a) The crankshaft is a h ig h -rig id ity die fo rg in g in te g

ral w ith the balance w eig ht.
An oil hole in each jou rn a l is th ro u g h to th at in pin,
fe eding so m e o f the main bearing lub rica ting oil to
the pin fo r lub rica tion o f the co nn ectin g rod bearing.
Flyw heel h o u sin g O -ring
The fro n t p o rtio n o f the crankshaft is a fla ng e type to

w h ich the crankshaft p u lle y is m o u n te d w ith bolts. A
torsional d a m p e r m o u n te d to the pulley absorbs the
to rsio na l v ib ra tio n o f the crankshaft.
(b) The crankshaft gear d rivin g tim in g gear is fitte d

onto the rear end o f th e crankshaft.
Note th at the crankshaft has an axial lip type oil seal
fitte d to each o f its fro n t and rear ends.
11-5
11 E N G IN E - GENERAL
la} Maim bearin g The m ain bearing is a split type plain bearing m ade o f
special alloy plated kelm et metal w ith backing metal.
The u p p e r main bearing has an internal oil g ro o ve
and oil hole w h ic h coincides w ith the oil hole in the
crankshaft.
Seven pairs o f m ain bearings are provided. Split type
th ru s t plates are m o u n te d to the rear-m ost bearing to
bear the th ru st o f the crankshaft.
U pper m ain Low e r m a in T h ru st plate

bearing bearing
B0382A
{7} Tim ing G ears
The tim in g gears are a cc o m m o d a te d in the flyw h e e l sh o w n above,

h ousing at the rear o f the engine. The gear train is as
11-6
ENGINE - GENERAL 11
Each gear is a carbon steel helical gear having a (8) F lyw h eel
high-prescision to o th surface m ach in e d by the sh a v
ing m achine and given surface tre a tm e n t to im p ro v e
d urability.
A tim in g m ark is sta m p ed on each tim in g gear.
Correct m eshing can be achieved by a lig ning the
tim in g marks at reassem bly.
The crankshaft gear, press-fitted o n to the crankshaft
and held in position by a d o w e l pin, drives all gears.
The fly w h e e l is m ade o f cast iron. The p ilo t bearing o f

the clutch shaft is installed at th e center o f the
flyw he el. The ring gear w h ich meshes w ith the starter
pin ion is shrinkage-fitted on the outside perip h ery of
the flyw heel.
The ring gear teeth crests are ind uctio n-h arde ne d to
assure high d urab ility. One side o f the teeth is
cham fered to make sure that the sta rter pinion fits
The idler gear is, at one end, m o u n te d to the easily.
crankcase w ith the idler shaft bolt, and supp orte d, at The cylin d e r n u m b e rs and angle scale are stam ped on
the othe r end, on the flyw he el housing. the outsid e p erip h ery o f the flyw he el as sh ow n in the
A b ushing is pressed into the idler gear w h ich turns figure.
on the idler shaft.
The bushin g is lubricated by the engine oil flo w in g
th ro u g h the inside o f the idler shaft fr o m the crank
case oil hole.
11-7
11 ENGINE - SPECIFICATIONS
2. S P E C IF IC A T IO N S
Item S pe cifica tio ns
E ngine m o de l 6D22 6D22-T 6D22-TC
Type W a te r cooled, W a te r cooled, W a te r cooled,

4-cycle diesel 4-cycle diesel 4-cycle diesel
N u m b e r o f cylin d e rs-a rra n g e m e n t 6 -in -lin e 6 -in -lin e 6 -in-line
V alve m echanism O verhead valve O verhead valve O verhead va lve
C o m b u stio n ch am b e r D irect D irect D irect
in je c tio n type in je ctio n type in je ctio n type
C y lin d e r b ore x stroke mm 130 x 140 130 x 140 130 x 140

Total d isp la cem e n t cc 11 149 11 149 11 149
C om p re ssio n ratio 17 16 15.5
Firing o rde r 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

C y lin d e r lin e r Type W e t typ e W e t type W et type
Piston Type Trunk, slip p e r Trunk, s lip p e r Trunk, slip p e r
skirt typ e skirt type skirt type
(C ooling c a vity p rovided)
Piston ring Q 'ty C om p re ssio n rin g : 2 C om pression rin g : 2 C om pression rin g : 2
Oil rin g : 1 Oil rin g : 1 Oil rin g : 1
11-8
ENGINE - SERVICE STANDARDS 11
3. 3EFVDCE S T A N D A R D S
3.1 S E R V IC E S T A N D A R D T A B L E
U nit: m m
D escrip tion N o m in a l value L im it C orrection and rem arks

(Basic d ia m e te rl
C om p re ssio n pressure 2.75 MPa 1.96 MPa D ifference betw een c y lin d e r w ith in
(at 200 rpm ) (28 kg f/c m 2) 20 kg f/c m 2 0.39 MPa (4 kg f/c m 2)
Rocker to rocker sh a ft clearance |28| 0.2 Replace bush in g.

0.03 to 0.08
O uter va lve sp rin g Free len g th 89.38 85 Replace.
Load (In sta lle d le n g th : 450 N (46.1 kgf) 380 N

58.35) (39 kgf)
Inner valve sp rin g Free len g th 65.04 62.0 Replace.
Load (Installed le n g th : 115 N (12 kgf) 100 N

50.35) (10.2 kgf)
Squareness - 2.5
Crankcase ta p p e t hole to ta p p e t clearance (35| 0.2 Replace tappet.

0.06 to 0.10
Push rod ru n o u t - 0.5 Replace.
C ylin de r head b o tto m surface d is to rtio n 0.07 o r less 0.08 C orrect o r replace.
H eig h t fro m to p to b o tto m surface o f c y lin d e r head 130 129.8 Replace.
Valve stem O.D. Inlet 11.95 to 11.96 11.85 Replace.
E xhaust 11.91 to 11.93
Valve stem to valve Inlet [12| 0.05 to 0.09 0.2 Replace valve guide.
guid e clearance
E xhaust 112[ 0.09 to 0.12
D epth o f va lve fro m c y lin d e r head Inlet 0.25 to 0.75 1.0 Replace valve seat insert.
b o tto m surface S ervice lim it: va lu e w he n a
n ew valve is installe d.
E xhaust -0 .0 5 to 0.45 0.7 ( - indica te s p ro je c tio n am ount.)
Valve seat angle 45 -
Valve m a rg in Inlet 2.2 1.7 Replace.
Exhaust 2.5 2.0
Seat w id th o f valve seat inse rt 2.69 to 2.96 3.5 C orrect o r replace.
E cce n tricity o f flyw h e e l h o u sin g - 0.2 C orrect in stalle d co n d itio n .
11-9
n ENGINE - SERVICE STANDARDS
U n it: m m
D escription N om in al value L im it C orrection and rem arks

[Basic d iam eter]
Flyw heel E ccentricity - 0.2 C orrect installe d co n d itio n .

(Flyw heel h ousing)
Friction surface d is to rtio n 0.1 o r less 0.2 C orrect.
D epth fro m clu tch co ve r m o u n tin g 48 49.5 Replace.

surface to fric tio n surface
Backlash Betw een cra nksh a ft gear and 0.12 to 0.26 0.4 Replace.
o f tim in g id le r gear "B "
gears
Betw een id le r gear " A " and 0.13 to 0.26 0.4
ca m sha ft gear
Betw een idle r gear "A " and 0.13 to 0.26 0.4
id le r gear "C "
Betw een in je ctio n p u m p gear and 0.12 to 0.26 0.4

id le r gear "C "
End p la y o f id le r gear 0.1 to 0.28 0.4 Replace th ru s t plate.
Id le r sh aft " A " to idle r gear " A " b u sh in g clearance I40] 0.2 Replace bush in g.
0.03 to 0.06
Id ler sh aft "C " to id le r gear "C " b u sh in g clearance (46] 0.2 Replace bush in g.
0.03 to 0.06
End pla y o f ca m sha ft gear 0.05 to 0.22 0.4 Replace th ru s t plate.
C am shaft No. 1 jo u rn a l I65] 0.25 Replace bush in g.

jo u rn a l to 0.03 to 0.08
ca m sha ft
b u sh in g No. 2 jou rn a l [65.25]
clearance 0.03 to 0.08
No. 3 jou rn a l (65.50]

0.03 to 0.08
No. 4 jo u rn a l (65.50]
0.03 to 0.08
No. 5 jo u rn a l (65.75]
0.03 to 0.08
No. 6 jou rn a l (65.75]

0.03 to 0.08
No. 7 jo u rn a l (66]
0.03 to 0.08
Cam p ro file Inlet (8.83| 8.3 In let: lobe h eig h t, 56.167;

(D ifference betw een lobe h e ig h t and base circle d ia m e te r, 47.334
base circle dia m e te r)
Exhaust (8.821 8.3 E xhaust: lobe h e ig h t, 56.036;
base circle d ia m e te r, 47.216
C am shaft bend 0.05 o r less 0.08 Replace.
Crankcase to p surface d is to rtio n 0.07 o r less 0.2 Correct.
11-10
E N G IN E - S E R V IC E S T A N D A R D S m
U n it: m m
D escrip tion N om in al value L im it C orrection and rem arks

IBasic d ia m e te r]
C ylin de r I.D. 130.014 to 130.054 130.25 Replace or correct to oversize.

lin e r
C ylin d ric ity 0.02 o r less -
(d ia m e te r base)
P rojection fro m crankcase to p 0 to 0.08 -

surface
Piston to 6D22 [1301 - R epair o r replace c y lin d e r liner,

c ylin d e r 0.178 to 0.204 or replace piston.
lin e r c le a r
ance (selec 6D22-T (130) -
tio n fit) 0.173 to 0.199
6D22-TC [130] -
0.188 to 0.214
Piston 1st ring 0.06 to 0.11 0.25 Replace p iston ring o r piston.
ring
g ro o ve 2nd ring 6D22 0.05 to 0.08 0.15
to ring
clearance 6D22-T, 6D22-TC 0.07 to 0.10
Oil ring 0.03 to 0.06 0.15
P iston rin g open end clearance 0.4 to 0.6 1.5 Replace.
P rojection o f p isto n fro m to p surface o f crankcase 0.87 to 1.33 - Check each part.
Piston p in hole to p isto n p in clearance [50] 0.1 Replace p iston or p istn pin.
0.01 to 0.02
Flatness o f c ylin d e r lin e r fla ng e s u p p o rtin g surface - M ore than Replace crankcase.
on crankcase 0.1
C onnecting Bushing to p isto n p in clearance [50] 0.1 Replace bushing.

rod 0.02 to 0.05
Bend and to rsio n - 0.05 o r less C orrect or replace.
End play 0.2 to 0.5 1.0 Replace.
C onnecting Oil clearance |84| 0.25 Replace bearing.

rod bearing 0.07 to 0.13
Tension w h e n free - Less than Replace.

90.5
C rankshaft End play 0.09 to 0.23 0.4 A d ju s t w ith oversize th ru s t plate.
Bend 0.04 or less 0.1 C orrect or replace.
O u t-o f-ro u n dn e ss o f jo u rn a l and pin 0.01 o r less 0.08 G rin d and correct to undersize.
C y lin d ric ity o f jo u rn a l and pin 0.006 o r less -
M ain Oil clearance [100| 0.25 Replace bearing.

bea rin g 0.08 to 0.15
Tension w h e n free - Less than Replace.

106.5
V alve clearance Inlet 0.4 - A djust.
Exhaust 0.6 - A d ju st.
11-11
11 ENGINE - SERVICE STANDARDS
3 .2 TBGIHITEMiMG TO RQ UE TABLE
D escrip tion Thread size T ig h te n in g torque Remarks

O-D. x Pitch m m N m (kgfm )
Engine C ylin de r M14 x 2 W et

prop e r head b o lt For tig h te n in g
p roce d u re re fe r to
5.2.3 (6).
Rocker sh aft bracket b o lt M 10 x 1.5 34 (3.5)
Rocker co ver bolt M 10 x 1.25 9.8 (1)
Rocker a d ju stin g scre w lock nut M 10 x 1.25 59 (6)
Oil je t check valve M 12 x 1.75 34 (3.5)
C onnecting rod nut M 13 x 1.25 115 (12) W et
M ain bea rin g cap b o lt M18 x 2.5 370 (38) W et
C rankshaft p u lle y b o lt M14 x 1.5 175 (18)
C am shaft g ea r nut M27 x 1.5 265 (27) W et
Id le r shaft b o lt " A " M 16 x 2 155 (16)
Id ler sh aft b o lt " C " M 16 x 2 155 (16)
Id ler sh aft n ut (fo r m o u n tin g collar) M 16 x 1.5 98 (10)
F lyw heel b o lt M 16 x 1.5 315 (32) W et
F lyw heel hou sin g b o lt M 12 x 1.75 69 (7)
11-12
E N G IN E - S P E C IA L T O O L II
SPECIAL T@OIL
11-13
11 ENGINE - SPECIAL TOOL
Tool nam e Part No. Shape Use
Rocker b u sh in g p u lle r MH061236 Removal and in s ta lla tio n o f rocker

Dushing
B5311A
V alve g u id e p u lle r 30091-08100 Removal and in s ta lla tio n o f valve g u id e
3 5 1 11a
V alve seat inse rt C aulking to o l b od y In s ta lla tio n and caulkin g o f valve seat
caulking to o l MH061360 inse rt
C aulking tool
1 b od y
C aulking ring in le t
MH061650 {Ip - C aulking
[ i ring
C aulking rin g exhaust

MH061651 O.D.
Inlet 59
E xhaust 54
D ia m e te r 12 B5202A
Valve lapper 30091-07500 L apping o f valve
B5261A
Id ler gear bush in g p u lle r MH061228 R em oval and in s ta lla tio n o f id le r gear
b u sh in g (Idler gear " A " )
' B5121A
MH062046 R em oval and in s ta lla tio n o f id le r gear

b ush in g (Idler g ea r "C ")
^ J -' B4384A
Crankcase table MH061889 M e a s u re m e n t o f flatness o f c y lin d e r

lin e r fla ng e s u p p o rtin g surface on
crankcase
B1480A
11-14
E N G IN E - S P E C IA L T O O L II
C ylin de r lin e r e xtra cto r MH061490 Rem oval o f c y lin d e r lin e r
1 2 9 .5 ^ ^ C
B5131A
C ylin de r lin e r in sta lle r MH061759 P ress-fitting o f c y lin d e r lin e r
\ O.D. 129.5
\\
w j
B5141A
C onnecting rod b ush in g p u lle r MH061238 Rem oval and in s ta lla tio n o f co nn e ctin g
rod bushing
B5321A
Rear oil seal slin g e r installe r MH061652 P ress-fitting o f rear o il seal slin g e r
D ia m e te r '.
123 \
B5161B
Front o il seal s lin g e r installe r MH061817 P ress-fitting o f fro n t o il seal s lin g e r
y
D ia m e te r \
95 V "
B0585A
Piston Piston guid e clam p MH061666 P is to n g u id e 1.IX 130 In s e rtio n o f p iston

g u id e
Piston guid e lever MH061658
P is to n g u id e le v e B5171B
11-15
11 ENGINE - SPECIAL TOOL
11-16
E N G IN E - S E R V IC E PROCEDURES m
5. S E R V IC E P R O C E B U R E S NOTE:
5.1 M E A S U R E M E N T <DP CO M PRESSIO N C over th e m ounting holes and in je c tio n
PRESSURE pipes to p reve n t e n try of dust and dirt.
C om pression pressure m u s t be m easured p rior to

d isassem bly o f the engine.
Measure the co m p re ssion pressure at regular inter NV ... N o m in a l Value
L ... L im it
vals and keep track o f its changes. D uring the break-in
period or after parts have been replaced w ith new
ones, there is a slight increase in the pressure as the
piston rings and valve seats fit sn u g ly in position. As
rough edges and friction betw een parts are gradually
reduced, the pressure com es dow n.
M e a s u re m e n t P ro c ed u re
B5561A
(3) Install C om pression Gauge A d a p to r (special tool)

(1) Retighten the cylin d e r head bolts to specified on th e injection nozzle m o u n tin g hole to g e th e r w ith a
to rq u e and let the e ngine w a r m up until the coolant gasket and connect the co m p re ssion gauge (m e a s u r
te m p era ture reaches 75C to 85C. ing instrum ent).
NOTE: (4) To make sure th a t the fuel is not fed u nder
In retigliitening th e cy lin d e r head bolts, pressure fro m th e inje ction p um p, pull th e stop lever
o b serve th e tig h te n in g seq u e n c e in {6} in o f the Injection p u m p all the w a y In th e stop direction
5 .2 .3 . beforehand.
(5) In th is co nd itio n, let the starter run the engine and
measure the c o m p re ssio n pressure at a rotating
speed o f 200 rpm.
NOTE:
1. M a k e sure th a t th e eng ine speed is also
m easu red as co m pressio n pressu re
va rie s w ith th e en g in e speed.
2. M a k e m e a s u re m e n t fo r all c y lin d ers, as
w e a r and o th e r co n d itio n s vary from
one c y lin d er to a n o th e r.
(2) Remove all injection nozzles fro m the cylinder

head.
11-17
11 ENGINE - SERVICE PROCEDURES
5.2 C Y LIN D E R HEAD AND VA LVE M E C H A N IS M

5.2.1 D isassem bly
<Disassembly sequence>
1 Rocker cover 13 Outer valve spring
2 Rocker bracket mounting bolt 14 Inner valve spring
3 Cylinder head bolt 0 Valve stem seal
4 Thrust plate 16 Lower retainer
5 Rocker 17 Inlet valve
'6 Set screw 18 Exhaust valve
7 Rocker shaft (T?) Nozzle tube
(D Rocker shaft bracket 20 Water director
9 Push rod 21 Sealing cap
10 Valve cap (22) Cylinder head
0 Valve cotter 23 Crankcase side cover
12 Upper retainer 24 Tappet
For d is a s s e m b ly o f parts w ith an e n circle d n um b e r, see fo llo w in g item s.
C1542A
11-18
D isassem bly P ro c ed u re (2} R em o val off C ylin d er H e ad A ssem bly
{11} [Removal off She R o cker S h aft B ra c k e t
A ssem bly
C ylinder head
C ylinder head
gasket
Knock pin
B9014B
The cylin d e r head is held in p osition by the d ow el

pins on th e to p surface of th e crankcase. To rem ove
(a) W here the push rod is fo rcin g the rocker up, the the cylin d e r head, lift it d ire c tly u pw ard .
rocker adjusting screws s h ou ld be loosened before all MOTE;

bolts are rem oved. 1. To rem o ve th e c y lin d e r h ead, maEse
sure th a t th e in je c tio n nozzle is re-
m oved b e fo reh a n d . {R efer to roup 13
Fuel and Engine C ontrol.} Iff th e c y lin d er
head is p la c e d ora a w o rk b e n c h w ith th e
n ozzle s till in s ta lle d , th e end off the
n ozzle e x te n d in g from th e b o tto m su r
fa c e off th e c y lin d e r head w ill Coe d a m
aged.
2. W hen th e c y lin d e r head g a s k e t is re
m oved, use c a re to p re v e n t d a m a g e to
th e cy lin d e r head and c ra n k c a s e .
(3} R em o val off V a lv e C o tte r
(b) The rocker shaft bracket assem bly is held in

p osition on the cylind er head by spring pins. Lift it
d irectly u pw a rd to rem ove it.
To rem ove the valve cotter, use special tools (Valve

Lifter and Hook) and co m p re ss even ly the valve
spring.
11-19
(4) Removal of Nozzle Tube
C1527A
MOTE:
The nozzle tube need not be removed
unless w a fe r leaks, gas leaks, e tc . are
evident.
11-20
E N G IN E - S E R V IC E PROCEDURES
5 .2 .2 Otispecora
11-21
Inspection Procedure (3) Inspection of V alve Spring

H)P@eker to IRoeker Shaft C learance
M esure the free le n g th and in sta lle d load o f the s p rin g
If the lim it is exceeded, replace the b u sh in g in the and replace if the m e a s u re m e n t exceeds the lim it. For
rocker. th e in n e r s p rin g , check also fo r squareness.
(2) R eplacem ent of R ocker Bushing (4) T app et to C rankcase C learance
To rem ove ^ 0 in stall
IMOTE:
1. Align the bushing and rocker oil holes.
2. Face the bushing jo int tow ard the ad*
justing screw .
If th e lim it is exceeded, replace the tappet.
11-22
E N G IN E - S E R V IC E PROCEDURES 11
(5) Runout of Push Rod (7) V a lv e S tem 0 , 0 .
M e asu rin g p o s itio n
C2747A C3102A
Check fo r ru n o u t and replace if the reading on the dial Replace the valve if the m e a s u re m e n t is b e lo w the
in d ic a to r exceeds the lim it. lim it.
(6) C ylinder H ead B o ttom S u rface P5$tr- (8) V a lv e G uide to V a lv e Stern C le a ra n c e

toon
C alculate the clearance fro m the va lve g u id e I.D. and

If the lim it is exceeded, co rre ct the d is to rtio n w ith a va lve stem O.D. If th e lim it is exceeded, replace the
surface g rind e r. va lve guide.
M OTE;
Grind th e eylieiider head only to th e e x te n t
th a t th e heig h t fromm th e top to bo tto m
su rface s is w ith in th e lim it.
11-23
ENGINE - SERVICE PROCEDURES
(9) R e p la c e m e n t of V a lv e G uide
If a ny unusual c o n ta ct pattern is noted, co rrect as
U sing Val.ve G uide P uller (special to o l), replace the fo llo w s .
valve guide. M in o r fa u lt: Lapping

S erious fa u lt: C orrect va lve and va lv e seat.
IMOTE:
W hen th e v a lv e guide is in s ta lle d , m a k e (1 1 ) C o rre c tio n off V a lv e F ac e
sure th a t th e v a lv e guide fla n g e is s e c u re ly
s e a te d on th e c y lin d e r head.
{10) V a lv e C o n ta c t w ith V a lv e S e a t In s e rt
G rin d th e va lve face w ith a va lve refacer to o b ta in th e

sp ecified va lve seat angle.
M@TE;
(a) A p p ly an even coat o f m in iu m to the valve seat 1. K e e p grinding m arg in to a m in im um .
inse rt surface in co n ta ct w ith the valve. 2. if th e v a lv e m arg in is b e lo w th e lim it
(b) U sing Valve Lapper (special to o l), let the va lve h it a fte r th e grindin g c o rre c tio n , re p la c e
a gainst the va lve seat in se rt once. th e v alve.
M TE;
3. A fte r th e grinding c o rre c tio n , fee sure to
1. W hen le ttin g th e v a lv e h it a g a in s t th e lap th e v a lv e and v a lv e s e a t in sert.
v a lv e s e a t in sert, do not tu rn th e v alve. [Fieffer to Ite m (1 4 ) th a t fo llo w s .]
2. C o n ta c t p a tte rn should be c h e c k e d
w h en th e valve guide is in s p e c te d or
re p la c e d .
11-24
E N G IN E - S E R V IC E PROCEDURES II
(12) C o rrec tio n of V alu e S e at In s e rt (13) R e p la c e m e n t o V alu e S e a t In s e rt
Since the valve seat in s e rt is in sta lle d by expa nsion
fit, replace it by th e fo llo w in g procedures.
C 3127A
(a) G rind in sid e surface o f the va lve seat in s e rt to

reduce the thickness and th en rem ove it at roo m
te m p e ra tu re .
(a) U sing a valve seat cu tte r, cu t the in se rt to o bta in

th e specified valve seat angle and seat w id th . Use 15
or 75 cu tte r firs t, then 45 one.
MOTE;
1. K eep th e am o u n t of c u t to a m in im um .
2. If th e value sin k a g e a fte r c u ttin g ex-
, see d s th e lim it, re p la c e th e ualue s e a t
in sert.
(b) A fte r co rre ctio n , lig h tly g rin d by h o ld in g a bo ut
#40 0 sandpaper betw een th e cu tte r and va lve seat
insert.
MOTE;
A fte r th e c o rre c tio n p ro ce d u re, he sure to
lap th e ualue and ualue s e a t in sert. [R e fe r
to Ite m (14) th a t fo llo w s .]
(b) M ake sure th a t the c y lin d e r head and valve seat

inse rt are p ro v id e d w ith s u ffic ie n t interfere nce .
(c) Im m e rse the valve seat in se rt In liq u id n itro g e n
fo r c o o lin g it, and fu lly heat th e c y lin d e r head.
11-25
(d) Install th e va lve seat in se rt u sing th e C aulking MOTE:

T ool B ody, C aulking Ring and C aulking T oo l (special 1. M ake sure th a t no com pound s tic k s to
to ols) and caulk the p e rip h e ry o f th e va lve sert insert. the valve stem .
M0TE: 2. (LPse interm ediate-m esh com pound (1 2 0
When the valve seat insert is installed, to 150 m eshes) first, then fin e -m esh
direct the cham fered side of th e caulking compound (2 0 0 m eshes or m ore) for
ring tow ard the valve seat insert. finishing.
3. Addition of a sm all am ount of en g in e oil
(e) Reface th e va lve seat in se rt so th a t the seat w id th
to the compound helps m ake it e a s ie r
and valve sinkage are up to sp e cifica tio n s.
to apply it evenly.
(14) Lapping the V alve and V alve Seat
Insert
The va lve and va lve seat in s e rt co n ta ct m u s t be even
th ro u g h o u t th e ir c o n ta ctin g surfaces.
They m ust be lapped w h e n e v e r e ith e r th e va lve o r
va lve seat in se rt has been co rrected o r replaced.
C3130A
(b) U sing Valve Lapper (special to o l), seat the valve

and va lve seat insert.
W h ile tu rn in g th e va lve s lig h tly at a tim e , strike it
a ga in st th e valve seat insert.
(c) W ash aw ay the c o m p o u n d in gas o il, etc.
(d) A p p ly eng in e o il to the c o n ta c tin g surface to seat
(a) A p p ly a th in , even coat o f la p p in g c o m p o u n d to th e m w ith oil.
-the seating surface o f the valve. (e) Check to ensure th a t th e y are p ro p e rly seated.
11-26
5 .2 .3 R e assem b ly
11-27
Reassem bly Procedure (3) In stallation of V alve Stem Seal

(1) In stallation of W ater D irector
The va lv e stem seal sh o u ld be in s ta lle d b y a p p ly in g
Install th e w a te r d ire c to r w ith its notch d ire cte d as e n g in e o il to the lip and s trikin g d o w n V alve Stem
sh ow n. Seal In s ta lle r (special to o l) u n til it to u ch e s the c y lin d e r

head.
(2) In stallation of Nozzle Tube
NOTEs
1. Before the valve is installed, apply a
Nozzle Tube
Installer B o lt . sm all am ount of engine oil to the stem .
MH061231
2. A fter in stallation, check to ensure th at
Nozzle Tube
Flange . 15 to 20 Nm the valve stem seal spring has not been
MH061416 (1.5 to 2.0 kgfm )
deform ed or dam aged.
Nozzle Tube
M8 x 1.25
Stam p (4) In stallation of Valve C otter
MH061229
O -ring
A p p ly engine oil.
Nozzle tu b e -
A p p ly sealant
(THREEBOND 1211
o r equivalent).
C6620B
(a) A p p ly sealant to the end o f th e nozzle tu b e and

in se rt in to the c y lin d e r head.
(b) U sing Nozzle T ube Flange (special to o l), press the
nozzle tu be a g a in st the cylin d e r.
(c) A p p ly eng in e o il to Nozzle Tube S tam p (special
to o l) and in se rt in to th e nozzle tube.
(d) Thread Nozzle T ube In sta lle r B o lt (special to o l) to
push the sta m p u n til it can be re m o ve d fro m the Install th e va lve c o tte r, w h ile c o m p re s s in g th e va lve
b o tto m o f the c y lin d e r head. s p rin g , using Valve L ifte r (special to ol).
(e) A fte r in s ta lla tio n , p e rfo rm leak te st to v e rify M QTEs
w a te r-tig h tn e ss. Install the valve spring w ith the closely
coiled portion tow ard the cylinder Snead.
11-28
{5} In s ta lla tio n of R o c k e t S h aft B ra c k e t (8) T ig h te n in g of th e C ylin d er H e ad Bolts
and C ylinder H ead
T ig h te n the c y lin d e r head b olts in the sequence

sh o w n above to 175 N m (18 kgfm ).
A fte r tig h te n in g , v e rify th e co rrect to rq u e , th en re
tig h te n 90 !_q .
Seat the c y lin d e r head on the crankcase, w h ile lin in g

it up w ith the lo ca tin g pin.
11-29
5.3 FLYWHEEL, TIM IN G GEAR AMO CAMSHAFT

5.3.1 Disassem bly
< W ith m echanical tachom eter d rve > < W ith electrical speed se n so r>
Dam age,
unusual w ear
in gear
Streaks on w o rn surface,
cracks, taper w ear
< D is a s s e m b ly se q u e n c e >
1 F lyw heel m o u n tin g b o lt (is) C ollar

2 P ilot bearing 7 F lyw heel h ou sin g
@ F lyw heel 8 Rear oil seal s lin g e r
O i l seal re ta in e r R in g gear
5 Oil seal 10 T a ch o m e te r d rive
10A Speed se nso r
For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
items.
C1926F
11-30
ENGINE - SERVICE PROCEDURES 11
-x-Cam shaft gear end play

NV 0.05 to 0.22
L 0.4
fii) Camshaft
*(2) Camshaft gear
13 Thrust plate
14 Idler shaft bolt
15 Thrust plate
16 Idler gear "C"
17 Idler gear "A"
18 Idler gear "B"
19 Idler shaft "A"
19A Idler shaft "C"
20 Rear plate
For d isa sse m b ly o f parts w ith an e ncircled n u m b e r, see fo llo w in g item s.
The part m arked -x- m u st be inspected before disassem bly.
Part m arked w ith * sh o u ld n ot be re m ove d unless defects are e vident.
C1927C
11-31
Disassem bly Procedure (3) M e a s u re m e n t of e a r B a cklash

(1) Rem oval i? Flyw heel
If th e backlash exceeds th e lim it, check id le r gear
Thread the m o u n tin g b o lt in to the re m o v in g th re ad e d b u sh in g and gears and replace parts as necessary.
hole to rem ove the fly w h e e l. MOTE:

(2) Rem oval of Oil S eal R etainer and Collier For a pair of gears, the backlash shouBd be
m easured a t m ore than three points to
determ ine w h eth er if is acceptable.
(4) M easurem ent of End Play Bn Idler ear
and Cam shaft ear
To rem ove the o il seal retainer, tu rn d o w n the

a tta ching b o lts in to the re m o v in g th re a d e d holes
e ven ly, w h ile m aking sure th a t th e o il seal reta ine r
does n o t have e cce n tricity, rem ove th e re ta in e r w ith
the o il seal attached. If th e end play exceeds th e lim it, replace the th ru s t
R em ove the c o lla r by scre w in g M 4 x 0.7 b o lts into plate.
th e re m o v in g th re ad e d holes.
11-32
E N G IN E - S E R V IC E PROCEDURES II
(5) R em o val of C a m s h a ft Seat* MOTE;
Do not s trik e th e g ears w ith a h am m er.
T hrust plate M a k e sure th a t th e g ea rs a re rem o ved by
use of a g ea r p u ller.
(7) R em o val off Ring G ear
C1932B
A ccessing th ro u g h the holes in ca m sh a ft gear, loosen

the th ru s t plate a tta ch in g b olts. Then, rem ove the
gear to g e th e r w ith th e cam shaft.
fSj R em o val off C a m s h a ft G ear

U sing an acetylene to rc h , heat e ven ly the ring gear
and a pp ly a rod to th e ring gear to ta p it th ro u g h o u t its
p erip h ery.
R em ove the lock n u t and lock w a sh e r fro m the

ca m sh a ft gear and, u sing G ear P uller (special to o l),
rem ove th e ca m sh a ft gear.
11-33
5.3.2 Dtispection
D epth fro m clutch cover L ... L im it
m o u n tin g surface to
fric tio n surface
NV 48
L 49.5
D isto rtio n o f fric tio n surface

NV 0.1 o r less
L 0.2
C2758C
11-34
BD Basic D ia m e te r
C2759C
11-35
In s p e c tio n P ro c ed u re (2) C o rrec tio n of F ly w h e e l F rictio n S u rface

(1) Oistortiiow of F ric tio n S u rface
C orrect the fric tio n surface w ith a surface grind e r.

Place th e fly w h e e l on a surface p late and m o ve a dial M ake sure th a t th e fric tio n surface is p arallel to
in d ic a to r in th e d ia m e tra l d ire c tio n o f the fly w h e e l to surface A w ith in 0.1 m m .
m easure d is to rtio n . If th e d im e n s io n o f p o rtio n B exceeds th e service
Use o f a p o rta b le jack w ill m ake it p o ssib le to take a lim it, replace.
m ore accurate reading. (3) Id le r G ear to Id le r S h a ft C le a ra n c e

If the d is to rtio n is in excess o f the re p a ir lim it, g rin d
the fric tio n surface.
MTEs
Off Site ring g e a r sh o w s and ab n o rm a l c o n d i
tion , re p la c e th e ring g e a r b efo re m e a s u re
m en t. [R e fe r to 5.3.1 (7)1
If the lim it is exceeded, the b ush in g in th e gear should

be replaced.
11-36
(4) R e p la c e m e n t of Id le r G ear Bushing (6) C a m s h a ft Jou rn al to C ra n k c a s e C a m
sh aft Bushing C le a ra n c e
Replace th e b ush in g by the p ro ced ures sh o w n in

illu s tra tio n , using Idler Gear B ushing P uller (special
to ol).
MOTE:
H. (Install th e hushing w ith c h a m fe re d side
of g e a r LO. in w a rd .
2. A fte r in s ta lla tio n , c h e c k to en s u re th a t
th e hushing to id le r s h a ft c le a ra n c e is
w ith in th e nom inal dim en sio n . Iff it is
b e lo w th e n o m in al dim en sio n , ream th e
bushing.
If the lim its are exceeded, the b ush in g In the cranio
(5) Gam P rofile case s h o u ld be replaced.
(7) Bend of C a m s h a ft
C4118A
M easure the lobe h e ig h t and base circle d ia m e te r and
replace the ca m sh a ft if the d iffe re n ce b etw een the
M easure the bend o f the ca m sh aft. If the lim it is
tw o is b e lo w the lim it.
exceeded, replace.
NOTE:
NOTE:
T h e cam m ust he m e a s u re d a t lo c a tio n s
Turn th e c a m s h a ft a turn and read th e
sho w n as it is ta p e re d .
d e fle c tio n of th e p o in te r, using a dial in
d ic a to r.
One h a lf off th e read in g is th e bend.
11-37
5.3.3 Disassem bly
For assem bly o f parts w ith an encircled nu m b e r, see fo llo w in g

item s.
For assem bly o f part m arked *, refer to G roup 61 Special
E quipm ent. ___________ B1902F
11-38
R e asse m b ly P ro c ed u re (3) In s ta lla tio n of C a m s h aft G ear
(1) In s ta lla tio n of R ear P la te
C6230C
Install the c a m sh a ft gear so th a t th e side having
The b o tto m o f gasket in sta lle d betw een the rear plate sta m p ed n u m b e rs " 4 " faces fro n t.
and crankcase w ill p ro tru d e . A fte r the fly w h e e l h o u s (4) In s ta lla tio n of C a m s h aft
ing has been installed , cu t aw ay the p ro tru d in g
p o rtio n .
(2) In s ta lla tio n of Id le r G ears
Install the c a m s h a ft so th a t th e a lig n m e n t m ark "4 " on

the ca m sh aft gear is a lig ne d w ith the a lig n m e n t m ark
"4" on id le r gear A.
T hen, in sta ll the id le r gear B so th a t its a lig n m e n t NOTE;
m ark " 1 " is a ligned w ith the a lig n m e n t m ark " 1 " on W hen th e c a m s h a ft is in serted , false c a re
th e cra n ksh a ft gear. not to d a m a g e th e c a m s h a ft bushing.
N ext, in sta ll id le r gears A and C so th a t th e ir
(5) C h eck c a m s h a ft g ea r and id le r g ea r for
a lig n m e n t m arks "2 " are alig ne d.
c o rre c t end play.
T ig h te n the id le r sh a ft b o lt to sp e cifica tio n .
[Refer to S ection 5.3.1 (4)]
|6J C h eck b a c k la s h on gears.

[Refer to S ection 5.3.1 (3)]
11-39
(7) In stallation of Reas1 @51 Seal Sliwger (9) In stallation of Flyw heel Housing
(8) In stallation of Ring Geai? Install the fly w h e e l hou sin g and gasket so th a t th ey
are a lig n e d w ith the loca ting p in s in the crankcase.
Cut the b o tto m p o rtio n s o f th e gasket after in s ta lla tio n
as th e y are excess.
Cut at the same tim e the excess p o rtio n s o f the gasket
betw een the rear plate and crankcase.
(10) Flyw heel Housing Eccentricity C h eck
(a) Heat the ring g e a rfo r 3 m in u te s w ith p iston heater

(ap prox. 100C).
' (b) Fit the ring gear o n to the fly w h e e l w ith the
n o n ch a m fe re d side o f the te eth end to w a rd the
flyw h e e l.
Install th e fly w h e e l h ou sin g to th e crankcase by

tig h te n in g to the specified torque.
M easure the m o u n tin g c o n d itio n (eccentricity) at the
fly w h e e l hou sin g jo in t. If the p o in te r o f a dial in d ic a to r
deflects beyo nd th e lim it, loosen the b o lts and lig h tly
strike th e hou sin g to co rrect the m o u n tin g c o n d itio n .
11-40
{111} installation off SI Seal (1 2 ) F ly w h e e l R u n o u t C h e c h
W hen p re ss-fittin g an o il seal to the reta ine r, a p p ly Install the fly w h e e l to the crankshaft by tig h te n in g to
force u n ifo rm ly to the e ntire p erip h e ry. the sp ecified to rq u e .
M easure the fly w h e e l m o u n tin g c o n d itio n (ru no ut). If
the p o in te r o f the dial in d ic a to r deflects beyond the
lim it, check the b o lt tig h tn e s s or m o u n tin g surface.
11-41
5.4 GRAN&CASE AMP MAflM M0WOMQ PARTS

5.4.1 Disassem bly
Damage, abnorm al w ear
Dam age, d isco lo ra tio n 7

X- Piston p rojection
NV 0.87 to 1.33
Scratches on o uter periphery,

cracks on top, m elted or
discolored
Cracks
Connecting rod end play

NV 0.2 to 0.5
L 1.0 Inner o r o uter periphery dam aged,
corroded o r peeled
NV ... N om inal Value

L L im it
y Inner o r o uter pe rip h e ry dam aged,
z co rroded or peeled
D isasse m b ly sequence
1 C on ne cting rod cap O il ring

2 L o w e r co n n e ctin g rod bearing 7 Piston pin
3 U p p e r co n n e ctin g rod bearing Piston
1 s t co m p re ssio n ring C on ne cting rod
2nd co m p re ssio n ring *10 C on ne cting rod b o lt
item s.
Part m arked w ith * should not be rem oved unless defects are
evident.
Service ite m s m arked w ith -X- should be inspected before disassem
bly.
C2337D
11-42
E N G IN E - S E R V IC E PROCEDURES
13 F ro n t o il seal 19 C rankshaft 24 Oil jet

14 F ront cover 20 U pp er m ain bearing 25 Oil spray plug
15 F ront oil seal slin g e r 1 @ C rankshaft gear 26 Crankcase
16 M ain bearing cap
items.
The part m arked x- m ust be inspected before disassem bly.
Parts m arked w ith 1 should not be rem oved unless defects are
evident.
For inspection o f the part m arked w ith *2, refer to G roup 12
Lubrication. B0599G
11-43
[Disassembly P ro ced u re (3) R em o val of Piston

(1) P iston P ro jectio n
The p iston p ro je c tio n m u st be up to sp e cifica tio n , as it
affects engine p e rfo rm a n ce and is also necessary fo r
p re ve n tin g inte rfe re n ce w ith the valve.
W hen the w ith d ra w in g the p iston fro m the crankcase

by push in g up to g e th e r w ith the c o nn ectin g rod.
M C Tis
W hen rem oving th e pistons, use c a re to
(a) H old the dial in d ic a to r to the to p surface o f the
p re v e n t d a m a g e to th e c y lin d er liner
crankcase and m ake zero a d ju stm e n t. (4) S e p a ra tin g P iston from C o n n ectin g Rod
(b) Find the to p dead ce nte r o f p iston w ith a dial
ind icato r.
(c) M easure th re e p o in ts on the to p surface o f p iston
to fin d the average value.
(d) If the p ro je ctio n is o u t o f sp e cifica tio n , check the
co nn ectin g rod, b u sh in g , p iston pin, co n n e c tin g rod
b earing, etc. and replace d efe ctive parts.
(2) C o n n ectin g Rod End Play
Rem ove the snap rin g and, using a rod, tap p iston pin
off.
If, h ow eve r, the p iston pin is hard to rem ove , heat the
p iston w ith a p is to n heater o r in h o t w ater.
M easure the end p lay o f each co n n e ctin g rod. If the

lim it is exceeded, replace the co n n e ctin g rod or
crankshaft.
11-44
(5) R em oval o Piston Ring (7) R em oval of M ain B earing Cap
(6) C ra n k s h a ft End P lay The re a rm o s t m ain bearing cap is held in p o s itio n by

d o w e l pins. Rem ove it by use o f a slide ham m er.
(S) R em oval off C ra n k s h a ft d e a r
B efore re m o vin g the m ain b e a rin g caps, m easure the

end p lay in the crankshaft.
If th e end p lay exceeds the lim it, replace the th ru s t (a) Rem ove th e rear oil seal s lin g e r fro m th e crank
plate w ith an oversize one. [R efer to S ection 5.4.3 (3)] sh aft by cu ttin g it w ith a punch.
(b) R em ove the cran ksha ft gear fro m the crankshaft,
using Gear P uller (special tool).
MOTE;
Bo not a tte m p t rem oving th e c ra n k s h a ft
g ea r by s trikin g w ith a h a m m e r or prying
w ith a lever.
11-45
5.4.2 Inspection
Open end clearance

NV 0.4 to 0.6
L 1.5
Clearance
BD 50 Piston ring g ro o ve to piston ring
NV 0.01 to 0.02 clearance
L 0.1 1st ring
NV 0.06 to 0.11
L 0.25
2nd ring
NV 0.05 to 0.08 < 6 D 2 2 >
0.07 to 0.10 <6D22-T, 6D22-TC:;
L 0.15
Oil ring
NV 0.03 to 0.06
L 0.15
Clearance
BD 50
NV 0.02 to 0.05
L 0.1
Clearance
BD 130
NV 0.178 to 0.204 < 6 D 2 2 >
0.173 to 0.199 < 6 D 22-T >
Bend or to rsio n 0.188 to 0.214 < 6D 22-TC :
L 0.05 o r less
D istortion o f to p surface
NV 0.07 o r less
L 0.2
Flatness o f cylin d e r liner

flange su p p o rtin g surface
L M ore than 0.1
BD Basic Diam eter

Projection o f cylin d e r lin e r NV N o m in al Value
from to p surface o f crankcase L L im it
NV 0 to 0.08
Inside diam eter

NV 130.014 to 130.054
L 130.25
Out of roundness o f cylin d ric ity

NV 0.02 o r less
Oil clearance
BD 84
NV 0.07 to 0. 13
L 0.25
T ension w hen free

L Less than 90.5
C2760C
11-46
E N G IN E - S E R V IC E PROCEDURES RH
[Inspection Procedure {2) Crankcase Top Surface Distortion

(1) Flatness off Ci/DimcOer Liner Flange Sup
porting Surface on Crankcase
M easure the crankcase to p surface d is to rtio n . If it

exceeds th e lim its , c o rre c t the d is to rtio n w ith a
Replace th e crankcase w ith n ew one if the lim it is surface g rind e r.
exceeded.
11-47
M OJ E: (4 ) C y lin d e r L in e r F la n g e P ro je c tio n
W h e n She c r a n k c a s e is g ro u n d , m a k e s u re
th a t th e p is to n p ro je c tio n d o e s n o t e x c e e d
th e n o m in a l v a lu e .
[R e fe r to Ite m (1 ), S e c tio n 5 .4 .1 .]
(3 ) C y lin d e r L in e r I.D .
If the p ro je c tio n is o u t o f s p e c ific a tio n , replace the

c y lin d e r lin e r o r crankcase. [For re p la c e m e n t o f the
c y lin d e r lin e r, refe r to Item (5).]
(5 ) R e p la c e m e n t o f C y lin d e r L in e r
(a ) Rem oval
M easure the c y lin d e r lin e r I.D. at six p o s itio n s as
sh ow n in the rig h t fig u re . If the I.D. is m o re th an the
lim its , replace the c y lin d e r lin e r o r bore it to oversize.
[For re p la ce m e nt o f the c y lin d e r line r, refe r to Item
(5).]
11-48
E N G IN E - S E R V IC E PROCEDURES U
(b) Installation
S iz e m a rk P is to n
3) S e cure ly seat the c y lin d e r lin e r on the crankcase
1) W hen rep la cing the c y lin d e r line r, use a c y lin d e r by lig h tly s trik in g the fla ng e p o rtio n , using C ylin d e r
lin e r w ith the sam e size m ark as th a t o f the piston to Liner In sta lle r (special tool).
be selected. MOTEs
1. Apply soap suds to the crankcase and
Size m ark o f p iston A B C cylinder loner fitting portions and make
Size m ark o f cylin d e r lin e r A B C sore that the rubber packing and -ring
are not twisted when inserted.
2. After installation, conduct the leak test
to verify air-tightness. Apply thrust
force to cylinder liner flange.
2) A fte r a new ru b b e r packing and O -ring have been

installed to the c y lin d e r lin e r, s lo w ly in se rt the
c ylin d e r lin e r in to the crankcase.
11-49
(6 ) S e le c tio n o f P is to n a n d C y lin d e r L in e r (b) O v e rs iz e p is to n

A p iston m ay be sta nd ard o r oversize, d e p e n d in g on Bore the c y lin d e r lin e r as fo llo w s a cco rd in g to the
w h ich the c y lin d e r lin e r is to be selected as fo llo w s . typ e o f p isto n ( + 0.5, + 0 .7 5 , + 1 .0 0 m m ).
(a ) S ta n d a rd p is to n
C ylin d e r lin e r I.D.
C4424A
Oversize piston O.D.
O.D. m easuring po sitio n
1) D eterm in e th e a m o u n t o f m etal to be bored fro m

the c y lin d e r lin e r b y ta king in to a c c o u n t th e p o rtio n
1) Select the p iston w ith th e sam e size m ark as th a t
w h ic h w ea rs m o s t w ith reference to th e m e a su re
stam ped on the c y lin d e r liner.
2) M ake sure th a t the w e ig h t o f p iston s fo r one m en ts o f I.D.s o f all c ylin d e rs.
2) Bore and h o n e -fin is h the c y lin d e r lin e r to o b ta in
eng in e (six pistons) is in the range o f 10 g o f the
the sp e cifie d clearance b etw een the oversize p is to n
w e ig h t stam ped.
and c y lin d e r liner.
MOTE;
W h e n e v e r th e p is to n is r e p la c e d , r e p la c e M O TE:
1 . E v e n w h e n o n ly o n e c y lin d e r re q u ire s
th e p is to n rin g s .
b o rin g , b o re a ll c y lin d e rs to th e s a m e
o v e rs iz e .
2 . R e p la c e th e p is to n rin g s to th o s e c o r-
re s p o n d in g to th e o v e rs iz e .
(7 ) P is to n to C y lin d e r L in e r C le a r a n c e
If th e clearance is o u t o f s p e c ific a tio n , replace the
p iston o r c y lin d e r liner.
[R efer to Item (6)]
11-50
{8} Piston to Piston Ring Clearance (9) Piston Ring Gap
M easure the p iston to p isto n ring clearance. If the M easure the p iston rin g gap w ith the p isto n ring
lim it is exceeded, replace the p iston rin gs or piston. h o riz o n ta lly pushed in to a sta nd ard c y lin d e r lin e r or
MOTE; actual one in the crankcase w ith a p isto n .
11. After carbon has been removed, m ea Replace the p is to n rin g if the gap exceeds the lim it.
sure the clearance all around the pis S tan da rd c y lin d e r lin e r I.D.: 130 0
ton. MOTE;
2. Replace the piston rings as a set. Use the piston to push the piston rings
horizontally into a standard gauge.
Thickness gauge (HO) Piston to Piston Pin Clearance
Piston pin
C4815A
The 1st co m p re ssio n rin g sh o u ld be m easured by

pressing the ring a ga in st the p iston w ith a s tra ig h t
edge.
If th e clearance is o v e r th e lim it, replace the p isto n pin
or piston.
M TEs
Whenever the piston is replaced, be sure
to replace the piston rings.
11-51
(1 1 ) P is to n P in to C o n n e c tin g Rod S m a ll (a) A lig n th e o il hole o f the b u sh in g w ith the o il hole

End C le a r a n c e o f th e c o n n e c tin g rod.
(b) Press the b ush in g in fro m the ch a m fe re d side o f
c o n n e c tin g rod end.
(c) A fte r the b u sh in g has been pressed in, in se rt the
p is to n pin and check to ensure th a t it tu rn s lig h tly
w ith o u t play.
(1 3 ) C o n n e c tin g Rod B e n d a n d T w is t
If the clearance is o ve r th e lim it, replace th e bush in g

in the co nn ectin g rod.
(1 2 ) R e p la c e m e n t of C o n n e c tin g Rod
B u s h in g
Replace the b u sh in g by p ro ced ures sh o w n in illu s tra
tio n , u sing C on ne cting Rod B ushing P uller (special
tool).
I
P
Connecting Rod
Bushing Puller
____ MH061238
^Bushing M easure the bend and to rs io n o f the co n n e c tin g rod

w ith C on ne cting Rod A lig n e r (m e a su rin g in s tru m e n t).
If th e rea din g is in excess of the lim it, replace or

To rem ove To install c o rre ct w ith a press.
NOTE:
1. In s ta ll th e b u s h in g a n d c o n n e c tin g rod
b e a rin g to th e c o n n e c tin g ro d b e fo re
m e a s u r e m e n t.
2 . T ig h te n th e c o n n e c tin g ro d a n d c o n
C5221B n e c tin g rod c a p to th e s p e c ifie d to rq u e
b e fo re m e a s u r e m e n t.
11-52
E N G IN E - S E R V IC E PROCEDURES M
{114} Ten sio n of C o n n ectin g Rod B earing (1) Main Bearing to Crankshaft Journal
and M ain B earing w h en Free Clearance
C rankshaft |o u rna l O.D.
M e asu rin g d ire c tio n M e asu rin g p o s itio n
C5523A
If the te n s io n is lo w e r than the lim it, replace the u pp er

and lo w e r b earings as a set.
MOTE;
Bo not use the bearing by artificially ex
panding it. M ain b e a rin g I D.
(15) Connecting Rod Bearing to Crank

shaft Pin Clearance
C5524A
If the lim it is exceeded, replace the u p p e r and lo w e r

bea rin gs as a set.
If the lim it is exceeded, replace the u p p e r and lo w e r

bearings as a set.
11-53
(1 7 ) C r a n k s h a ft R o u n d n e s s a n d C y lin d ri- (1 9 ) C o rre c tio n o f C r a n k s h a ft to U n d e r

c ity s iz e
If the jo u rn a l o r pin is d am aged o r seized, g rin d the
Roundness C ylin d ricity c ra n ksh a ft by the fo llo w in g procedures. Replace the
M easuring directio n M easuring p o sitio n b e a rin g w ith an undersized one.
D eterm in e the o u t-o f-ro u n d n e s s on the basis o f the

cran ksha ft jo u rn a l and pin O.D. m easurem ents.
If th e lim it is exceeded, g rin d to undersize. [R efer to
(19)] (a) W h e n the cra n ksh a ft is g ro u n d , take care n ot to
change the ce nte r d istance o f jo u rn a l and pin.
(1 8 ) C r a n k s h a ft B en d (b) G rind the c ra n ksh a ft in such a w a y as n ot to
change the w id th o f jo u rn a l and pin.
(c) Finish the fille t s m o o th to the sp e cifie d R.
(d) Check fo r g ro u n d cracks by the m a g n e tic p a rticle
in s p e c tio n m e th o d . The surface h ardness (Hs 75 o r
m ore) s h o u ld also be checked to c o n firm th a t it has
n ot decreased.
M easure the bend o f th e cran ksha ft. If the lim it is

exceeded, co rrect w ith a press o r g rin d to undersize.
NOTE:
Ulead th e c r a n k s h a ft c e n t e r jo u rn a l ru n o u t
w ith a d ia l in d ic a to r. O n e h a lf o f th e r e a d
in g is th e b e n d .
11-54
G rinding Finishing
' ft
V A/v.' *' - J \ r
\ \ G rinder
W hestone or
sand paper
Crankshaft
C5509A
(e) To g rin d the cra n ksh a ft w ith g rin d e r, the g rin d e r

and cran ksha ft sh o u ld be tu rn e d clockw ise as vie w e d
fro m the cran ksha ft fro n t end.
(f) To fin ish the cra n ksh a ft w ith a g rin d s to n e o r
sandpaper, tu rn the cra n ksh a ft co u n te rclo ckw ise .
U n it: m m
Undersize Jo u rn a l O.D. Pin O.D. O ut-of- C ylind-

fin ish d im e n sio n fin is h d im e n s io n ro un d n ess ric ity
-0.25 0.01 or 0.006 or

99 75 " 0 08 83 75 0 06
a - 0.10 0 0 / 0 - 0.09 less less
-0 .5 0 - 0.06
99 50 ~
aa.ou _~ 8
0 '^1Q
8
83,50 - 0.09
-0.75
99 25 0 08
80,25 - 0.10 83,25 1 o'o9
-1 .0 0
99 00 ~
sa.uu _ 8
Q'^1Q
8
83,00 ' 0*09
11-55
5 .4 .3 R e a s s e m b ly
11-56
(Reassembly Procedure (3) Installation of Upper Main (Bearing and
(15 Installation of Oil Spray Plug Thrust Plate
Install the oil spray plug w ith the a rro w sta m p ed on MOTEs
the plug to w a rd th e to p o f th e engine. 1. Install the thrust plate with the oil
grooveless side toward the crankcase.
(2) Installation off Oil Jet and Check Valve
2. Line up the lug off the main bearing and
the groove off the crankcase.
The upper main bearing is one with oil
holes. Take care not to confuse it with
the lower ene.
3. Oversize (0.115, 0.30, 0.45 mm) thrust
plates are available for adjusting the
end play in crankshaft [refer to Item (6),
Section 5.4.1]. Iff any orne of these is
used, ensure the correct off the thrust
plate to be installed to the main bearing
cap [refer to Item (7)].
(4) Installation off Crankshaft dear
(a) Install the oil jet, w h ile m aking sure th a t Its
loca ting pin fits In the crankcase.
(b) M o u n t the lock w a sh e r in such a w a y th a t its
b ending p o rtio n w ill fit the end o f the o il jet.
(c) A fte r the check valve has been tig h te n e d to the
specified to rq u e , bend the lock w a sh e r to fit the
hexagonal p o rtio n o f the check valve.
(a) Heat th e gear to a b o u t 100C, using a p iston

heater, etc.
11-57
(b) Locate th e gear so th a t the d o w e l pin o f the (7 ) In s ta lla tio n o f L o w e r M a in B e a rin g s a n d

cran ksha ft w ill fit in the n otch o f th e gear and fit the M a in B e a rin g C a p s
gear by lig h tly s trik in g th e gear end w ith a s o ft F o llo w th e p ro ced ure g ive n b elow .
h am m e r.
(c) Install the rear oil seal sling er.
[Refer to Item (7), S e ction 5.3.3.]
(5 ) In s ta lla tio n o f F ro n t @51 S e a l S lin g e r
(a) D rive the lo ca tin g d o w e l p in s in to the re a rm o s t

m ain bea rin g cap in the d ire c tio n show n.
Install the fro n t oil seal slin g e r, using Oil Seal S lin g e r
In sta lle r (special to o l).
(6 ) In s ta lla tio n o f C r a n k s h a ft
L ift the cra n ksh a ft w ith chain blocks, etc. W h ile

keeping it in h o rizo n ta l p o s itio n , s lo w ly lo w e r it into
th e crankcase.
(b) M ate th e lo w e r m ain bea rin g w ith each m ain

bea rin g cap, m aking sure th a t th e lug in bearing is
fitte d in to the lug g ro o v e in cap.
11-58
E N G IN E - S E R V IC E PROCEDURES Hi
(c) O nly to both sides o f th e re a rm o st m ain bearing (f) Check to see if the end p la y o f the cra n ksh a ft is
cap, install the th ru s t plates fa cing th e ir oil g ro ove less w ith in n o m in a l value.
side to w a rd the cap. [R efer to Item (6), S ection 5.4.1.]
M OTE? (0) flrsstalfiaffioM) off Connecting Rod Bolt
Iff an oversize ffinrast piaffe is used, use the A fte r checking the co n n e ctin g rod fo r d am age and
bearing cap rear ffhrusff piaffe off the same b u rr in the b o lt hole, a p p ly eng in e o il to the co n n e c t
size as that off the thrust plate in the ing rod b o lt and p re s s -fit it in to the co n n e c tin g rod.
crankcase rear end [liefer to Item (3)].
Mote, however, that the bearing cap ffront
and rear thrust plates may be off difffferent
sizes.
(d) Install the m ain bea rin g caps, m aking sure th a t
the side w ith the lug g ro o ve placed on the rig h t-h a n d
side o f the eng in e and th ey are in sta lle d in the o rd e r
o f em bossed n u m b e rs fro m the fro n t o f engine.
(e) T igh ten m ain bea rin g cap b o lts to specified
to rq u e . Then, tig h te n m ain bearing cap side b olts to
sp ecified to rq u e .
A fte r the b o lts are tig h te n e d , m ake sure th a t the
cran ksha ft is free to rotate by hand.
11-59
{9} R e a s s e m b ly o? Piston and Connecting (10) In stallation of Poston Ring

Rod
U sing Piston Ring T ool (special to o l), in sta ll the p iston

C onnect the p iston to th e c o n n e ctin g rod w ith the rin g s in th e fo llo w in g sequence.
p isto n pin so th a t the F ro n t m ark on p iston and lug 1. Oil ring
g ro o ve m ark in co n n e ctin g rod are placed on the 2. 2nd c o m p re s s io n ring
sam e side. 3. 1st c o m p re s s io n ring
If the p iston and p iston pin are hard to insert, heat the
, p iston w ith a p iston hea ter o r in h o t w ater.
M TE :
T h e p a rts fo r an e n g in e m u s t b e of th e
s a m e w e ig h t m a rk .
W e ig h t m arks
H eavy < ------------------------------------------------------------- > L ig h t

A B C D E F G H J K
11-60
(11) Dnsfallafiou of Upper amd Lowes' Con MOTE:
necting Rod Bearings 11. Make sure that the size symbol of the
piston is the same as that off the cylin
der liner.
2. Make sure that the piston ring open end
directions do not change.
3. Put a vinyl hose or something else on
the bolt of connecting rod for protec
tion of the crankshaft pin against dam
age by the bolt.
Using the Piston Guide d a m p and Piston
Guide Lever (special tools).
Install the u p p e r co n n e ctin g rod b ea rin g, m aking sure

th a t th e bea rin g lug is a lig n e d w ith the lug g ro o v e in
the co n n e ctin g rod.
Install the lo w e r co n n e ctin g rod b earing, m aking sure
th a t th e bearing lug is a lig n e d w ith the lug g ro o v e in
the co n n e ctin g rod cap.
MOTE:
Mole that the only the upper connecting
rod bearing has an oil hole.
(12) Installation of Piston and Connecting
Line up the Piston G uide w ith the p iston skirt and set
Bod
the leve r in to p o s itio n . Then, tu rn th e a d ju s tin g b o lt
so th a t th e clam p I.D. e quals p iston O.D. A fte r th e
a d ju s tm e n t, a p p ly eng in e o il to p isto n o u te r surfaces,
Piston G uide in n e r surfaces, and c y lin d e r lin e r in n e r
surfaces.
A fte r these p ro ced ures have been c o m p le te d , fit
Piston G uide o n to the p isto n so th a t it is flu s h w ith th e
p iston he ad . U sing a m a lle t o r w o o d block, tap p iston
Into p o s itio n w ith care n ot to dam age it.
U sing Piston G uide C lam p and Piston G uide Lever

(special to o ls), in sta ll the p isto n and co n n e c tin g rod
so th a t the fro n t m ark on p isto n head faces th e fro n t
o f engine.
11-61
(1 3 ) In s ta lla tio n of C o n n e c tin g Rod C a p s 5 .5 IN S P E C T IO N A N D A D J U S T M E N T F

VALVE CLEARANCE
The va lve clearance sh o u ld be checked and a djusted
as described b e lo w w h ile the e n g in e is cold.
M ake sure th a t the a lig n m e n t m arks and lug g ro o v e

m arks on the co n n e ctin g rod cap and co n n e ctin g rod B5713A
are alig ne d.
(1 4 ) C h e e k th e c o n n e c tin g ro d e n d p la y . (1) Crank the e n g in e to alig n the p o in te r o f the

in sp e ctio n w in d o w o f th e fly w h e e l h o u s in g w ith th e
(Refer to Item (2), S ection 5.4.1.]
inscribe d m ark 1.6 o f th e fly w h e e l. Check the push
(1 5 ) C h e c k th e p ro je c tio n o f th e p is to n .
rods, and the p isto n w h o se push rod is n o t pushing
[Refer to Item (1), S ection 5.4.1.) up th e rocker is at the to p dead ce nte r o f the
(1 6 ) In s ta lla tio n of F ro n t O il S e a l co m p re s s io n stroke.
(2) W hen the No. 1 c y lin d e r p iston is at the to p dead
center on the co m p re s s io n stroke, check and a d ju s t
the clearance o f va lve s m arked " o " in th e fo llo w in g
table.
W hen the No. 6 c y lin d e r p iston is at th e to p dead
ce nte r on the co m p re s s io n stroke, check and a d ju s t
the clearances o f va lve m arked " x " . T urn the cra n k
sh aft th ro u g h a ro ta tio n , and m ake sure th a t valve
clearance insp ectio n and a d ju s tm e n t are p e rfo rm e d
fo r all o f the six c y lin d e rs .
C y lin d e r No. 1 2 3 4 5 6
V alve In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
a rra n g e m e n t
E venly press th e o il seal th ro u g h o u t its e n tire No. 1 at TDC

on th e c o m p re s o o o o o o
p e rip h e ry to p re ve n t it fro m tiltin g . P ress-fit th e oil
sion stroke
seal in to the fro n t co ver u n til the o il seal fla n g e is held
No. 6 at TDC
tig h t up a ga in st th e fro n t cover. on the c o m p re s X X X X X X
sion stroke
11-62
(3) M easure the rocker arm to va lv e cap clearance
w ith a thickness gauge to d e te rm in e w h e th e r the
clearance is up to sp ecificatio n.
If the thickness gauge o f the sp ecified thickness is
s o m e w h a t hard to m ove, the clearance is good.
If the clearance is o u t o f s p e c ifica tio n , loosen the lock
n ut and a d ju s t w ith the a d ju s tin g screw . A fte r a d ju s t
m ent, tu rn d o w n the lock n ut to lock th e a d ju stin g
screw s.
M O TE:
A fte r th e lo c k n u t h a s b e e n fu m e d d o w n ,
r e c h e c k th e c le a r a n c e .
11-63
11 ENGINE - TROUBLESHOOTING
. TR O U B L E S H O O T IN G
S ym p to m P robable cause R em edy Ref. grou p
E ngine w ill Inadequate o il visco sity Replace G roup 12

n o t sta rt
In co rrect fuel in use G roup 13
L ow c o m p re ssio n pressure
o In co rrect valve clearance A d ju s t
D efective head gasket Replace
0 W o rn va lve and va lve seat, ca rbo n dep o sit
D e terio ra te d va lve sp rin g
o W o rn o r d am aged p iston ring
o W o rn o r d am aged p isto n ring groo ve
o W o rn p isto n and cylin d e r lin e r C hange to oversize
D efective preheater
o D efective sta rte r sw itch C orre ct o r replace G ro u p 16
D efective h eater relay
In co rrect in je c tio n tim in g A d ju s t G ro u p 13
In s u ffic ie n t in je c tio n a m o u n t
D efective in je c tio n p um p C orrect o r replace G ro u p 13
In co rrect in je ctio n a m ou n t
C oo lin g syste m n ot fu n c tio n in g p ro p e rly C orrect o r replace G ro u p 14
R ough idle Inadequate o il visco sity Replace G ro u p 12
In co rre ct fuel in use G ro u p 13
D efective co o lin g system C orrect o r replace G ro u p 14
L ow co m p re ssio n pressure (See "E n g in e w ill n ot s ta rt''.)
D efective fuel system

o D efective in je ctio n p u m p C orrect o r replace G ro u p 13
o D efective in je ctio n nozzle
A ir tra p p e d in fuel system
A b n o rm a l In co rrect fu e l in use Replace G ro u p 13

exhaust
gas c o lo r C oo lin g system n o t fu n c tio n in g p ro p e rly C orrect o r replace G ro u p 14
Intake/exhaust system not fu n c tio n in g p ro p e rly

C logged a ir cleaner C orrect o r replace G ro u p 15
C logged m u ffle r
O il leaks to intake /exh a u st pipes
L ow co m p re ssio n pressure (See "E n g in e w ill n ot s ta rt''.)

D efective in je c tio n p u m p C orre ct o r replace G ro u p 13
o D efective in je c tio n nozzle
In co rrect in je ctio n tim in g A d ju s t
Excessive e ngine oil A d ju s t G ro u p 12
B ind in g o f m a jo r m o v in g parts C orrect o r replace
11-64
E N G IN E - T R O U B L E S H O O T IN G
S ym p to m Probable cause R em edy Ref. g ro u p
Low o u tp u t In adequate o il v isco sity Replace G ro u p 12
Inco rrect fuel in use G ro u p 13
D efective c o o lin g system C orrect o r replace G ro u p 14
Intake/exhaust syste m not fu n c tio n in g p ro p e rly

C logged a ir clea n e r C orrect o r replace G ro u p 15
C logged m u ffle r
L ow co m p re ssio n p ressure (See "E n g in e w ill n o t s ta rt".)

D efective in je c tio n p u m p C orrect or replace G ro u p 13
D efective in je c tio n nozzle
A ir tra p p ed in fuel system
In co rrect in je c tio n tim in g A d ju s t
Large oil Oil leaks fro m lu b ric a tio n system Check and correct G ro u p 12
co n su m p tio n
O il leaks fro m e n g in e and related parts
D efective gasket and o il seal Replace
O il entered to co m b u s tio n ch a m b e r fro m p iston side

W o rn c y lin d e r lin e r and p iston C orrect o r replace
W o rn , d am a g e d o r seized p isto n ring R eplace as a set
C logged p isto n and o il ring o il holes Clean
Oil entered to co m b u s tio n ch a m b e r fro m valve side

W o rn va lve stem and va lve g u id e Replace
W o rn va lve stem seal
A b n o rm a l N oise prod u ce d fro m a ro u n d the engine

e ng in e noise Check and co rrect
Loose p ip in g o r h osin g co nn e ctio n
In je ctio n p u m p , a lte rn a to r o r o th e r Check and adjust G ro u p 13 and 16

a u x ilia ry u n its d efe ctive or in c o rre c tly m o un ted
Loose o r dam a g e d V-belt Replace G ro u p 14
C rankshaft p u lle y in c o rre c tly m o u n te d Check and a dju st
A ir cleaner, m u ffle r n o t fu n c tio n in g p ro p e ly C orrect o r replace G ro u p 15
N oise p rod u ce d fro m a ro u n d rocker cover

In co rrect va lve clearance A d ju s t
D efective va lve sp rin g Replace
D efective rocker sh aft and bracket Check and co rrect
o Poor lu b ric a tio n in rocker shaft Check
N oise p rod u ce d fro m a ro u n d fly w h e e l hou sin g

In co rrect tim in g gear backlash Replace
Poor lu b ric a tio n a ro u n d tim in g gear and id le r shaft Check
11-65
11 ENGINE - TROUBLESHOOTING
S y m p to m P robable cause Rem edy Ref. g rou p
A b n o rm a l N oise p rod u ce d fro m c ylin d e r head o r crankcase

e ngine noise
L ow co m p re ssio n pressure (See "E ng in e w ill n ot s ta rt")
In co rrect in je ctio n tim in g A d ju s t G ro u p 13
In co rrect sp ra y co n d itio n C orrect o r replace
W o rn c o n n e ctin g rod sm all end bushing and p is to n pin Replace
W o rn o r dam a g e d cra nksh a ft pin and co nn e ctin g rod

b ig end bearing
W o rn o r d am aged cra nksh a ft jo u rn a l and m a in bearing
Excessive crankshaft, to ca m sha ft end play Replace th ru s t plate
W o rn ta p p e t and ca m sha ft Replace w o rn part
11-66
12
l_UBRICATION
COM TENTS
1. GENERAL ...................................... 2 4.2 DISASSEMBLY, INSPECTION AND

2. SPECIFICATIONS .......................... HO REASSEMBLY ............................ 13
3. SERVICE STANDARDS .................. 10 4.2.1 Oil Pump ................................. 13
3.1 SERVICE STANDARD TABLE ..... 10 4.2.2 Oil Filler .................................. 18
3.2 TIGHTENING TORQUE TABLE ... 11 4.2.3 050 Cooler ................................
4. SERVICE PROCEDURES ................ 12 4.2.4 Regulator Valve ......................
4.1 REMOVAL AMD INSTALLA 4.2.5 Check Valve ...........................
TION ........................................... 12 5. TROUBLESHOOTING .................... 19
12-1
12 LUBRICATION - GENERAL
1. G E N E R A L
E ngine lu b ric a tio n is a cco m p lish e d by fo rce d lu b ric a
tio n syste m u sin g gear p u m p . The e n g in e o il in th e oil
pan is d ra w n up th ro u g h the oil stra in e r by the oil
p u m p and fo rce -fe d to the o il filte r and o il c o o le r to
lu b rica te all parts.
Oil pressure
gauge
B1539F
12-2
L U B R IC A T IO N - GENERAL 12
fH J 050 P u m p
Oil p um p gear
A t the tim e , the engine oil is d ra w n in fro m the suction

side by the n egative pressure pro du ced as the gear
tu rn s along the inside o f th e p u m p case, and is carried
along the gear and case insid e w a ll to the d e live ry
side.
The oil s tra in e r at the su ction p o rt p re ven ts e n try of
fo re ig n m a tte r in th e o il pan and air. The engine oil Is
/ ^ rou ted to the crankcase by the oil pipe connected to
the d e liv e ry port.
B1540A
The o il p u m p , o f a gear p u m p typ e , is m o u n te d in the

rear b o tto m p o rtio n o f the crankcase, d rive n by the
cra n ksh a ft gear.
An o il stra in e r is m o u n te d at the su ctio n p o rt o f the oil
p u m p ; an oil pipe at the d e liv e ry port.
The cran ksha ft gear d rive s th e o il p um p id le r gear and
o il p u m p gear to tra n s m it ro ta tio n to th e oil p u m p
d riv e gear. In the oil p u m p , th e o il p u m p d riv e gear is
in m esh w ith the o il p u m p d rive n gear. W hen the oil
p u m p d rive gear is d riv e n , the oil p u m p d riv e n gear is
tu rn e d in the o p p o site d ire ctio n .
Since the o il p u m p is d rive n at speeds p ro p o rtio n a l to
the e ng in e 's, the d e liv e ry pressure o f the o il p um p
increases d u rin g s ta rtin g in cold w ea th er. A relief
va lve is p ro v id e d in the oil p u m p to m ake sure th a t no
excessive pressure acts on the lu b ric a tio n system .
12-3
(2 ) O il F ilte r
B1543A
W hen the oil filte r e le m e n t is c log ge d and the
d iffe re n ce in pressure betw een the filte re d and u n fil
The o il filte r is a d o u b le oil filte r co n sistin g o f a
te re d oil exceeds the lim it sp ecified, the va lve in the
fu ll-flo w filte r m ade in te g ra l w ith bypass filte r. Ele
oil bypass alarm m oves a ga in st th e s p rin g force,
m e n t is a filte r paper e lem ent.
a llo w in g the u n filte re d o il to flo w to the filte re d o il
Engine o il fed u n d e r pressure fro m the oil p um p
path.
passes th ro u g h the o il hole in the crankcase and flo w s
The o il bypass alarm has e le ctric contacts th a t are
fro m the oil filte r head into the fu ll- flo w filte r and
closed to tu rn on the p ilo t lam p, w a rn in g the d riv e r o f
, bypass filte r. The e n g in e o il filte re d th ro u g h the
clog ge d e le m e n t w h e n the va lve is opened.
fu ll-flo w filte r is rou ted fro m the oil filte r head th ro u g h
th e crankcase oil hole to th e o il co oler. The eng in e oil
filte re d th ro u g h the bypass filte r re tu rn s to the oil pan.
12-4
L U B R IC A T IO N - GENERAL 12
(3) I C ooler
Oil cooler e le m e n t
B1545A
The sh e ll-a n d -p la te typ e (m u lti-p la te type) o il c o o le r Is (4) Bypass V a lv e

m o u n te d in the co o la n t path on th e left side o f the
crankcase.
E ngine oil fo rce d th ro u g h the o il filte r flo w s insid e the
o il co o le r e le m e n t; w hereas the co o la n t fo rce d fro m
th e w a te r p u m p flo w s a ro u n d the e lem ent. The
e n g in e o il in th e e le m e n t is th e n cooled o r heated
b efo re it flo w s to the m ain o il gallery.
W hen the o il v is c o s ity is high at lo w te m p e ra tu re s or

w hen the e le m e n t has high resistance to flo w because
o f c lo g g in g , the bypass va lve installed at the o il c o o le r
opens to a llo w eng in e oil to flo w to th e m ain gallery
bypassing th e oil cooler.
12-5
(5 ) R e g u la to r V a lv e (b) C a m s h a ft
B1529A
The re g u la to r va lve is m o u n te d in the m ain o il g a lle ry L u b rica tio n o f the ca m sh aft b u sh in g s is a ccom plishe d
in the crankcase to m ake sure th a t no excessive by the oil flo w in g th ro u g h the o il holes fro m the
pressure acts on the lu b ric a tio n system . o u tsid e p e rip h e ry o f the cran ksha ft m ain bearing to
the in d iv id u a l ca m sh aft b ush in g.
(6 ) L u b ric a tio n o f AID F a rts
The e n g in e o il rou ted to th e m ain oil g a lle ry lubricates (c ) V a lv e m e c h a n is m
all parts as described in the fo llo w in g .
(a ) M a in b e a rin g , c o n n e c tin g rod b e a rin g ,

a n d c o n n e c tin g ro d b u s h in g
The o il hole extends fro m the m ain o il g a lle ry to the

cran ksha ft m ain bearing to lu b rica te th e m ain bear
ing. Part o f the eng in e oil th a t has lu b rica te d th e m ain
bearing passes th ro u g h the o il hole in the crankshaft
to lu b rica te the co n n e ctin g rod b earing, and then
th ro u g h the oil hole in the co nn ectin g rod to lub rica te
The eng in e o il th a t has lu b ric a te d the No. 1 ca m sh aft
co n n e ctin g rod bushing.
b ush in g flo w s th ro u g h the o il hole p ro v id e d at the to p
On 6D22-TC, there is a hole p ro vid e d in to p o f
o f the crankcase to each c y lin d e r head.
co n n e ctin g rod, fro m w h ic h oil sp urts o u t to the
piston.
12-6
L U B R IC A T IO N GENERAL 12
E ngine o il fed to the c y lin d e r head flo w s th ro u g h the (e) Cooiirag th e piston (oiO je t)
o il holes in the rocker sh aft bracket and rocker sh aft to
lu b rica te each rocker b ush in g. The eng in e oil is also
sprayed o u t o f the rocker arm o il holes fo r lu b ric a tio n
o f the slid in g surfaces o f va lve cap and valve stem as
w e ll as the slid in g surfaces o f push rod and a d ju stin g
screw . The oil th en flo w s th ro u g h the push rod holes
in the c y lin d e r head and crankcase to lu b ric a te the
ta p p e t and cam o f the ca m sh a ft and retu rns to the oil
pan.
(d) Tmrag g e a r s
B1535B
The oil je t p ro v id e d u n d e r the m ain o il g a lle ry fo r each

c y lin d e r sprays eng in e oil against th e reverse surface
o f the p iston to cool the piston.
The oil je t is e qu ip pe d w ith a check valve w h ic h opens
and closes at sp ecified o il pressure, p re v e n tin g the
decreased a m o u n t o f oil at lo w oil pressure and loss
in o il pressure.
On the p iston fo r the 6D22-TC, a c o o lin g c a vity is
p ro v id e d . The oil inje cted fro m the o il je t enters the
c o o lin g ca vity to cool the p iston.
The tim in g gear id le r sh a ft are lu b rica te d , as sh ow n in

the fig u re , by eng in e o il flo w in g th ro u g h the oil holes
rou te d fro m the m ain oil g a lle ry and the crankshaft
m a in bearing in the rear end. Each gear is lub rica te d
by the eng in e oil sprayed fro m the oil sp ra y plug.
12-7
(7 ) L u b ric a tio n o f T u rb o c h a rg e r The in je c tio n p u m p and air c o m p re s s o r are lub rica te d

as fo llo w s :
Part o f th e eng in e o il is d irected th ro u g h the oil pipe

fro m the crankcase in to th e tu rb o ch a rg e r. The engine
o il passes th ro u g h the o il hole in th e tu rb o c h a rg e r
bearing h ou sin g to lu b rica te th e bearings. It is then
retu rne d th ro u g h the o il o u tle t at the b o tto m o f the
bearing h o u sin g back to the crankcase and to th e oil
pan. A p isto n ring is in sta lle d on the o u tsid e o f each
b earing, serving as an o il seal.
(8 ) In je c tio n P u m p a n d A ir C o m p re s s o r
12-8
LUBRICATION - GENERAL 12
(9) L u b ricatio n of W a te r Pump
The eng in e o il d ra w n by the oil p u m p is routed The engine oil is th en fo rce d back fro m the drain p ort
th ro u g h the crankcase oil passage to the w a te r pum p. to the crankcase and retu rn s to the oil pan.
The engine o il d elivered to th e w a te r p u m p flo w s
th ro u g h the o il hole o f the w a te r p u m p and lub rica te s
the bearings.
12-9
12 LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS
2n S P E C IF IC A T IO N S
Item S p e cifica tio ns
Engine oil Q uality (W ith o u t tu rb o c h a rg e rl

API c lassifica tio n Class CC o r better
(W ith tu rb o c h a rg e r)
API c lassifica tio n Class CD o r bette r
[For general pow er) (For c o n s tru c tio n m a chin e ry)
Oil pan capacity A p p ro x . 27 lit. A p p ro x . 25 lit.
Oil filte r capacity 4 to 4.5 lit. 4 to 4.5 lit.
Lub rica tion m ethod Forced lu b ric a tio n b y o il p u m p
Oil pum p Type Forced lu b ric a tio n b y gear p um p

(w ith b u ilt-in re lie f valve)
R elief valve Type Ball va lve
Oil filte r
F u ll-flo w filte r elem ent Type F ilte r p ap e r type
Bypass filte r elem ent Type F ilte r pap e r type
Oil bypass alarm Type Piston v a lve typ e w ith b u ilt-in e le ctric contacts
Oil cooler Type S hell and p late typ e (m u lti-p la te type)
Oil bypass valve Type Piston va lve type
R egulator valve Type Piston va lve type
O il jet
Check valve Type Piston v a lv e type
3. SER VIC E STANDARDS

3.1 SERVIC E SYAM OAR0 TABLE
U n it: m m
D escription N om in al value L im it C orre ctio n and rem arks

(Basic diam eter)
Oil pressure A t idle 145 kPa 49 kPa Inspection.

(Oil tem per- (1.5 kgf/'cm 2) o r m ore (0.5 k g f/c m 2)
ature at
70 to 90' C A t m a xim u m speed 295 to 490 kPa 195 kPa A d ju st.
(3 to 5 k g f/c m 2) (2 kg f/c m 2)
O il pum p Backlash betw een cra nksh a ft 0.13 to 0.25 0.4 Replace.
gear and o il p u m p id le r gear
Backlash betw een id le r gear 0.11 to 0.24 0.4 Replace.

and o il p u m p gear
D ifference betw een p u m p case 0.05 to 0.11 0.15 Replace.

depth and gear heig h t
G ear to o th tip to p u m p case 0.11 to 0.18 0.2 Replace.

clearance
D rive gear shaft to co ver (20) 0.15 Replace.

D riven gear shaft to d rive n (20) 0.15 Replace.

gear clearance 0.04 to 0.07
Id ler gear shaft to id le r gear (22) 0.15 Replace bush in g.

12-10
L U B R IC A T IO N - S E R V IC E S T A N D A R D S 12
D escription N om in al value L im it C orre ctio n and rem arks
IBasic dia m e te r)
Oil R elief valve 1180 kPa Replace s p rin g .

pum p valve o pe n in g pressure (12 k g f/cm ')
Relief valve sp rin g load 150 to 165 N

(Installed le n g th : 46.3) (15.3 to 16.9 kgf)
Oil bypass a la rm valve o pe n ing pressure 345 to 390 kPa Replace.

(ON start pressure) (3.5 to 4 kgf/cm '')
Oil co o le r bypass valve o pe n ing pressure 175 to 215 kPa Replace.

(1.8 to 2.2 kg f/c m 2)
R eg u lator Valve o p e n in g pressure 360 to 420 kPa Replace.

valve (3.7 to 4.3 kg f/c m 2)
S p rin g load 76 to 80 N
(Installed le n g th : 48.3) (7.8 to 8.2 kgf)
Check valve o pe n ing pressure 265 to 325 kPa Replace.

(2.7 to 3.3 k g f/c m 2)
3 .2 T IG H T E N IN G TO R Q U E TABLE
D escrip tion Thread size T ig h te n in g torque Rem arks

O.D. x Pitch m m N m (kgfm )
Oil p u m p id le r gear shaft nut M12 x 1.25 59 to 78 A p p ly LOCTITE

(6 to 8) No. 262.
Oil bypass alarm M 20 x 1.5 44 to 54

(4.5 to 5.5)
Oil filte r ce nte r b o lt M 16 x 1.5 59 to 69

(6 to 7)
Oil co o le r bypass valve M27 x 1.5 15 to 20

(1.5 to 2.0)
R eg u lator valve M27 x 1.5 98 to 115

(10 to 12)
Oil pan d rain plug M 18 x 1.5 69 (7)
Oil jet check valve M12 x 1.75 34 (3.5)
12-11
12 LUBRICATION - SERVICE PROCEDURES
4. SERWOCE PROCEDURES MOTE:

1. To rem o ve th e oil co o le r, rem o ve th e
At idle in je c tio n pum p b e fo reh a n d .
NV 145 kPa (1.5 k g f/c m 2)
o r m ore
2. A fte r th e e le m e n t has b een in s ta lle d ,
L 49 kPa (0.5 kg f/c m 2) s ta rt the en g in e and c h e c k c o n n e c tio n s
A t m a x im u m speed for oil le a k s .
NV 295 to 490 kPa
(3 to 5 kg f/c m 2)
L 195 kPa (2 k g f/c m 2)
(2) Oil Pum p, Oil S tra in e r
NV . N o m in a l V alue
L . L im it
B9016A
W ith th e .o il pressure sw itch rem ove d and pressure

gauge installed , w o rm up the eng in e u n til the oil
te m p e ra tu re reaches 70C to 90C.
M easure the o il pressure at idle and m a x im u m
speeds. If the m e a su re m e n t is b e lo w the lim it,
o verha ul the lu b ric a tin g system .
4.1 REM O VAL AMO IN S T A L L A T IO N

(1) Oil F ilter, Oil C o oler
M OTE:
1. M e a s u re th e b a c k la s h in a d v a n c e of
rem o va l of oil pum p.
2. T h e oil s tra in e r and oil p ipe should be
rem o ve d to g e th e r w ith th e oil pum p
unless an yth in g w rong is e v id e n t.
3. A fte r th e oil pum p has b een in s ta lle d ,
ve rify th a t th e b a c k la s h is w ith in th e
s p e c ifie d range.
12-12
L U B R IIC A T IO N - S E R V IC E PROCEDURES 12
4 .2 D ISA SS EM B LY , IM SPECYIOM AMD REASSEMBLY
4.2.1 Oil Pump
(1) D isassem bly and In s p e c tio n
1 Oil strainer 6 Idler gear

(2) Oil pump cover 7 Seat
3 Driven gear 8 Spring
4 Driven gear shaft 9 Ball
5 Idler gear shaft 10 Case and gear assembly
For disa sse m b ly o f parts w ith an e ncircled n um b e r, see fo llo w in g item s.
The part m arked * m u st be inspected b efo re disassem bly.
NOTE:
1. Do n o t re m o v e th e d riv e n g e a r s h a ft u n le s s it is fa u lty .
R e m o v a l o f th e s h a ft m a y re s u lt in lo s s o f a llo w a n c e
fo r tig h te n in g th e o il p um p c a s e .
2. T h e c a s e and g e a r a s s e m b ly is a n o n -d is a s s e m b le d
ty p e . R e p la c e th e a s s e m b ly if it is d e fe c tiv e .
C9518D
12-13
D isassem bly and In s p e c tio n P rocedure

(a) Before disa ssem b ly, m easure and record the
backlash betw een the o il p u m p gear and the id le r
gear.
2) M easure the clearance betw een th e d riv e and

d rive n gear to o th end and the o il p u m p case w ith a
thickness gauge.
(b) Rem ove the o il s tra in e ra n d d riv e o u t th e o il p um p

cover w ith a plastic h a m m e r etc.
INIOTE;
The oil pum p co v er is lo c a te d by th e d ow el
pins in s ta lle d to th e oil pum p case.
(c) Before the d rive n gears are rem o ve d , m easure
and record the fo llo w in g item s.
(d) M easure and record the o utsid e d ia m e te r o f each

o f th e d rive gear shaft, d rive n gear sh aft and id le r
gear shaft. T hen, m ea sure and reco rd the inside
d ia m e te r o f each o f the o il p u m p case, co ve r and
d rive n gear b u sh in g s. C alculate the clearance b e
tw e en each s h a ft and b u s h in g . If the service lim it is
exceeded, replace the assem bly.
1) M easure the d iffe re n ce b etw een the d riv e and

d riven gear h e ig h t and the o il p u m p case d epth w ith a
thickness gauge.
12-14
L U B R IC A T IO N - S E R V IC E PROCEDURES 12
(2) R eassem b ly
N O TE:
1. B e fo re re a s s e m b ly , a p p ly e n g in e o il to all p a rts u n le s s
o th e rw is e s p e c ifie d .
2. T e m p o ra rily tig h te n th e o il s tr a in e r , ta k in g in to c o n s id
e ra tio n its in s ta lla tio n to th e c ra n k c a s e .
C9525C
12-15
4 .2 .2 O il F ilte r
1 Drain plug
2 Center bolt
3 Washer
4 Oil filter case
5 Oil filter element
6 Element retainer
7 Oil filter head
8 Oil bypass alarm
C9705C
In s p e c tio n o f O il B y p a s s A la rm
W ith no air pressure a p p lie d , check fo r c o n tin u ity

across the te rm in a ls as s h o w n and replace the oil
bypass alarm if th e re is c o n tin u ity .
Next, w ith the air pressure a p p lie d and g ra d u a lly
increasing, m easure the a ir pressure w h e n th ere is
co n tin u ity .
If the m e a su re m e n t is o u t o f sp e c ific a tio n , replace the
o il bypass alarm .
12-16
L U B R IC A T IO N - S E R V IC E PROCEDURES 12
4 .2 .3 51 C ooler
Damage, cracks,
scale, o il leaks
1 Oil c o o le r e le m e n t
2 Bypass valve
3 Oil c o o le r cover
NV ... N o m in al Value
C9804C
{1 ) G le a m in g |2 ) Air P ressu re T e s t
(a) Check fo r carbon or slud ge d ep osite d in the oil To check fo r oil leaks due to a broken o r cracked
passage o f the oil co oler e le m e n t and bypass valve. If e le m e n t, air pressure te st s h o u ld be p e rfo rm e d .
c o n ta m in a tio n is e vid en t, w ash in a clea nin g oil. A p p ly 1470 kPa (15 k g f/c m 2) air pressure to the
(b) If th ere is m uch scale on the e le m e n t and cover, e le m e n t to check fo r leaks. If air leaks o r o th e r defects
w ash w ith tap w a te r (p re fe ra b ly h o t w ater). are e vid en t, replace the e le m e n t.
MTEs
M a k e sure th a t tine s p e c ifie d a ir p ressure
Is not e x c e e d e d .
12-17
4 .2 .4 R e g u la to r V a lu e
4 .2 .5 C h e c k V a lv e
For the check va lve m o u n tin g p o s itio n , re fe r to (e) in (6) in 1 G eneral and (2) in 5.4.3 in G rou p 11 Engine.
12-18
L U B R IC A T IO N S - T R O U B L E S H O O T IN G 12
5 TPUBLESHOTDIMG
Oil pressure A b n o rm a l o il level

does not increase
0 Oil leaks in to co ola n t C orrect and fill to
s p ecifie d level
Oil leaks
Incorrect o il v isco sity

O il o ut o f life Replace
Fuel in oil R eplace (cause)
Oil pressure sw itch n ot fu n c tio n in g p ro p e rly Replace
Loaded o il filte r e le m e n t Replace e le m e n t
Loaded o il stra ine r, loose o il p u m p jo in t, cracked pipe C orre ct o r replace
Relief valve, bypass va lve n ot fu n c tio n in g p ro p e rly
W orn o r d am aged o il p u m p prop e r Replace
Excessive oil Oil leaks fro m eng in e C orrect o r replace G ro u p 11

c o n su m p tio n
Oil leaks fro m cra nksh a ft fro n t or re ar o il seal C orrect o r replace
Leaks to c o o lin g syste m

D efective o il co o le r w a te r jacket C orre ct o r replace
A b n o rm a l co m p re ssio n pressure Check G ro u p 11
12-19

FODtliL AND ENGINE

CONTROL.
eO PJTEM TS
1. GENERAL ......... . 2 5 .3 FE E D P U M P .............................. 81

2. SPECIFICATIONS .......................... 22 5 .3 .1 D is a s s e m b ly , In s p e c tio n andl
3. SERVICE STANDARDS .................. 23 R e a s s e m b ly .......................... 81
3.1 SERVICE STANDARD TABLE ..... 23 5 .3 .2 T e s t a n d A d ju s tm e n t ............ 82
3.2 TIGHTENING TORQUE TABLE ... 25 5 .4 A U T O M A T IC T IM E R ................. 83
4. SPECIAL TOOL .............................. 27 5 .4 .1 SA T y p e A u to m a tic T im e r .... 83
5. SERVICE PROCEDURES ................ 30 5 .4 .2 SP T y p e A u to m a tic T im e r .... 88
5.1 INJECTION PUMP ...................... 31 5 .4 .3 T e s t a n d A d ju s tm e n t ............
5.1.1 Removal ................................. 31 5 .5 P U M P D R IV E C A S E ..................
5.1.2 AD Type Injection Pump ......... 32 5 .5 .1 R e m o v a l a n d In s ta lla tio n .....
5.1.3 P Type Injection Pump ........... 40 5 .5 .2 D is a s s e m b ly a n d In s p e c
5.1.4 Adjustment after tio n ....................................... 93
Reassembly ............................ 49 5 .5 .3 R e a s s e m b ly .......................... 94
5.1.5 Installation ........ . 57 5 .6 IN J E C T IO N N O Z Z L E ................ 95
5.1.6 Bleeding the Fuel System ...... 60 5 .6 .1 R e m o v a l a n d In s ta lla tio n ..... 95
5 .1 .7 In s p e c tio n a n d A d ju s tm e n t of 5 .6 .2 D is a s s e m b ly ......................... 95
F u e l In je c tio n S ta r t T im in g .... 61 5 .6 .3 C le a n in g a n d In s p e c tio n ...... 96
5 .1 . In s p e c tio n a n d A d ju s tm e n t f 5 .6 .4 R e a s s e m b ly a n d A d ju s tm e n t
N o -lo a d M in im u m a n d (1 -s p rin g n o z z le ) ................... 97
M a x im u m S p e e d s ................... 6 2 5 .6 .5 R e a s s e m b ly a n d A d ju s tm e n t
5 .2 G O V E R N O R .................................... 64 (2 -s p rin g n o z z le ) ................... 98
5 .2 .1 R S V T y p e G o v e rn o r ................ 6 4 5 .7 F U E L F IL T E R ............................ 104
5 .2 .2 R FD T y p e G o v e rn o r ................ 6 7 5 .8 W A T E R S E P A R A T O R ............... 105
5 .2 .3 A d ju s tm e n t a fte r R e a s s e m b ly 70 6 . T R O U B L E S H O O T IN G .................. 106
5 .2 .4 In s p e c tio n an d A d ju s tm e n t off
N o -lo a d M in im u m a n d M a x im u m
S p e e d s ............................................ 80
13-1
13 FUEL AND ENGINE CONTROL - GENERAL
1. G E N E R A L
NOTE:
The fig u re s h o w s th e AD im p ro v e d
ve rsio n in je c tio n p um p .
B2115A
The fu el system co n sists o f the in je c tio n pum p

general a ssem bly (in je ctio n p u m p p ro p e r, g o v e rn o r,
tim e r, feed p u m p and c o u p lin g ), fu e l filte r, w a te r
separator, in je c tio n pipe, in je c tio n nozzle, fu el leak-off
pipe, etc.
The in je ctio n p u m p is d riv e n at o n e -h a lf th e engine
speed.
13-2
FUEL A N D E N G IN E CONTROL - GENERAL 13
(1) In je c tio n Pum p Ps-opes1
(a) In je c tio n pum p
The ca m sh aft d riven at h a lf th e e n g in e speed is 3) To p re v e n t the fu e l in the o il s u m p fro m leaking

su p p o rte d by ta p e r ro lle r b ea rin gs at b oth ends. The in to th e cam ch a m b e r, an O -ring is p ro v id e d on the
ca m sh aft has a cam fo r o p e ra tin g th e p lu n g e r and a o u te r c irc u m fe re n c e o f th e p lu n g e r b arre l, th e re b y
cam fo r o p e ra tin g the feed p um p. m a in ta in in g its tig h tn e s s .
A ta p p e t o p e ra tin g w ith the p u m p h ou sin g as the 4) A d e fle c to r is p ro v id e d on the o u te r circ u m fe re n c e
g u id e is in co nta ct w ith th e cam shaft. The ta p p e t o f the p lu n g e r barrel to p re v e n t e ro s io n o f th e p um p
changes the rota ry m o tio n o f th e cam to u p -a n d -d o w n h ou sin g th a t m ay be caused by c o u n te r flo w o f fu e l at
m o tio n w h ich is tra n s m itte d to the p lu n g e r. the end o f an in je c tio n .
The P typ e in je c tio n pum p o ffe rs the fo llo w in g
features.
1) The p u m p h ou sin g is a to ta lly enclosed typ e.
2) The p lu n g e r barrel has an o b liq u e h ole m ade to
retu rn the fuel th a t has leaked to th e o il su m p to
m in im ize the leakage o f th e fu e l in to th e cam
cham ber.
13-3
{lb ! P lu n g e r The p lu n g e r has an o b liq u e g ro o v e and a ve rtica l

g ro o ve , w h ile the p lu n g e r barrel has 2 in le t-o u tle t
holes.
Pressurized fe ed ing o f fu el o il begins w h e n the
p lu n g e r, pushed up by the cam o f ca m sh aft, closes
the in le t-o u tle t holes o f p lu n g e r barrel. W hen th e
p lu n g e r is fu rth e r p ushed up, fu e l o il is d isch arg ed
th ro u g h the v e rtica l g ro o v e o f p lu n g e r fro m th e
in le t-o u tle t holes.
Fuel B e g in n in g o f Pressure End o f
d ra w n in p ressu re feed feed pressure
feed
B2204A
AD ty p e in je c tio n p u m p P ty p e in je c tio n p u m p
C on tro l rod
P lun g e r barre l P lunger
B2224A B2206A
A d e fle c to r is in sta lle d on the p e rip h e ry o f th e p lu n g e r w h ic h engages w ith th e c o n tro l rod (or the c o n tro l
barrel so th a t hig h pre ssure fu el o il d isch arg ed fro m rack and p in io n ). Since the d riv in g face o f p lu n g e r
in le t and o u tle t p o rts w ill n o t erode the p um p m eshes w ith the c o n tro l sleeve at the lo w e r p art
h o u sin g . Fuel in je c tio n v o lu m e is c o n tro lle d by the th e re o f, th e p lu n g e r tu rn s w ith th e ro ta tio n o f c o n tro l
g o v e rn o r w h ich m ove s th e c o n tro l rod (or the c o n tro l sleeve and in je c tio n v o lu m e is c o n tro lle d th ro u g h th e
rack) le ft and rig h t and ro ta te s th e c o n tro l sleeve c h a n g in g o f the e ffe ctive stroke.
13-4
A d e liv e ry va lve sto p p e r, p ro v id e d on th e to p o f the
d e liv e ry valve s p rin g , lim its the lift o f the d e liv e ry
Effective stroke va lve to p re v e n t the s u rg in g o f the va lve d u rin g high
speed o p e ra tio n . It also reduces the dead v o lu m e
b etw een the d e liv e ry va lve and nozzle and stabilizes
the in je c tio n rate.
(d) O v e rflo w v a lv e
B2205A
The e ffe ctive stroke m eans th e le n g th o f the p lu n g e r

stroke fro m the tim e w h e n the u p p e r end o f p lu n g e r
closes the in le t-o u tle t holes o f p lu n g e r barrel u n til the
o b liq u e g ro o ve o f p lu n g e r opens to the in le t-o u tle t
holes. W hen the e ffe ctive stroke stands at zero, it
ind icate s th a t no fu e l in je c tio n takes place.
(c ) D e liv e ry v a lv e
W hen th e fu el pressure in th e in je c tio n p u m p exceeds
a p re d e te rm in e d pressure, the steel ball in the
o v e rflo w va lve is pushed up to let th e fuel flo w o u t
fro m the in je c tio n p u m p and retu rn to the fu e l tank,
th e re b y s ta b iliz in g th e fu e l te m p e ra tu re and te m p e ra
tu re d is trib u tio n in the in je c tio n p u m p and m a in ta in
ing th e in je c tio n rate in to each c y lin d e r constant.
The fuel h ig h ly pressurized by the p lu n g e r pushes the

d e liv e ry va lve up and gushes out. W h e n d e liv e ry o f
the fu el u nd er pressure by the p lu n g e r is co m p le te d ,
the d e live ry va lve is pushed back by th e d e liv e ry valve
sp ring and closes th e fuel passage to p re ve n t c o u n te r
flo w o f the fuel.
The d e live ry va lve is fu rth e r b ro u g h t d o w n u n til it is
held a ga in st the seat surface tig h tly . The a m o u n t o f
fuel co rre s p o n d in g to the stroke d u rin g the p erio d is
d ra w n back fro m a bove to in s ta n tly lo w e r the residual
pressure in the line b etw een the d e liv e ry va lve and
nozzle. The d ra w back e ffe ct im p ro v e s th e c u ttin g o f
fuel fro m the nozzle and p re ve n ts a fte r-in je c tio n
d rip p in g .
13-5
(2) Governor
(aj KSW ftype governor
S u p p o rtin g lever
B2657B
The RSV typ e g o v e rn o r is a c e n trifu g a l ty p e all-speed The g o v e rn o r, as sh o w n , consists o f fly w e ig h ts

g o v e rn o r co up le d to the ca m sh a ft o f the in je c tio n m o u n te d to the in je c tio n p u m p cam shaft. W hen the
p um p. The g o v e rn o r n o t o n ly c o n tro ls th e m a x im u m fly w e ig h ts tu rn in g on the fly w e ig h t s u p p o rtin g shaft
and m in im u m speeds b u t also a u to m a tic a lly c o n tro ls open o u tw a rd , the ro lle r m o u n te d to the end of
th e e ng in e speed at any in te rm e d ia te speed p o s itio n . fly w e ig h t arm pushes th e end o f the sleeve in the
axial d ire c tio n . The g o v e rn o r sleeve, being m ade
in te g ra l w ith the c o n tro l block th ro u g h a bearing,
m oves o n ly in the axial d ire c tio n .
The c o n tro l block, m o u n te d to th e g u id e lever hung
on the s u p p o rtin g leve r s h a ft o f th e g o v e rn o r cover,
p revents ro ta tio n .
13-6
W hen the g o v e rn o r s p rin g receives te nsio n, the
b o tto m end o f the te n s io n lever touches the a d ju s t
able fu ll-lo a d s to p p e r bolt.
W hen the angle o f the a d ju s tin g lever is changed, the
angle o f the s w ive l lever is also changed and the
te n s io n o f the g o v e rn o r spring changed. T his is
because th e tu rn in g ce nte r o f the sw ivel lever and the
m o u n tin g p o s itio n o f the g o v e rn o r spring installed to
the te n s io n lever are eccentric to each o th e r as
m e n tio n e d above.
An a d ju s tin g screw is also m o u n te d to the sw ivel
lever. A d ju s tm e n t o f the screw changes th e te nsio n o f
the g o v e rn o r s p rin g , th e re b y m aking it p ossible to
a d ju s t th e speed re g u la tio n .
An U n g le ich s p ring is p ro v id e d in the b o tto m p o rtio n
o f the te n sio n lever. A d ju s t the tension o f the sp ring
by a d d in g or re m o v in g shim s.
An id lin g sub s p rin g a d ju sta b le fro m o u tsid e is
p ro v id e d in the m id d le o f the g o v e rn o r cover. D uring
id lin g , th e s p rin g a lw a ys keeps in co nta ct w ith the
te n s io n lever to m a in ta in a co nsta nt id lin g speed.
The sto p lever, m o u n te d th ro u g h the s u p p o rtin g lever
to the b o tto m end o f the c o n tro l lever, returns th e
The c o n tro l lever is m o u n te d to th e m id d le o f the c o n tro l rack to the sto p p o s itio n w ith a s lig h t pressure
g u id e lever by the s h a ft w ith th e b o tto m end as the irre s p e c tiv e o f the a d ju s tin g lever p o sitio n .
fu lc ru m , w he re a s the to p o f th e lever is coup le d
th ro u g h the shackle to th e c o n tro l rack. H| S ta rt of eng ine
The sta rt sp rin g , attached to th e to p end o f the c o n tro l
lever, a lw a ys p ulls th e c o n tro l rack in th e d ire c tio n
th a t fu e l is increased.
W hen th e a d ju s tin g leve r is m ove d to the s ta rt

p o s itio n (u n til it to u ch e s the m a x im u m speed s to p
per), th e s w iv e l leve r w h ic h m oves w ith the a djustin g
The tu rn in g sh aft o f th e sw ive l leve r is fitte d in to the lever p u lls the g o v e rn o r s p ring and m oves the tension
b ush in g o f the g o v e rn o r co ve r and its ce n te r is lever u n til it to u ch e s th e fu ll-lo a d s to p p e r bolt.
eccentric w ith respect to the m o u n tin g p o s itio n o f the
g o v e rn o r s p rin g in sta lle d to the te n s io n lever. The
g o v e rn o r sp rin g is in sta lle d to the end o f the sw ivel
lever.
13-7
13 FUEL A N D E N G IN E CONTROL - GENERAL
A t th a t tim e , th e fly w e ig h ts are s ta tio n a ry , and the 3 ) M a x im u m s p e e d c o n tro l

sta rt sp rin g w ith w eak te n sio n p u lls th e c o n tro l lever
in the d ire c tio n th a t fu el is increased.
A t the sam e tim e , the c o n tro l block and g o v e rn o r
sleeve push the fly w e ig h t ro lle r to the left.
As the result, the te n sio n leve r and c o n tro l block are
spaced th a t m uch a part, and the c o rre s p o n d in g
a m o u n t o f fuel is su pe rch a rg e d to fa c ilita te s ta rtin g .
2 ) Ddling c o n tro l
W hen th e a d ju s tin g lever is m ove d to the fu ll-lo a d

p o s itio n , th e te n sio n o f the g o v e rn o r sp ring is in
creased and p u lls th e te n sio n lever u n til it to u ch e s the
fu ll-lo a d s to p p e r b olt.
W h e n th e eng in e exceeds the specified speed, the
c e n trifu g a l fo rc e o f fly w e ig h ts becom es larger than
th e fo rce of the g o v e rn o r sp ring p u llin g the te n sio n
lever. So the te n sio n leve r is m oved to the rig h t and
m oves the c o n tro l rack in the d ire c tio n th a t fu e l is
Once the eng in e is started and the a d ju s tin g lever reduced, th e re b y p re v e n tin g th e eng in e fro m exceed
retu rn e d to th e id lin g p o s itio n , th e te n s io n o f the ing th e sp ecified speed.
g o v e rn o r sp rin g is d ra s tic a lly reduced. If th e speed fu rth e r increases, the ce n trifu g a l force o f
N ow the fly w e ig h ts can m o ve o u tw a rd even at a lo w fly w e ig h t increases and pushes the te nsio n lever to
speed, so the te n sio n lever is p ushed back u n til it th e rig h t and also co m p re sses th e id lin g sub s p rin g to
to uch es th e id lin g sub sp rin g and places the c o n tro l p u ll th e c o n tro l rack back to the no-load m a x im u m
rack at th e id lin g p o sitio n . In th is state, the c e n trifu g a l speed p o s itio n , th e re b y p re ve n tin g over-speed o p e ra
fo rce o f the fly w e ig h ts and th e w eak-state g o v e rn o r tio n o f the engine.
s p rin g and id lin g sub s p rin g achieve balance and The RSV type g o v e rn o r c o n tro ls the e ntire speed
m a in ta in s m o o th id lin g . range fro m id lin g to m a x im u m speed. If load in
W hen the speed falls, the c e n trifu g a l force decreases, creases o f decreases at a certain speed d e te rm in e d by
the fly w e ig h ts m o ve in w a rd , and the id lin g sub sp ring the p o s itio n o f th e a d ju s tin g lever, the g o v e rn o r
pushes the te n sio n lever to th e le ft and m oves the a u to m a tic a lly fu n c tio n s and m a in ta in s th e eng in e
c o n tro l rack in the d ire c tio n th a t fu el is increased. speed c o n s ta n t at all tim es.
If the speed fa lls ra d ica lly, the sta rt sp rin g w ith w eak
te n sio n acts and m oves th e c o n tro l rack in the
d ire c tio n th a t fu el is increased to m a in ta in the id lin g
speed.
13-8
4) UsugleSch o p e ra tio n The a ir intake rate o f the eng in e fa lls as the engine
speed increases. The in je c tio n p um p, on the o th e r
hand, increases the per-stroke in je c tio n as the speed
W hen m ax. in je ctio n is set increases, even w ith the c o n tro l rack at the sam e
at low -speed operation
\ Injection m atched p o s itio n .
\ w ith a ir intake rate T he refo re , if fu ll load is set at p o in t A to derive
A 1 - 4- - - 1 e n o ug h o u tp u t at lo w speeds, the in je c tio n w ill reach
Injection/stroke B
A' B as the speed increases, and the e n g in e w ill produce
1
W h e n m a x. in je c tio n is set
at h ig h -s p e e d o p e ra tio n |
black sm oke.
If fu ll load is set at p o in t B' to pre ven t black sm oke, the
Engine speed lo w speed in je c tio n w ill com e d o w n to A ', a llo w in g
c o m b u s tio n o f m ore fuel.
B2663A
So the U ng leich device a ccom plishe s the fu n c tio n o f
se ttin g fu ll load at p o in t A to d erive the largest
The U ng leich device c o n tro ls fu e l in je ctio n in such a possible to rq u e in the lo w speed range, and c h an ging
w a y as to m atch the e n g in e p e rfo rm a n c e (the re it to a d ju s t the in je ctio n to p o in t B' in th e high speed
q u ire d in je c tio n va ries w ith e n g in e speed). range.
n , / \ Enqine speed (rpm )

Pum p speed Irpm ) ^ a r
B2664A
W hen the eng in e speed is lo w and the c e n trifu g a l

fo rce o f fly w e ig h t sm a lle r th an the pressure o f the
U ng leich sp rin g , th e c o n tro l blo ck is m ove d as m uch
as th e U ng leich stroke to the left, so the c o n tro l rack
m oves in the d ire c tio n th a t fu e l is increased to
increase the to rq u e o f the e n g in e at lo w speeds.
13-9
5) S to p p in g of e n g in e
As th e e n g in e speed increases, th e ce n trifu g a l fo rc e o f

fly w e ig h t increases. If it becom es la rg e r than the W hen the sto p lever is m ove d to the sto p p o s itio n , the
pressure o f the U ng leich s p rin g , the U n g le ich sp ring c o n tro l rack is m ove d to the sto p p o s itio n to s to p the
is s lo w ly co m p re ssed b e fo re the sta rt o f hig h speed e ng in e regardless o f the p o s itio n o f the a djustin g
co n tro l, and th e co n tro l rack m oves in the d ire c tio n lever.
th a t fu el is reduced. The U ng leich stroke is c o m p le te d
at the p o s itio n w h e re th e c o n tro l block d ire c tly
to u ch e s the te n sio n lever.
6) O p e ra tio n of to rq u e s p rin g [O p tio n ]
B2667A
C o n stru ctio n m a ch in e ry eng in es are o fte n su bjected o fte n lead to stalls. To p re ve n t th is , a to rq u e sp ring is
to a large load d u rin g o p e ra tio n , and reduced speeds p ro v id e d .
13-10
FUEL AM D E N G IN E CONTROL - GENERAL 13
W hen the a d ju stin g lever is fixe d in the lever set A t the tim e , the te nsio n lever pin pushes the b o tto m
p o sitio n , a sudden increase o f load, if no to rq u e o f the to rq u e c o n tro l lever, and the leve r m oves w ith
sp rin g is p ro vid e d , w ill m ove th e c o n tro l rack along the pin " A " as the fu lc ru m , w hereas th e p o rtio n "B " is
the B-D curve as the speed falls. The ro ta tio n a l pushed to rig ht. As the result, th e to rq u e spring
d isp la ce m e n t at the tim e m ay be expressed as P,. p e rfo rm s the fu n c tio n o f reducing m o v e m e n t o f the
If a to rq u e sp rin g is p ro vid e d , th e c o n tro l rack m oves te n sio n lever.
along B-C, and the ro ta tio n a l d is p la c e m e n t at the tim e
m ay be expressed as P2. T he refo re , large changes (b) RFD (type governor [O ption]
o ccur in P2 and eng in e speed, and because of
increased fu el in je ctio n , the e n g in e to rq u e increases,
and large c o m b u s tio n noise w a rn s th e o p e ra to r o f th e
increased load, e na b lin g h im to take p ro p e r action to
p re ven t sto p p in g the engine.
The RFD typ e g o v e rn o r is a m in im u m -m a x im u m

g o v e rn o r w h ic h c o n tro ls o n ly the m in im u m and
m a x im u m speeds.
The RFD typ e g o v e rn o r m ake it p ossible to increase or
reduce fu el by the load c o n tro l lever w h ic h operates
In an a b ru p t increase o f load occurs w h e n the eng in e the c o n tro l rod. A n y desired speed can be set as a
is ru n n in g at c o n tin u o u s ra tin g , th e eng in e speed d is p la c e m e n t o f the speed c o n tro l lever changes the
falls. So the fly w e ig h ts are m o ve d in w a rd and the te nsio n o f th e g o v e rn o r sp ring .
te n sio n lever p ulled to left by the co n tro l sp rin g , Because o f the c o n s tru c tio n described above, the RFD
causing the co n tro l rack to m ove in the d ire c tio n th a t g o v e rn o r can be o pe ra te d as an all-speed g o v e rn o r by
fuel is increased. h o ld in g the load c o n tro l lever in the FULL p osition
and o p e ra tin g the speed c o n tro l lever.
On the to p o f the g o v e rn o r, an eng in e sto p lever is
p ro v id e d w h ic h creates a no-fuel in je ctio n state fo r
s to p p in g the e ngine. A cancel s p rin g is p ro v id e d to
m ake sure th a t w he n the lever is operated, no undue
fo rc e is a p p lie d to the link.
13-11
1) S ta r t o f e n g in e a n d c o n tro l of id lin g
Increase Injection rate *- Decrease
B2605A
If the load c o n tro l lever is placed to the id lin g p o s itio n
W hen the e ng in e is sta tio n a ry, the fly w e ig h t is in after the eng in e has started, the flo a tin g lever w ill
closed p o s itio n , pushed by the g o v e rn o r s p rin g , id lin g m ove the c o n tro l rod back to a p o s itio n w h e re a fuel
sp rin g and sta rt sp ring . in je c tio n rate su ita b le fo r the id lin g speed is available,
If, in th is c o n d itio n , the load c o n tro l lever is m ove d all w ith the p o in t B as th e fu lc ru m .
the w a y to th e FULL p o s itio n (in th e d ire c tio n o f As the eng in e speed increases, the fly w e ig h ts w ill
g re a te r fu e l d e live ry), the sta rt sp rin g and id lin g m ove o u tw a rd by the c e n trifu g a l fo rce and w ill s h ift
sp ring w ill cause the c o n tro l rod to m ove to the fuel the s h ifte r by the p o in t A u n til the s h ifte r com presses
increasing p o sitio n . the id lin g sp ring .

A t th is tim e , the fu lc ru m B w ill also s lig h tly m ove
to w a rd the te n sio n lever and w ill m ove the co ntrol
rod back in the d ire c tio n fo r red ucin g th e fuel inje ction
rate.
As the eng in e speed decreases, the ce n trifu g a l force
o f the fly w e ig h ts w ill decrease and the fly w e ig h ts w ill
m ove in w a rd , so the p o in t A w ill retu rn to w a rd the
p u m p h ousing. This w ill set the s h ifte r in the free
state, p ush in g it back to w a rd the p u m p hou sin g by
id lin g sp ring force.
13-12
A t th e sam e tim e , the fu lc ru m B w ill also s lig h tly As the eng in e speed increases, the ce n trifu g a l fo rce o f
m ove to w a rd the p u m p h o u sin g to push the co n tro l the fly w e ig h t w ill increase, and the fly w e ig h t w ill
rod back in the d ire c tio n fo r decreasing the fuel push the sh ifter. In the n o rm a l speed range, h ow eve r,
in je ctio n rate. the s h ifte r w ill have o n ly a th ru s t eno ug h fo r c o m
In th is m anner, the id lin g speed is m a in ta in e d stable pressing th e id lin g s p rin g and w ill n o t be able to push
by s lig h t a d ju s tm e n t o f the in je c tio n rate. the te nsio n lever o ut by o v e rc o m in g the te n sio n o f the
g o v e rn o r sp ring .
2 } N o r m a l s p e e d o p e r a t io n In th is m anner, the fu el in je c tio n rate is increased or
reduced s im p ly by o p e ra tio n o f the load c o n tro l lever
w h ic h m oves the c o n tro l rod.
3 ) G o r jir a l o f m a x im u m speed
Increase In je ctio n rate -*- Decrease
If th e c o n tro l lever is m ove d to w a rd FULL (in the

d ire c tio n o f g re a te r fuel d e live ry), the e ccen tric sh aft
co up le d to the load c o n tro l leve r w ill cause the sliding
lever to tu rn w ith the p o in t D o f the te n sio n lever as
th e fu lc ru m . In a d d itio n , the flo a tin g leve r w ill push If th e e n g in e speed exceeds a p re d e te rm in e d m a x
th e c o n tro l rod back in the d ire c tio n o f g re a te r fuel im u m speed because o f changes in eng in e lo a d ,th e
in je c tio n rate, w ith the p o in t B as the fu lc ru m . c e n trifu g a l fo rce o f the fly w e ig h t w ill o ve rco m e the
te n sio n o f th e g o v e rn o r s p rin g and w ill push the
te n sio n leve r to g e th e r w ith the sh ifter.
13 -13
M o v e m e n t o f th e s h ifte r w ill m o ve the p o in t B, and

m o v e m e n t o f the te n sio n leve r w ill m ove the p o in t D,
W ith sm oke set
and w ill also m o ve th e p o in t C w ith the p o in t E as the assem bly
fu lc ru m .
M o v e m e n t o f th e p o in t B and m o v e m e n t o f the p o in t
C w ill co m b in e to p u ll the c o n tro l rod back in the
d ire c tio n o f less fu el in je c tio n rate, th e re b y p re ve n tin g
the e ng in e speed fro m increasing.
If an e n g in e c o n tro l m e ch a n ism w h ic h operates the
speed c o n tro l leve r a d ju stin g the te n sio n o f the
g o v e rn o r s p rin g is e m p lo ye d , the g o v e rn o r can be
o pe ra te d as an all-speed g o v e rn o r w h ic h m ain ta in s a
desired e n g in e speed co nsta nt.
45 Start booster (smoke set assembly)
Pum p speed (rpm )
B2674B
As ind icate d by th e g o v e rn o r ch aracte ristics sh o w n

above, w he n w ith o u t th e sm oke set assem bly, the
s h ifte r and flo a tin g lever are pushed back by the
id lin g sp ring force, m o v in g the c o n tro l rack to w a rd
fu el increasing d ire c tio n w he n p u m p speed reaches
N.. N am ely, N. is the sm oke lim it in th is case.
W hen w ith the sm oke set assem bly, th e s p rin g force
o f the sm oke set a sse m b ly o vercom es th a t o f th e
id lin g sp ring so th a t the flo a tin g lever m o tio n is
in h ib ite d u n til the speed reaches N2. T hus, the sm oke
lim it decreases fro m N. to N2.
It is also p ossible to secure rack p o s itio n Rs needed at
tim e o f start.
The sm oke set a sse m b ly in sta lle d to the rear o f the

g o v e rn o r has a sp rin g w ith se ttin g fo rc e and a s to p p e r
as fu n c tio n a l parts. It also has sleeve, stroke a djustin g
nut, s p rin g a d ju stin g n u t and cap.
13-14
5} E n g in e s to p The flo a tin g lever A p ushed by the flo a tin g lever link
tu rn s in such a w a y as to m ake the cancel spring bend
o ver the sh aft B. So no load is placed on the flo a tin g
lever C blocked by the idle s to p p e r b o lt o u tsid e the
g o v e rn o r.
O p eratio n o f the u ng le ich device is the sam e as the
RSV typ e g o v e rn o r.
{3} F e e d P u m p
To stop the e ng in e, fu el is cu t o ff by o p e ra tin g the

sto p lever on the to p o f the g o ve rn o r.
If the sto p leve r is o pe ra te d, the in te rn a l lever pushes
th e paw l o f th e flo a tin g lever lin k to fo rce the c o n tro l
rod o u t to the n o -in je c tio n p o s itio n .
Since the a m o u n t the c o n tro l rod is m ove d by
o p e ra tio n o f the sto p lever exceeds the o p e ra tin g
range o f the flo a tin g lever m e ch a n ism , d am age to the
lin k and allied parts is p re ven te d by the cancel S u p p ly o f fu el to th e in je c tio n pum p p ro p e r is
m ech an ism sh ow n. a c c o m p lis h e d by the feed p u m p m o u n te d to the side
o f the in je c tio n p u m p p ro p e r and d rive n by th e cam o f
the in je c tio n p u m p c a m s h a ft p ro v id e d fo r the p u r
pose.
The p rim in g p u m p m o u n te d to the feed p u m p m akes
it possible to lift fu e l m a n u a lly w he n th e eng in e is
s ta tio n a ry.
B1631A
13-15
W hen the pressure o f the pressure c h a m b e r or the

d e liv e ry pressure exceeds sp e c ific a tio n , th e piston
c a n n o t be b ro u g h t back by the pressure o f the p iston
s p rin g , so the pum p a ction stops and th e fu el
pre ssure in the fuel filte r does n ot rise m o re than
necessary.
(4 ) A u to m a tic T im e r
The in te rv a l b etw e en fu e l in je c tio n in to th e c y lin d e r
and its ig n itio n is called th e ig n itio n delay inte rva l.
The ig n itio n d elay in te rv a l is c o n s ta n t regardless o f
the e n g in e speed. If the ig n itio n tim in g is alw ays
co nsta nt, changes in the e n g in e speed w ill v a ry the
The feed p u m p feeds fu el u n d e r pressure as fo llo w s . re la tio n b etw een the p is to n p o s itio n and ig n itio n
W hen the p iston is p ushed up by th e cam o f the tim in g , m aking it im p o s s ib le to o b ta in the best eng in e
ca m sh aft, the fuel in the su ctio n c h a m b e r opens the p e rfo rm a n ce . To m a in ta in the re la tio n b etw een the
o u tle t check valve, so m o st o f th e fu el is fo rce d o ut p isto n p o s itio n and ig n itio n tim in g c o n s ta n t at all
and d ra w n in to the pressure ch am be r. W hen the cam tim e s , the in je c tio n tim in g m u s t be chan ge d to m atch
is m ove d aw ay by ro ta tio n o f th e ca m sh aft, th e p iston the e n g in e speed.
is p ushed back by the pre ssure o f th e p isto n s p rin g . At The a u to m a tic tim e r is a device w h ic h a u to m a tic a lly
the tim e , the o u tle t check va lve closes and th e in le t changes the in je c tio n tim in g accordin g to the eng in e
check va lve opens. So fu e l is d ra w n in to the su ction speed.
ch am be r, w hereas the fu el in the pressure c h a m b e r is
fo rce d out.
(a) SA type automatic timer [6P22]
F ly w e ig h t
B3210A
13-16
The tw o fly w e ig h ts have a hole at one end. The pins
o f the fly w e ig h t h o ld e r fit in the holes. The fla n g e legs e At m a x im u m
Spnng , .
advance anqle
touch the curve d surfaces o f the fly w e ig h ts . T im e r e xte n sio n J
s p rin g s are m o u n te d to the fly w e ig h t p ins and fla ng e

legs.
R otation o f the e n g in e is tra n s m itte d to the fla n g e and
fro m th ere to the fla n g e legs, fly w e ig h ts and fly w e ig h t
h o ld e r and to the in je c tio n p u m p cam shaft.
B3212A
W hen the e n g in e runs at a hig h speed, a c e n trifu g a l

fo rce acts on the fly w e ig h ts and causes th em to open
o u tw a rd w ith the pins o f the fly w e ig h t h o ld e r as the
fu lc ru m s . The fla n g e legs are pushed b y the curved
surfaces o f the fly w e ig h ts in the d ire c tio n o f th e tim e r
s p rin g co m p re s s io n , b ut th e y cannot be m oved
because th e y are co up le d to the d rive side.
As a result, the p ins o f the fly w e ig h t h o ld e r are draw n
D uring lo w speed o p e ra tio n o f th e e ngine, no c e n tri in th e tu rn in g d ire c tio n , w h ile co m p re s s in g the tim e r
fu g a l fo rce acts on the fly w e ig h ts , so the tim e r s p rin g s sp ring s, and m ove the c a m sh a ft o f the p u m p in the
have th e lo n g e st in sta lle d len gth. tu rn in g d ire c tio n to advance the in je c tio n tim in g .
If the eng in e speed changes fro m a high to lo w speed,
the c e n trifu g a l fo rc e o f the fly w e ig h ts w ill decrease
and the fly w e ig h ts w ill retu rn to th e ir o rig in a l p o s i
tio ns. A t the sam e tim e , the pins o f the fly w e ig h t
h o ld e r w ill be pushed back by the tim e r sp ring s.
13-17
13 FUEL A N D E N G IN E C O N T R O L - GENERAL
{IsSSP ty p e a u to m a tic tim e r [6 0 2 2 -Y , T C ]
Oil seal
B3201A
T w o fly w e ig h ts are fitte d on th e p in s o f th e tim e r T im e r s p rin g s are held b e tw e e n th e s p rin g seats fitte d
h o u sin g and are held in th e tim e r h o u s in g . On the on the tim e r h ou sin g p in s w h ic h exten d th ro u g h the
o th e r hand, th e in je c tio n p u m p co n n e c tio n side fla n g e fla n g e and fly w e ig h t. These parts are housed in the
has a curve d surface, and the ro lle r fitte d on the pin tim e r h o u sin g and are to ta lly enclosed w ith a cover,
in sta lle d in the fly w e ig h t to u ch e s the cu rve d surface. O -ring and oil seal.
13-18
FUEL AND ENGINE CONTROL - GENERAL 13
(5 ) C o u p lin g
[For AD type]
T im e r sp rin g Flange
B3405A
[For P typ e]
B3202A
W hen the e n g in e is ru n n in g at a lo w speed, the tim e r

s p rin g pressure is s tro n g e r th an th e c e n trifu g a l force
o f fly w e ig h t, so the ro lle r o f fly w e ig h t is held d o w n by
the fla n g e , crea ting no advance state.
W hen the e n g in e reaches a hig h speed, the c e n trifu g
al fo rce o f fly w e ig h t becom es stro n g e r, the ro lle r o f
fly w e ig h t pushes th e curve d surface o f fla n g e w ith the
The c o u p lin g w h ic h tra n s m its d riv e p o w e r fro m the
tim e r h o u sin g pin as the fu lc ru m , and the fly w e ig h t
a ir c o m p re s s o r cra n ksh a ft o r in je ctio n p u m p drive
o pens o u tw a rd , w h ile co m p re ssin g th e tim e r springs.
cra n ksh a ft to the a u to m a tic tim e r is a lam ina te d
In th is m a n n e r, the ro lle r in sta lle d on the fly w e ig h t
c o u p lin g c o n sistin g o f th in plates placed one upon
m ove s th e fla n g e in the tu rn in g d ire c tio n and a d v
another.
ances th e in je ctio n tim in g .
The la m in a te d c o u p lin g , thanks to th e re v e rs ib ility of
th e plates, absorbs excess forces o th e r than the
to rq u e , th e re b y p ro v id in g p ro te c tio n a ga in st a p p lica
tio n o f forces o th e r than necessary to th e in je ctio n
p um p.
A d ju s tm e n t o f the fu e l in je c tio n sta rt tim in g is m ade
by c h a n g in g the in s ta lle d c o n d itio n o f the d riv in g
c o u p lin g .
13-19
{6} Pump five C ase The high pressure fuel w h ic h has fo rce d the needle
va lve up is inje cted fro m the o rific e at the end o f the
nozzle in to the eng in e c o m b u s tio n cham ber.
S om e o f the hig h pressure fu el lu b rica te s th e needle
valve, etc. and is re tu rn e d th ro u g h the fuel leak-off
pipe to the fu e l tank.
The in je c tio n pressure o f the in je c tio n nozzle is
a djusted by c h a n g in g the te n sio n o f th e nozzle s p rin g
w ith the a d ju s tin g screw .
(b) Hole type (2-spring nozzle) [Option]
The p u m p d rive case is m o u n te d on th e fly w h e e l

h o u sin g on the le ft side o f th e e n g in e and is d riv e n by
the tim in g gear o f the e n g in e at h a lf the e n g in e speed. Cap n ut
To le a k-o ff pipe
The p u m p d riv e sh aft, w ith its end co nn ecte d to the A d ju s tin g screw
c o u p lin g o f the in je c tio n p u m p , d rive s th e in je c tio n From in je c tio n p um p
p um p. 2 sp rin g
(7) Oirajectiori IMozzle P re lift adju stin g shim
Spacer
(a) Hole type (1-spring nozzle)
No. 2 p ush ro d
Nozzle hold e r
V alve o p e n in g pressure
a d ju s tin g shim
No. 1 spring
No. 1 push rod
Nozzle
N eedle valve
R etaining nut
B3406A
The fu e l d e liv e re d fro m the in je c tio n p u m p enters th e

nozzle h o ld e r and o ve rco m e s the No. 1 and No. 2
sp rin g s, d e p e n d in g on its pressure, and pushes th e
needle va lv e up.
The high pressure fu el w h ic h has fo rce d the needle
va lve up is p ro p e rly in je cte d fro m the o rific e at th e
end o f th e nozzle in to the e n g in e c o m b u s tio n c h a m
ber.
S om e o f the hig h pressure fu el lu b rica te s the needle
valve, etc. and is re tu rn e d th ro u g h th e fuel lea k-o ff
B3407A
pipe to th e fu e l tank.
The fu e l d e live re d fro m th e in je c tio n p u m p e nte rs the The in je c tio n pressure o f the in je c tio n nozzle is
nozzle h o ld e r and has a pre ssure h ig h e r th a n the adjusted by ch a n g in g th e te n s io n o f th e nozzle s p rin g
sp ecified pressure. So the fu e l o ve rco m e s the nozzle w ith the sh im and a d ju s tin g screw .
sp rin g and pushes the needle va lve up.

13-20
(3 ) F u e l F ilte r (9} W a te r S e p a r a to r [O p tio n ]
B3551A
The fuel filte r is a sp in -o n typ e. So the e le m e n t Is T he s e d im e n te r ty p e w a te r s e p a ra to r separates gas

easily replaceable. oil and w a te r c e n trifu g a lly by ta king adva nta g e o f
The fu el filte r separates th e w a te r co n ta in e d in the th e ir d iffe re n c e in s p e cific g ra v ity .
fuel fed u n d e r pressure fro m the feed p u m p o f the The fu el th a t has flo w e d in fro m the in le t c o n n e c to r is
in je ctio n p u m p and rem ove s d u st and d irt by the squeezed by the fuel path o f the head to increase the
elem ent. flo w v e lo c ity and spins. The separated w a te r is
se d im e n te d in the case, w h e re a s the w ate r-se p a ra te d
fu e l is d ra w n th ro u g h the fu e l path in the ce nte r o f the
head in to the feed p um p.
The w a te r s e p a ra to r s e d im e n ts n o t o n ly w a te r but
also m ud c o m p o n e n ts .
A red flo a t goes up and d o w n w ith the w a te r level in
th e s e m i-tra n s p a re n t case, m aking it possible to
v is u a lly check the w a te r q u a n tity .
13-21
13 FUEL AND ENGINE CONTROL - SPECIFICATIONS
2. SPECIF0CAT0ONS
Item S pecifica tio n
(Diese Kiki Co., Ltd. p ro d u ct)

16D22I (6D22-TJ 16D22-TC)
In je ctio n p u m p p ro p e r (S tandard) (O ption) (S tandard) (O p tio n )
Type Bosch in -lin e Bosch in-line Bosch in -lin e Bosch in-line Bosch in-line
type type type type type
M o de l AD AD P P
T u rn in g d ire ctio n C lockw ise C lockw ise C lockw ise C lockw ise C lockw ise
(as view e d fro m d rive side)
P lun g e r D ia m e te r mm 10.5 10.5 12 12 12
G o ve rn o r Type A ll speed M in im u m A ll speed M in im u m A ll speed
g o v e rn o r m a x im u m g o v e rn o r m a x im u m g o v e rn o r
m echanical m echanical
g o v e rn o r g o v e rn o r
M odel RSV RFD RSV RFD RSV
Feed p u m p M odel KE KE K K K
A u to m a tic tim e r Type M e chanical M echanical M echanical M echanical M echanical
a u to m a tic tim e r a u to m a tic tim e r a u to m a tic tim e r a u to m a tic tim e r a u to m a tic tim e r
M odel SA SA SP SP SP
In je ctio n nozzle (S tandard) (O ption) (S tandard) (O ption)
Type Piole typ e Piole type H ole typ e H ole type Hole typ e Hole type
(1-spring nozzle) (1-spring nozzle) (2-sprin g nozzle) (1-sprin g nozzle) (1-spring nozzle) (2-spring nozzle)
M odel DLLA DLLA DLLA DLLA DLLA DLLA
No. o f o rifice s 4 4 4 4 5 5
O rifice 0.37 0.37 0.37 0.37 0.36 0.36
d ia m e te r mm
O rifice ang le 154 154 154 154 150 150
In je ctio n pressure 21.6 (220) 21.6 (220) 17.7 (180) 21.6 (220) 21.6 (220) 17.7 (180)
MPa (kg f/cm 2)
Fuel filte r Type S p in-on type
W a te r se pa ra to r S e d im e n t tra p type
13-22
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E S T A N D A R D S 13
3c SEPVDGE STAE\3DA13I0)S
3H S E R V IC E S T A N D A R D T A B L E
(1 ) In je c tio n P u m p
U n it: m m
D e scrip tion N o m in a l value L im it C orre ctio n and

(Basic dia m e te r) rem arks
Fuel in je ctio n sta rt tim in g (BTDC) D ependent on - A d ju st.

s p ecifica tio n
E cce n tricity w ith respect to a ir co m p re sso r crankshaft 0.2 o r less - A d ju st.

(or p u m p d rive shaft)
In jectio n p um p In je ctio n spacing 60 30' - A d ju st.

p ro p e r
Prestroke AD type 4.5 0.05 - A djust.
P type 4.8 i 0.05 -
O verall ta p p et clearance - 0.2 Replace.
O v e rflo w va lve o p e n in g pressure 6D22 155 kPa Replace.

(fo r general (1.6 k g f/c m 2)
p o w e r a pp licatio n )
6D22 (fo r 255 kPa

co n s tru c tio n (2.6 k g f/c m 2)
m a chin e ry)
6D22-T, 6D22-TC
End p la y o f ca m sha ft 0.02 to 0.06 0.1 A d ju s t shim s.
S lid in g resistance o f c o n tro l rack AD type 1.5 N o r less - Check.

(w hen sta tio n a ry) (150 g f o r less)
S lid in g resistance o f c o n tro l rod P type 1.3 N or less - Check.

(w hen sta tio n ary) (130 g f o r less)
T appet clearance AD type 0.3 o r m ore A d ju st.
Full stroke o f co n tro l rack (o r c o n tro l rod) 21 o r m o re - Check.
Backlash betw e e n c o n tro l rack and AD type 0.15 0.3 Replace.

p in io n
G o ve rn o r D im e n sio n fro m g o v e rn o r h o u sin g RSV type 19 to 19.2 - A d ju s t shim s.

to sh ifte r
RFD type 33 to 33.4 -
13-23
FUEL AND ENGINE CONTROL -
SERVICE STANDARDS
U n it: m m
D escrip tion N om in al value L im it C orrection and

(Basic dia m e te r) rem arks
Feed T ig htn ess (w hen 195 kPa (2 kg f/cm z) o f air pressure 0 cc/m in. - Replace.
pum p is applied)
L iftin g No. o f stro ke s re q u ire d before 25 strokes o r less

capacity liftin g w h e n ope ra te d at 60
to 100 strokes per m in u te
D elivery 100 rpm KE type 60 Replace.

(m in.)
fo r 15 K type 60
seconds
cc 500 rp m KE typ e 340
K typ e 260
1000 rpm KE typ e 405
K type 530
1500 rp m KE type 430
K type 520
{ 2 ) Qnjectsora quoszO
U n it: m m
D escrip tion N om in al value L im it C orrection and

(Basic diam eter) rem arks
In je ctio n nozzle in je ctio n O ne-sp rin g nozzle 21.6 MPa (220 kg f/c m 2) A d ju s t o r replace
pressure nozzle.
T w o -sp rin g nozzle 17.7 MPa (180 k g f/c m 2)
P re lift 0.10 0.02 A d ju st.
2-sprin g re g u la te d p ressu re (open pressure) 24.8 to 25.4 MPa A d ju st.

(253 to 259 k g f/c m 2)
2-sprin g re g u la te d pressure (cover pressure) w ith 23 to 23.5 MPa A d ju st.

a 0.05 needle va lve lift (235 to 240 k g f/c m 2)
13-24
S E R V IC E S T A N D A R D S 13
3 .2 T IG H T E N IN G TO R Q U E TABLE
D escrip tion Thread size T ig h te n in g to rq u e Rem arks

O.D. x pitch N m (kgfm )
(m m )
In jectio n p u m p bracket M 10 x 1.5 35 to 53 (3.6 to 5.4)
Injection AD type in je ctio n D e livery valve h o ld e r 64 to 69 (6.5 to 7)

pum p pum p
Lock plate 4.4 to 5.9 (0.45 to 0.6)
P typ e in je ctio n Flange sleeve nut 39 to 44 (4 to 4.5)

pum p
D e live ry va lve h o ld e r 110 to 115 (11 to 12) T ig hte n th re e tim e s to
the s p ecifie d to rq u e.
G o ve rn o r fly w e ig h t nut 49 to 59 (5 to 6)
SA typ e a u to m a tic tim e r R ound nut 83 to 98 (8.5 to 10)
SP typ e a u to m a tic tim e r R ound nut 125 to 145 (13 to 15)
Cap screw 29 to 39 (3 to 4)
C over m o u n tin g b o lt 22 to 24 (2.2 to 2.4)
(For AD type in je ctio n pum p) A b o lt 49 to 54 (5 to 5.5)
B B b o lt 29 to 34 (3 to 3.5)
wf \ C b olt 29 to 34 (3 to 3.5)
Q C
-
E g "* A
/
* \
B
B3408A
(For P type in je ctio n pum p) A b o lt 74 to 83 (7.5 to 8.5)
B b o lt 59 to 64 (6 to 6.5)
C b o lt 59 to 64 (6 to 6.5)
B
Xji
c[ / r A B
B3401A
In jectio n O ne-sp rin g nozzle R etaining nut M 22 x 1.5 59 to 78 (6 to 8)

nozzle
In le t co nn e cto r M14 x 1.5 69 to 78 (7 to 8)
Cap n ut M14 x 1 39 to 49 (4 to 5)
T w o -sp rin g nozzle R etain ing nut M 19 x 1 59 to 78 (6 to 8)
Set screw 49 to 59 (5 to 6)
Lock n ut 20 to 25 (2 to 2.5)
Cap n ut M22 x 1.5 39 to 49 (4 to 5)
In le t c o n n e cto r M14 x 1.5 69 to 78 (7 to 8)
13-25
13 F U E L A M D E N G IN E C O N T R O L -
S E R V IC E S T A N D A R D S
D e scrip tion Thread size T ig h te n in g torque Remarks

(m m )
In je ctio n nozzle b o lt (fo r a tta ch in g to c y lin d e r head) M 8 x 1.25 15 (1.5)
In jectio n On p u m p side P type M 14 x 1.5 29 (3)

pipe unio n
nut AD typ e M 12 x 1.5 29 (3)
On nozzle side M 12 x 1.5 29 (3)
Leak o ff p ip e eye b o lt M8 x 1 9.8 to 15 (1 to 1.5)
Fuel filte r C o n n e cto r bolt M 14 x 1.5 25 (2.5)
W ater Ring nut - 5.9 to 7.8 (0.6 to 0.8)

se pa ra to r
D rain plug - 2.9 to 3.9 (0.3 to 0.4)
A ir plug M 8 x 1.25 7.8 to 9.8 (0.8 to 1.0)
C on n e cto r b o lt M 14 x 1.5 25 (2.5)
In jectio n Fuel inle t - 20 to 25 (2 to 2.5)

pum p
p ip in g Fuel feed (feed p u m p ) - 20 to 25 (2 to 2.5)
tig h te n in g
e yeb o lt Fuel feed (p u m p p ro p e r) - 20 to 29 (2 to 3)
Fuel o v e rflo w - 20 to 29 (2 to 3)
L ub rica nt (inlet) A D type - 9.8 to 13 (1 to 1.3)
P type - 12 to 15 (1.2 to 1.5)
L ub rica nt (outlet) AD type - 15 to 18 (1.5 to 1.8)
P type - 20 to 29 (2 to 3)
In je ctio n p u m p gear m o u n tin g n ut o f p u m p d rive case M 24 x 1.5 22 (2.2)
13-26
FUEL A N D E N G IN E CONTROL - S P E C IA L T O O L 13
SPECDAL TOOL
U n it: m m
In jectio n p u m p ce n te rin g to o l M H 061270 C entering o f bracket o f AD type

in je c tio n p u m p
B5032A
MH061340 C en te rin g o f bracket o f P type

in je c tio n p u m p
B5031A
F ilte r w ren ch MH061572 R em oval o f fuel filte r e le m e n t
94 2 1
B5222A
BieseO K iki [Producs

f Uj AB T yp e In je c tio n Pum p Prop er
The p art n u m b e rs are the DIESEL KIKI p art num bers.
Special T ool N am e Part No. Use
A D typ e in je c tio n p u m p special 105790-1060 D isassem bly and re asse m b ly

to o l set
U n ive rsa l vice 105794-0090 M o u n tin g base
T a p p et pin 157931-7320 S u p p o rtin g o f ta p p e t
M e asu rin g device 105782-4130 M e asu re m e nt o f c a m sha ft end play
W rench 157910-1120 Rem oval and in s ta lla tio n o f screw
G uide 157920-5400 P rotection o f o il seal
R oller pincers 157921-3020 R em oval and in s ta lla tio n o f tappet
T a p p e t pincers 157931-6120
P lun g e r pincers 157921-6120 R em oval and in s ta lla tio n o f p lu n g e r
W rench 157914-0500 R em oval and in s ta lla tio n o f d e liv e ry va lve h o ld e r
E xtra cto r 157925-6520 R em oval o f in n e r race
157925-0520 R em oval o f o u te r race (tim e r side)
157925-0120 Rem oval o f o u te r race (g o v e rn o r side)
R eam er 157930-4620 C orrection o f p u m p hou sin g
13-27
13 FUEL AM D E N G IN E CONTROL - S P E C IA L T O O L
The part n um b e rs are the DIESEL KIKI p art num bers.
Stand 105781-0430 Test and a d ju s tm e n t o f in je c tio n p u m p
M e asu rin g device 105782-6010
105782-4020
H older 157931-4400
Nozzle h o ld e r w re n ch 157916-8220
(2 ) P T y p e O bjection P u m p P ro p e r
The p art n um b e rs are the DIESEL KIKI part num bers.
Special T o o l Nam e Part No. Use
P type in je ctio n p u m p special 105790-7050 D isa sse m bly and reassem bly
to o l
U nive rsal vice 105794-0010 M o u n tin g base
Fittin g plate 157944-3620 In s ta lla tio n
Plate 157944-3820
Tappet h o ld e r 157931-4700 S u p p o rtin g of tappet
Bracket 157920-9900 R em oval o f bearing co ver
E xtra cto r bea rin g cover 157920-7720
Tappet m o u n tin g device 157921-8020 R em oval and in s ta lla tio n o f ta p p et
P lunger in se rt 157921-4820 R em oval and in s ta lla tio n o f p lu n g e r
P lunger c la m p device 157921-5620 R em oval and in s ta lla tio n o f c o n tro l sleeve
E xtractor 105792-0030 R em oval o f p lu n g e r block assem bly
Fittin g plate 157944-3520 D isa sse m bly and re asse m b ly o f p lu n g e r b lock a ssem b ly
Socket w ren ch 157914-0500 R em oval and in s ta lla tio n o f d e liv e ry h old e r
Special w ren ch 157915-6500 R em oval and in s ta lla tio n o f screw bush in g
Inner race e xtra cto r 157925-7120 R em oval o f inn e r race
O uter race e xtra cto r 157925-2020 R em oval o f o u te r race
O -ring inse rt 105792-0000 In s ta lla tio n o f O -ring
Plate m e asu rin g 157828-7200 P o s itio n in g o f g o v e rn o r side ta p e r ro lle r bearing
C am shaft m e asu rin g device 105782-4140 M e asu re m e nt o f c a m sha ft end play
Fixing stand 105781-0170 Test and a d ju s tm e n t o f inje ctio n p um p
M e asu rin g device 105782-4210
105782-4270
13-28
FUEL A N D E N G IN E CONTROL - S P E C IA L T O O L 13
{3) R8W T y p e G o v e rn o r
The part n u m b e rs are the DIESEL KIKI part num bers.
Special Tool N am e Part No. Use
Handle 157910-1 120 R em oval and in s ta lla tio n o f lock nut
S ocket w rench 157914-0500
W rench 157915-0100 R em oval and in s ta lla tio n o f ro un d nut
E xtra cto r 157926-5320 R em oval and in s ta lla tio n o f fly w e ig h t
Special w ren ch 157916-2620 A d ju s tm e n t o f A n g le ich
(41 T y p e G o v e rn o r
The part n u m b e rs are the DIESEL KIKI p art num bers.
Handle 157910-1120 R em oval and in s ta lla tio n o f lock nut
Socket w ren ch 157914-0500
Special w ren ch 157915-0100 R em oval and in s ta lla tio n o f ro un d nut
E xtra cto r 157926-5320 R em oval o f fly w e ig h t
Special w ren ch 157916-2620 A d ju s tm e n t o f idle speed
G uide screw 157976-3100 A d ju s tm e n t o f rack lim it
(S}SA Type Automatic Timer

The p art n u m b e rs are the DIESEL KIKI p a rt num bers.
SA type a u to m a tic tim e r special to o l set 105790-5010 D isassem bly and re asse m b ly
Special spanner 157916-5320 R em oval and in s ta lla tio n o f ro un d nut
E xtractor 157926-6210 Rem oval
G uide b o lt 157924-0200 D isassem bly and re asse m b ly
Base 157924-0110
H and spanner 157916-6120 R em oval and in s ta lla tio n o f tim e r case
T h ru st bush in g 157924-1500 In sta lla tio n o f o il seal
G uide bush in g 157924-1200
Block 157924-0800
G uide b u sh in g 157924-1300
G uide 157924-0900
S u p po rt 157932-0100 In sta lla tio n o f fly w e ig h t
G uide 157924-0400
T h ru st bush in g 157924-0500 In s ta lla tio n o f fla ng e
O il seal guid e 157914-0600 Inse rtio n o f tim e r case
13-29
13 FUEL A N D E N G IN E C O N T R O L - S P E C IA L T O O L ,
S E R V IC E P R O C E D U R E S
(6) SP Type Automatic Timer

The p art n u m b e rs are the DIESEL KIKI part n um bers.
SP typ e a u to m a tic tim e r special to o l set 105790-5050 D isassem bly and reassem bly
Box spanner 157915-2320 R em oval and in s ta lla tio n o f ro un d nut
Box w ren ch 157916-2800
Special sp anner 157916-5320 R em oval and in s ta lla tio n
E xtractor 157926-7220
Base 157924-2520 D isassem bly and reassem bly
Special sp anner 157916-8320
{7 } in je c tio n M o b ile
The p art n u m b e rs are th e DIESEL KIKI part num b e rs.
Nozzle clea n ing to o l 105789-0010 C leaning o f nozzle
Nozzle tester 105785-1010 A d ju s tm e n t and te stin g
A d ju s tin g device set 105789-0500 A d ju s tm e n t and te s tin g of 2-sprin g nozzle

( * : C om p o n en ts)
A d ju stin g device *157892-0220
Dial gauge *157954-3800
Pin ( = 50 *157892-1200
Pin ( = 60.5 *157892-1100
C onnector *157892-1320
Base *157892-1800
Gasket *157892-1500
R etaining nut *157892-1420
Gasket *026508-1140
5 SERVICE PROGiDyRES S cru p u lo u s care m u s t be exercised w he n d isa ssem b

W h e re ver p ossible , te st the fu e l syste m parts before ling and rea ssem bling critica l parts.
d isa sse m b ly to p re cise ly kn o w th e ir c o n d itio n s . Use the sp ecified special to o ls fo r d isa sse m b ly and
Select a clean site fo r d isa sse m b ly and reassem bly rea ssem bly; never a p p ly excessive force or handle
w o rk, as even sm all d u st p article s on th e fu e l system parts carelessly.
parts can a dve rse ly a ffe ct e n g in e p erfo rm a n ce . W hen Before d isa ssem b ly, te st the system to kn o w e xactly
d isa sse m b lin g the in je c tio n p u m p , keep w o rk bench the tro u b le spots.
clean and d isa ssem b le d parts n e a tly arran ge d fo r
each cylin d e r. Use special care to ensure co rrect
c o m b in a tio n o f p lu n g e r and p lu n g e r barrel and o f
d e live ry valve and d e liv e ry va lve seat.
13-30
SERVICE PROCEDURES 13
5.1 IMJECTOOM PU M P
5.1.1 IRemoval
2 1 AD ty p e -
< P ty p e >
Fuel hose B9147A

Injection pipe
Overflow pipe
Oil pipe N o te :
!5j Injection pump N e v e r re m o v e th e in je c tio n p um p b r a c k e t u n le s s it is
6 Injection pump bracket u n a v o id a b le d u e to c ra c k s , e tc .
B9153C
(1) A t rem ova l, firs t loosen b o lts ind icate d by a rro w s (2) Use a w o o d block to store in je c tio n p u m p lest
in fig u re fro m co u p lin g . excess fo rce m ig h t be a pp lie d to tim e r.
13-31
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
5 .1 .2 AD T y p e In je c tio n P u m p
(1 ) D is a s s e m b ly
NV... N om inal value

L ... L im it
Damage, w o rn seat 22
Dam age, seizure 23

Damaged race, / p
24 w o rn rolle r /?T\
Bend,
broken to o th 25
S liding resistance
(when stationary)
1.5 N (0.15 kgf) o r less 6 Damage, wear, seizure
o f cam surface
Backlash
NV 0.15 m m 'End play
L 0.3 m m NV 0.02 to 0.06 m m
L 0.1 mm
O ve rflo w valve ope ning pressure
NV 155 kPa (1.6 kgf/cm 2)
Remarks For general p o w e r application
' 1 6 Broken tooth 8
NV 255 kPa (2.6 kgf/cm 2) Seizure, wear, peeling
Remarks For co n stru ctio n m achinery
< D is a s s e m b ly se q u e n ce >
1 H ousing co ver
i2) S crew
3 Screw
(4) Bearing cover
5 Oil seal
6 C am shaft
7 Taper ro lle r bea rin g
8 C enter bearing
(9) T appet
10 Shim 20 D elivery valve s p rin g
@ Plunger 21 D elivery valve
@ L ow er sp rin g seat 22 D elivery valve seat
13 P lunger sp rin g 23 P lunger barrel
14 U pp er sp rin g seat 24 Screw
15 C on trol sleeve 25 C on trol rack
16 Pinion 26 Pum p housing
17 Lock plate
@ D elivery va lve h o ld e r For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
items.
19 S top pe r The part marked * m ust be inspected before disassem bly.
D1566B
13-32
S E R V IC E P R O C E D U R E S 13
(a) Install the in je c tio n p u m p in U nive rsa l Vice (spe (f) Rem ove the hou sin g cover.
cial to ol). Insert T appet Pins (special to ols) into the ta pp et holes
(b) Rem ove the feed pum p. o f all the c y lin d e rs to space th e tappets aw ay fro m the
(c) Rem ove the c o u p lin g and a u to m a tic tim e r. [Refer cam shaft.
to 5.4.1.]
(d) Rem ove the g o ve rn o r. (Refer to 5.2.1 o r 5.2.2.)
(g) M easure the end p la y o f the ca m sh aft w ith

M easuring Device (special to ol). If the end play is in
(e) M easure the s lid in g resistance o f the c o n tro l rack excess o f the lim it, a djust by using sh im s or replace
w ith a s p rin g balancer. the bearing.
T urn the ca m sh a ft and m easure th e s lid in g resistance
Shim thickness: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50,
in all o f the rising and fa llin g p o s itio n s o f the cam.
1.00 m m
If th e rea din gs are in excess o f th e n o m in a l value, the
fo llo w in g causes are p robable.
MOTE;
1) D am aged co n tro l rack, a b n o rm a l teeth Select tim er and governor side shims so
2) A b n o rm a l teeth o f p in io n , co n ta ct w ith h ou sin g
that tSueir thicknesses will be about equal.
3) O ve rtig h te n e d d e liv e ry va lve h o ld e r
13-33
SERVICE PROCEDURES
B9093A
(h) R em ove the screw s at the b o tto m o f th e in je ctio n (j) Push the ta pp ets up fro m th e b o tto m o f the
p u m p w ith W rench (special to ol). in je ctio n p u m p w ith R oller Pincers (special to o l) and
rem ove the T appet Pins (special tools).
(i) In sert a s c re w d riv e r in to the g ro o ve in the bearing

co ve r to rem ove the bearing cover and o il seal. (k) H old a ta p p e t in T appet Pincers (special to o l),
MOTE: rem ove the R oller Pincers (special to o l), and th en take
H. T o p r e v e n t d a m a g in g th e oil s e a l, r e o u t the ta p p e t and shim .
m o v e She w o o d ru ff k e y fro m th e c a m
s h a ft a n d p u t Mode (s p e c ia l to o l} on th e
th r e a d e d p o rtio n .
2 . T o re m o v e th e c a m s h a ft, d ir e c t th e firs t
c a m lo b e on th e re m o v a l s id e of c a m
s h a ft to w a r d th e to p o f th e p u m p to
p re v e n t th e c a m s h a ft lo b e fro m
to u c h in g th e ta p p e ts , a n d th e n lig h tly
s tr ik e .
( l) Rem ove the p lu n g e r to g e th e r w ith the lo w e r

sp ring seat, using P lunger Pincers (special tool).
(m) M easure the backlash betw een the c o n tro l rack
and p in ion . If th e backlash is in excess o f the lim it,
13-34 replace.
(n) Use W rench (special to o l) to rem ove the d e liv e ry
valve holder.
MOTE:
Immerse the delivery valve combined wish
delivery valve seat and the plunger com
bined with plunger barrel in gas oil without
changing their combinations.
(2) Inspection and Correction
(a) Plunger and plunger barrel A fte r cleaning in gas o il, check to see th a t the p lu n g e r
fa lls s m o o th ly in th e p lu n g e r barrel u nd er its ow n
w e ig h t.
Check by the fo llo w in g procedure.
1) T ilt the p lu n g e r barrel app ro x. 60.

2) Pull the p lu n g e r a b o u t 20 m m out.
3) T urn the p lu n g e r and check several points.
13-35
SERVICE PROCEDURES
(b) D e liv e ry v a lv e (cl) R e p la c e m e n t o f ta p e r ro lle r b e a rin g

In n e r ra c e
Clean th e va lve and va lve seat p o rtio n s o f th e d e liv e ry

va lve in gas oil and check w o rn co n d itio n . To rem ove, use E xtra cto r (special to ol).
Seal o ff the b o tto m o f the va lve seat p o rtio n w ith a To install, p ut the rin g and sh im s and th e n in sta ll the
fin g e r tip and press d o w n the va lve p o rtio n w ith a ta pe r ro lle r bearing.
fin g e r. If the valve p o rtio n bounces back w hen
released, the valve p o rtio n is g oo d. If it does not O u te r ra c e
bounce back, the va lve p o rtio n is b a d ly w o rn .
Replace the d e live ry valve.
(c) Tapped
The bearing co ve r side o u te r race sh o u ld be rem ove d

by use o f O uter Race E xtra cto r (special to o l).
To install, p ut a new o il seal in p o s itio n , and th en
install the o u te r race.
Hold a dial gauge to th e ro lle r p o rtio n o f ta p p e t and
check the o ve ra ll clearance by m o v in g the ro lle r up
and d o w n .
If the o ve ra ll clearance is in excess o f th e lim it, replace
the ta p p e t assem bly.
13-36
(3} Reassembly
-i - i 4.5 to 5.8 Nm
O C f$i (0.45 to 0.6 kgfm )
o 18 64 to 68 Nm
(a) M o u n t the p u m p h ou sin g in U niversal Vice (spe (b) Insert the p lu n g e r barrel into th e h ou sin g.
cial to o l). A fte r th e co n tro l rack has been inserted, M @ TEs
th re a d the screw in to th e back o f the p u m p h ou sin g. H. Align She notch of the plunger barrel
Check to see if the c o n tro l rack lig h tly operates. with the dowel pon of the housing.
2. Do not lightly strike the plunger barrel
but securely push in by finger.
13-37
SERVICE PROCEDURES
M anufacturer mark
B9109A B9111A
(c) Place the p u m p h o u sin g on its side and set the NOTE:
co n tro l rack so th a t the pun che d m arks o f the c o n tro l In s ta ll th e p lu n g e r w ith th e s ta m p e d m o d e l
rack w ill be p o sitio n e d the sam e d im e n s io n aw ay n u m b e r to w a r d you (th e h o u s in g c o v e r}.
fro m the ends o f the h o u sin g . A fte r th e p in io n and
co n tro l sleeve have been c o m b in e d , p u t the p in io n in
m esh w ith th e teeth o f the co n tro l rod.
M OTE;
H. In s ta ll th e p in io n a n d c o n tro l s le e v e so
th a t th e jo in t of th e p in io n a n d n o tc h of
th e c o n tro l s le e v e w ill b e fa c e d to w a rd
you.
2 . A fte r e a c h p in io n h a s b e e n in s ta lle d ,
m o v e th e c o n tro l r a c k to c o n firm th a t it
c a n b e m o v e d th e s a m e a m o u n t to rig h t
an d le ft.
(e) H old the ta p p e t and sh im In T a p p e t Pincers

(special to o l) and in se rt in to the h ou sin g.
(d) Install the lo w e r sp rin g seat and p lu n g e r to g e th e r,

using P lunger Pincers (special to ol).
(f) Push the ta p p e t inserted in to the h o u sin g up w ith

R oller Pincers (special to o l) and in se rt T a p p e t Pin
(special to o l) in to the hole in th e ta ppet.
13-38
F U E L A N D E N G IN E C O N T R O L ---
M OTE: (h) Install the screw s, using W rench (special to ol).

w h e n She camshaft is in s e rte d , face the (i) Install the fo llo w in g parts.
inscribed line on the end of She camshaft G o ve rn o r (Refer to 5.2.1. o r 5.2.2.)
toward the timer. Feed p u m p
(g) C o n firm the fo llo w in g item s. A u to m a tic tim e r (Refer to 5.4.1.)

C oupling
1) End play o f ca m sh aft [R efer to 5.1.2 (l)(g ).]
(j) A fte r the re a ssem bly has been c o m p le te d , a djust
2) S lid in g resistance o f c o n tro l rack [R efer to 5.1.2
the in je ctio n pum p.
(1 He).]
Check after rem ova l o f T ap pe t Pin (special tool).
13-39
SERVICE PROCEDURES
5 .1 .3 P T y p e O njection P om p
^ W e a r , dam age,
1 2 'd is c o lo r a t io n
6 W o rn or dam aged
Rotating
co n d itio n
O ve rflo w valve opening pressure W ear,

NV 255 kPa (2.6 kgf/cm 2' damage
< D is a s s e m b ly se q u e n ce :
1 O v e rflo w va lve (18) P lunger block a ssem bly

2 B o tto m cover 19 D eflector
3 S crew plug 20 D elivery valve h o ld e r
4 Shim 21 S top pe r
Bearing cover 22 D elivery valve s p rin g

6 Oil seal 23 D elivery valve
7 C enter bearing 24 D elivery va lve seat
8 C am shaft 25 P lunger barrel
9 R oller bearing 26 D istance ring
(tg) T appet assem bly 27 Flange sleeve
L ow er s p rin g seat 28 S crew b ush in g
P lunger 29 Pin
13 P lunger sp ring 30 Bushing
14 U pper sp rin g seat 31 C on trol rod
C ontrol sleeve 32 Bushing

16 C over 33 Pum p hou sin g
17 Nut
items.
D1568A
13-40
(a) Rem ove the feed pum p.
(e) R em ove the screw p lu g, tu rn th e c a m s h a ft to

(b) Install F itting Plate (special to o l) in U niversal Vice place the ta p p e t at the to p dead ce nte r p o s itio n , and
(special to o l)1. inse rt T ap pe t Plolder (special to o l) into the screw plug
hole to space the ta p p e t aw a y fro m the cam shaft.
(f) Rem ove the c o u p lin g .
(g) Rem ove the a u to m a tic tim er.
(Refer to 5.4.2)
(h) R em ove the g o ve rn o r.
(Refer to 5.2.1 o r 5.2.2)
(c) U tilizin g the th re ad e d hole, install Plate (special

tool).
(i) Rem ove the bearing cover, using Bracket and

Bearing C over E xtra cto r (special tools).
MOTE;
1. W hen th e b ea rin g coves is rem o ved , use
c a re not So lose th e end play ad ju stin g
shim s.
2. C h eck th e oil seal and do not rem o ve it
unless d e fe c tiv e .
(d) Install the inje ction p u m p in U nive rsa l Vice (spe

cial tool).
13-41
(I) R em ove the p lu n g e r, using P lunger Insert (special

tool).
SVIOTEs
Put th e rem o ve d plungers ord erly in a tra y
c o n ta in in g c le a n gas oil.
(j) Install T appet M o u n tin g D evice (special to o l) to

the p u m p housing.
Then operate the lever to push the ta p p e t up, rem ove
T appet H old er (special to o l), and take o u t the ta pp et
assem bly.
(m) R em ove the u p p e r s p rin g seat and c o n tro l sleeve.

The c o n tro l sleeve can be e asily re m o ve d by use o f
P lu ng er C lam p Device (special tool).
NO TE:
T h e c o n tro l s le e v e cannot he rem oved
unless th e ball m o u n ted ora th e fla n g e of
th e c o n tro l s le e v e and th e ta p p e t guide
groove in th e pum p housing a re in a lig n
m en t.
Extractor
(k) Rem ove T appet M o u n tin g Device (special tool),

install a w ire in the hole o f the lo w e r sp rin g seat, pull
it to g e th e r w ith the p lu n g e r u n til th e lo w e r s p ring seat
can be rem oved, and rem ove o n ly the lo w e r sp ring
seat.
(n) M o u n t E xtra cto r (special to o l) to th e d e liv e ry

h o ld e r and rem ove the p lu n g e r blo ck assem bly.
13-42
1
Fitting Plate
157944-3520
(o) D isassem ble the p lu n g e r block a ssem bly by the (q) Rem ove the g o v e rn o r side screw b u sh in g w ith
fo llo w in g procedure. special W rench (special to o l) and rem ove the pin and
a) M o u n t F itting Plate (special to ol) in the vice. b ush in g.
Then rem ove the c o n tro l rod and b u sh in g fro m the
tim e r side.
NOTE:
1. Arrange all removed parts orderly by
cylinders.
2. Be sure not to change the combination
of the paired plunger barrel and plunger
and that of delivery valve and delivery
valve seat.
(p) Secure th e p lu n g e r block assem bly to the F itting

Plate (special to o l) and loosen the d e liv e ry valve
h o ld e r w ith Socket W rench (special tool).
13-43
SERVICE PROCEDURES
(2) Inspection and Correction

The insp ectio n p ro ced ure is the sam e as th a t fo r the
AD typ e except the fo llo w in g .
Replacement o taper roller bearing Outer race

Inner race
R em ove the bea rin g co ve r side o u te r race by use o f
Rem ove in n e r race by use o f Inner Race E xtractor O uter Race E xtra cto r (special to o l).
To in s ta ll, in sta ll a n ew o il seal and then install the
(special tool).
To install, use press. o u te r race.
13-44
(3} R eassem b ly
Control rod
sliding resistance
(when stationary) 110 to 115 Nm
MV 1.3 N (11 to 12 kgfm )
(0.13 kgf) or less (Tighten three tim es)
The end w ith sm aller

distance betw een end
face and hole facing
d o w n w a rd
NV... N om inal Value

L ... L im it
< A sse m b ly sequence>
(27 25>24>23>22>21 26 19) 18

1 7 - 1 5 - 1 4 13
33 32 30 31- 29 2 8 -------------------
>t?> 11fto }-> 7 -9 >2 1 16
For disassem bly of parts w ith an encircled n u m b e r see fo llo w in g
items.
D1569B
13-45
SERVICE PROCEDURES
(a) M o u n t the p u m p h o u sin g in U nive rsa l Vice (spe (c) U sing Socket W re nch (special to o l), tig h te n the
cial tool). d e liv e ry va lve h o ld e r to the sp ecified to rq u e (tigh ten
Then install b u sh in g s and c o n tro l rod, pin and screw in th re e stages).
b ush in g w ith Special W rench (special to o l). Check to NO TE:
see th a t the c o n tro l rod lig h tly operates. Df th e tig h te n in g to rq u e is s m a lle r th an th e
s p e c ifie d to rq u e , oil le a k a g e or d a m a g e to
th e re la te d p a rts cou ld re s u lt.
If th e tig h te n in g to rq u e is e x c e s s iv e , un
sm ooth p lu n g er m o v e m e n t r d a m a g e to
th e re la te d p a rts cou ld re s u lt.
(b) Install the O -ring on the u p p e r side o f the p lu n g e r

barrel, and inse rt the lo w e r side O -rin g in to th e p u m p
h ou sin g w ith O -ring Insert (special to ol).
NOTE:
M a k e sure th a t th e lo w e r sid e O-ring is not
s e t on th e p lu n g er b a rrel and slid ed along (d) M o u n t the p lu n g e r to P lunger In sert (special to o l)
th e w a ll su rfa c e of pum p housing. and in se rt it in to the p lu n g e r barrel.
13-46
(e) M o u n t T appet M o u n tin g Device (special to o l) to (g) Install the g o v e rn o r h o u sin g . A t th is tim e , p e rfo rm
the p u m p housing. th e fo llo w in g o p e ra tio n . M o u n t M ea suring Plate (spe
Then install the ta p p e t by o p e ra tin g the T appet cial to o l) to the tim e r side ta p e r p o rtio n o f the
M o u n tin g Device. ca m sh aft, and install and p o s itio n the g o v e rn o r side
A t th is tim e , co m p re ss the p lu n g e r sp rin g and inse rt ta p e r ro lle r bearing o u te r race in the ring so th a t the
the m itt p o rtio n o f the p lu n g e r in to th e g u id e g ro ove d im e n s io n fro m the end o f the p um p h ou sin g to the
in the co n tro l sleeve, and in se rt T appet H older end o f th e M e a suring Plate w ill be 13.85 0.5 m m .
(special to o l) into the screw plu g hole. The o p e ra tio n
o f in se rtin g the m itt p o rtio n o f the p lu n g e r into the
guide g ro o ve o f the co n tro l sleeve can be easily
p e rfo rm e d by in se rtin g the m itt p o rtio n , w h ile m o v in g
the c o n tro l rod to rig h t and left.
In s ta lla tio n o f the ta p e r ro lle r bearing o u te r race w ill

p ro du ce a clearance b etw e en the g o v e rn o r h o u sin g
and ta p e r ro lle r bearing o u te r race. Change s h im s to
e lim in a te the clearance.
S him th ickne ss: 0.6, 1.2, 1.5, 1.8, 2.0 m m

(f) Insert the ca m sh aft fro m the tim e r side.
W hen the ca m sh aft is installed , face th e inscribe d line
o f the end o f the ca m sh a ft to w a rd the tim e r side.
13-47
(h) M easure the ca m sh a ft end play.

Install C am shaft M e a su rin g Device (special to o l) to check to see th a t the c o n tro l rod slides s m o o th ly o ver
the tim e r side o f the ca m sh a ft to m easure th e end the e ntire stroke w ith o u t e xceeding th e standard
play. s lid in g resistance value.
R em ove the T ap pe t Pin (special to o l) b e fo re checking.
(j) Install th e fo llo w in g parts.
G o v e rn o r (Refer to 5.2.1 or 5.2.2.)
Feed p u m p
A u to m a tic tim e r (Refer to 5.4.2.)
C ou p lin g
(k) A fte r re a ssem bly has been c o m p le te d , a djust the
in je c tio n p um p.
,lf the ca m sh a ft end p la y is o u t o f the n o m in a l value,

a djust by ch a n g in g s h im s b etw e en the bea rin g cover
and p um p h ou sin g.
S him th ickne ss: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50
mm
13-48
5 .1 .4 A d ju s tm e n t a fte r R e assem b ly
For fuel in je ctio n rate a d ju stin g sta nd ard , see Service
In fo rm a tio n p u b lish e d separately.
(11} AD T yp e In je c tio n Pum p
(a) Install the p u m p on the in je c tio n p u m p te s te r

Fixing Stand (special to o l) and secure it.
MOTE:
M a k e sure th a t She c e n te r of coupling 5s
a lig n e d w ith th a t of in je c tio n pum p so th a t
She co u p lin g and in je c tio n pum p turn
sm o o th ly.
MOTE:
1. Supply ool So She in je c tio n pum p cam
ch a m b er.
2 . ' A djust She in je c tio n a m o u n t a fte r a d
ju stin g She governor.
In je c tio n s eq u en ce
1 5 3 6 2 4
13-49
SERVICE PROCEDURES
(c) C hecking stroke o f c o n tro l rack
M ove the c o n tro l rack to c o n firm th a t the to ta l stroke

is o ver the sp ecified value.
In a d d itio n , check to see th a t the s ta rt s p rin g and
id lin g s p rin g s m o o th ly m o v e the c o n tro l rack in the
m a x im u m in je c tio n d ire c tio n .
(b) S e ttin g p o s itio n 0 o f c o n tro l rack
M o u n t M ea suring Device (special to o l) to th e in je ctio n

pum p.
< W ith RSV g o v e rn o r>

1) Keep the p u m p ru n n in g at 750 rpm .
2) Loosen the sto p p e r b o lt and p u ll th e a d ju stin g
lever to w a rd the n o n -in je c tin g d ire ctio n . (d) A d ju s tin g prestroke
3) Press the end o f the m e a su rin g device all th e w ay 1) Pull the c o n tro l rack o u t to the to ta l in je c tio n
to w a rd the g o v e rn o r and a d ju s t th e p o s itio n o f p o in t p o s itio n and secure it there.
"0 " on the scale o f the m e a su rin g device. 2) Place the p lu n g e r o f the No. 1 c y lin d e r in the
< W ith RFD g o v e rn o r> b o tto m dead ce nte r p o s itio n and m o u n t M ea suring
1) Fix the load c o n tro l leve r at the id lin g p o sitio n . D evice (special tool). Set th e c o n ta c to r on the ta p p e t.
2) Let th e p u m p run at 500 to 600 rp m and te m p o r 3) C ouple th e in je c tio n p u m p and te s te r nozzle.
a rily fix the speed c o n tro l lever so th a t th e g o v e rn o r
w ill begin to p ro v id e c o n tro l at th e speed.
3) Press the end o f the m e a su rin g device all the w ay
.tow ard the g o v e rn o r and a d ju st the p o s itio n o f p o in t
" 0 " on the scale o f the m e a su rin g device.
NTEs
Off th e in je c tio n pum p is not running a t th e
speed m e n tio n e d a b o ve, po sitio n 6 w o n t
be o b ta in e d eve n iff th e c o n tro l racEt is
pressed w ith a strong p ress u re, and th e re
w ill be d an g er off d a m a g e to th e link
m e ch a n is m off th e pum p.
4) Send a hig h pressure fu el in to the in je c tio n p u m p

to let the fuel flo w o u t fro m the o v e rflo w pipe o f the
nozzle holder.
13-50
MOTE:
The pressure of the fuel forced into the
injection pump must be higher than the
delivery valve opening pressure.
7) A fte r a d ju s tm e n t o f th e prestroke, check to see

th at, at the sta tic in je c tio n b e g in n in g , the inscribe d
lines o f the p o in te r and tim e r are in a lig n m e n t.
If th ey are o u t o f a lig n m e n t, resta m p a line on the
5) S lo w ly tu rn the ca m sh aft u n til th e fu el ceases to a u to m a tic tim e r.
flo w fro m the o v e rflo w pipe o f the nozzle h o ld e r (until

sta tic in je ctio n begins).
MOTE:
Make measurement by turning the cam
shaft clockwise.
(e) A d ju s tm e n t o f in je c tio n s ta rt in te rv a l
1) C ouple te ste r nozzles to all the c y lin d e rs o f the

in je c tio n p u m p as in the case o f a d ju s tm e n t o f the
prestroke.
2) Force fu e l in to the in je c tio n p u m p to let the fuel
6) Read the prestroke fro m the b o tto m dead center flo w o u t fro m the te s te r nozzle.
to the p o in t w h e re th e fu e l ceases to flo w (static 3) On the basis o f th e sta tic in je c tio n b e g in n in g o f
in je ctio n begins), using a dia l gauge. the No. 1 c y lin d e r, m easure the in te rv a l w h e n the fuel
If the p re stroke is o u t o f sp e c ific a tio n , a d ju s t by ceases to flo w o u t a c c o rd in g to the in je c tio n se qu
shim s. [Refer to (e).j ence, u sin g an ang le scale.
MOTE:
Injection sequence
1 5 3 6 2 4
13-51
13 SERVICE PROCEDURES
3) M easure the stroke o f the ta p p e t fro m the top

dead ce nte r to the p o in t w h e re th e p lu n g e r barrel is
touched.
4) If the ta p p e t clearance is less th an the n om in a l
value, a d ju s t w ith in the e xten t p e rm itte d by the
in je c tio n sta rt interval.
If c o rre c tio n w ith in the p e rm itte d e x te n t is im p o s s ib le ,
set the p re stroke of the No. 1 c y lin d e r to the
m a x im u m o f the set va lu e and readjust.
4) If the prestroke and in je c tio n sta rt in te rv a l are o u t

o f sp e cifica tio n , in se rt a H o ld e r (special to o l) b etw een
the ta p p e t and lo w e r seat and th en a d ju s t by ch a n g
ing the sh im thickness.
S him th ickne ss: 0.2 to 1.60 m m , 29 typ es in 0.05 m m

in cre m e n t
(g) A d ju s tm e n t o f fu el in je c tio n a m o u n t
To check w h e th e r th e in je c tio n a m o u n t is up to
s p e c ific a tio n at th e sp ecified rack p o s itio n and speed,
m easure w ith a m e a su rin g cylin d e r.
If th e in je c tio n a m o u n t is o u t o f s p e c ific a tio n , a d ju s t
by the fo llo w in g procedures.
1) Loosen th e screw o f th e p in io n .
2) W h ile b lo cking m o v e m e n t o f the c o n tro l rack, tu rn
D3522A
the c o n tro l sleeve w ith an a d ju s tin g rod.
3) T ig h te n the screw o f the p in io n .
(f) A d ju s tm e n t o f ta p p e t clearance
M O TE:
1) Place th e ta p p e t in the to p dead ce n te r p o s itio n . 1. A m a la d ju s te d in je c tio n a m o u n t w ill
2) Raise the ta p p e t w ith a sc re w d riv e r, etc. u n til the p ro d u c e m a rk e d e ffe c ts on e n g in e per
d riv in g face o f the p lu n g e r to u ch e s the b o tto m end o f fo r m a n c e . M a k e s u re tlhe in je c tio n
the p lu n g e r barrel. a m o u n t is c a r e fu lly a d ju s te d .
13-52
2. T h e in je c t io n a m o u n t v a r ie s o n d if f e (h) A d a p ta tio n to eng in e
r e n t n o z z le s a n d p ip e s . M a k e s u r e t h a t
A fte r the g o v e rn o r has been adjusted, m easure the
th e m e a s u r in g c o n d it io n s a r e o b s e r v e d .
fu el in je c tio n rate a da pta b le to the engine.
3. I n je c t io n a m o u n t u n e v e n r a t io
(i) In spe ction o f fu el and oil leaks
M a x im u m in je c - A v e ra g e in je c
tio n a m o u n t in tio n a m o u n t of a Fuel leaks fro m d e liv e ry va lve a tta ch in g p o s itio n
e a c h c y lin d e r e a c h c y lin d e r and o th e r parts
U n e v e n ra tio (+ ) -----------------------------------------------------------x 1 0 0 (% j
Oil leaks fro m o il seals and o th e r parts
A v e ra g e in je c tio n a m o u n t of
e a c h c y lin d e r (j) In spe ction o f parts
Check parts fo r unusual noise and bea rin gs fo r

M in im u m in je c - A v e ra g e in je c
excessive heat.
tio n a m o u n t in tio n a m o u n t of
e a c h c y lin d e r e a c h c y lin d e r
U n e v e n ra tio () ---------------------------------------------------------- x 1 0 0 (% )
e a c h c y lin d e r
(2 ) P T y p e I n je c t io n P u m p
A d ju s tm e n t o f in je c tio n
sta rt interval
NV 60 30'
A d ju s tm e n t o f prestroke
NV 4.8 0.05 m m C hecking stroke o f c o n tro l rod
NV 21 o r m ore
NV ... N om in al Value
N O TE :
1. S u pp ly o il to th e in je c tio n p um p c a m c h a m b e r.
2. A d ju s t th e in je c tio n a m o u n t a ft e r a d ju s tm e n t o f th e
g o v e rn o r.
B9146A
13-53
SERVICE PROCEDURES
< W ith RFD g o v e rn o r>

1) Fix th e load c o n tro l leve r at the id lin g p o sitio n .
2) Let the p u m p run at 500 to 600 rpm and te m p o r
a rily fix the speed c o n tro l lever so th a t the g o v e rn o r
w ill begin to p ro v id e c o n tro l at the speed.
3) Press th e end o f the m ea suring device all the w ay
to w a rd the g o v e rn o r and a d ju s t th e p o s itio n o f p o in t
" 0 " on the scale o f th e m ea suring device.
M TE:
H. Of t h e p o s it io n 0 off t h e c o n t r o l ro d is
s e t b y o p e r a t in g t h e lo a d c o n t r o l le v e r ,
t h e r e is d a n g e r off d a m a g e t o th e Oink
m e c h a n is m a n d o th e r p a r t s o f t h e g o v
(a) M o u n t tw o F ixing S tands (special to o ls ) to an e r n o r . D n o t s e t t h e p o s it io n 0 b y
in je c tio n p u m p tester. o p e r a t in g t h e lo a d c o n t r o l le v e r .
Secure the in je c tio n p u m p fir m ly to th e special to ols. 2 . W h e n t h e p o s it io n 0 is s e t, r e m o v e th e
M OTEs d a m p e r s p r in g b e fo r e h a n d .
T o m a k e s u r e t h a t She c o u p lin g a n d in je c
t io n p u m p r o t a t e s m o o th ly , a lig n t h e c e n
t e r s off t h e c o u p lin g a n d in je c t io n p u m p
a c c u r a t e ly .
(c) C hecking stroke o f c o n tro l rod
M ove the c o n tro l rod to c o n firm th a t the to ta l stroke is

D3409A
m ore th an the sp e cifie d value.
Check to see th a t th e c o n tro l rod is m o ve d s m o o th ly
(b) S e ttin g p o s itio n " 0 " o f c o n tro l rod in the m a x im u m in je c tio n a m o u n t d ire c tio n by the
M o u n t M ea suring Device (special to o l) to th e in je c tio n sta rt s p rin g and id lin g sp rin g .
p um p.
< W ith RSV g o v e rn o r>

1) Keep the p u m p ru n n in g at 750 rpm .
2) Loosen the s to p p e r b o lt and p u ll the a d ju stin g
lever to w a rd the n o n -in je c tin g d ire ctio n .
3) Press the end o f the m e a su rin g device all the w a y
to w a rd the g o v e rn o r and a d ju st the p o s itio n o f p o in t
"0 " on th e scale o f the m e a su rin g device.
13-54
5) S lo w ly tu rn the fly w h e e l of the p u m p te ste r
clockw ise u n til the fuel ceases to flo w o u t fro m the
o v e rflo w pipe (un til static in je c tio n begins).
Prestroke
(d) A d ju s tm e n t o f prestroke
1) R em ove th e g o v e rn o r side No. 1 c y lin d e r d e liv e ry D3414A
valve h olde r; sp rin g , d e liv e ry valve and gasket.

2) M o u n t M ea suring D evice (special to o l) to the 6) M easure the prestroke o f the p lu n g e r fro m the
fla ng e sleeve. b o tto m dead center to the p o in t w he re the fu e l ceases
3) T urn the fly w h e e l o f the p u m p te ste r to d etect the to flo w o u t (static in je c tio n b eg in n in g ).
b o tto m dead ce nte r o f the p lu n g e r w ith a dial gauge.
7) If the p re stroke is o u t o f s p e c ific a tio n , a djust by

4) W ith the c o n tro l rod set in th e fu ll p o s itio n , fo rc e a ch a n g in g th e sh im th ickne ss betw een the flange
hig h pressure fu el in to th e in je c tio n p u m p to let the sleeve and p u m p h ou sin g.
fu e l flo w o u t fro m the o v e rflo w pipe. Shim th ickn e ss: 0.50 to 1.975 m m , 59 typ es in 0.025
in c re m e n t
If the p re stroke is s m a lle r, increase th e thickness. If

the p re stroke is larger, reduce the thickness.
MOTEs
To in s ta ll th e p lu n g er b lo ck, ap p ly g reas e
to e a c h -ring. A fte r insertiong th e O-ring in
th e lo w e r p a rt of th e p lu n g er b a rre l onto the
pum p housing ion a d v a n c e , ap p ly g reas e to
th e s k irt portio n of th e p lunger b arrel and
th en in s ta ll th e p lu n g er b arrel.
13-55
13 SERVICE PROCEDURES
D3416A D3427A
8) A fte r a d ju s tm e n t o f th e p restroke, check to see 3) S lo w ly tu rn the fly w h e e l o f the p um p te ste r

th a t th e inscribe d line o f the tim e r and th a t o f the clockw ise u n til th e fuel ceases to flo w o u t fro m th e
p o in te r are in a lig n m e n t. te ste r nozzle.
If th e y are o u t o f a lig n m e n t, inscribe a n o th e r line on Read th e ro ta tio n angles (in je ctio n start intervals)
the tim e r. W hen th e a u to m a tic tim e r w as replaced w h e re th e fuel ceases to flo w , according to the
w ith a n ew one, proceed in the sam e w ay. in je c tio n sequence.
4) If th e in je c tio n s ta rt in te rva l is o u t o f the standard
angle, a d ju s t by the sam e pro ced ures as fo r prestroke
a d ju s tm e n t.
KIOTEs
In je c tio n s e q u e n c e ; H 5 3 6 2 4
(e) A d ju s tm e n t o f in je c tio n sta rt in te rva l
1) Set the static in je c tio n b e g in n in g p o s itio n o f the

No. 1 c y lin d e r on th e p u m p te ste r scale plate.
2) Force a high pressure fu e l in to the in je c tio n p um p
to let the fu e l flo w o u t fro m the o v e rflo w pipe o f the
tester nozzle. (f) A d ju s tm e n t o f fuel in je c tio n a m o u n t
M OTE; A t the sp ecified rack p o s itio n and speed, m easure the

T h e p ressu re of th e fu el fo rc e d into th e in je c tio n a m o u n t and u neven ra tio w ith a m easuring
in je c tio n pum p m ust be hig h er th an th e c y lin d e r to check w h e th e r th e y are up to specification.
d e liv e ry v a lv e opening p ressu re. If the in je c tio n a m o u n t is o u t o f sp e cifica tio n , a djust
13-56
1) Loosen the tw o nuts tig h te n in g the fla ng e sleeve. M in im u m in je c - A v e ra g e in je c
2) T urn th e fla n g e sleeve by lig h tly strikin g . tio n a m o u n t in tio n a m o u n t of
3) T ig h te n the nuts to the sp e cifie d to rq u e to secure
U n e v e n ra tio ( - ) -----------------------------------------------------------x 1 0 0 (% )
the fla ng e sleeve. (39 to 44 Nm (4 to 4.5 kgfm )] A v e ra g e in je c tio n a m o u n t of
P e rform the o p e ra tio n s repeatedly. e a c h c y lin d e r
MOTE:
(g) A d a p ta tio n to engine
1. m a la d ju s t e d in je c t io n a m o u n t w il l
p r o d u c e c o n s id e r a b le e f f e c t s o n e n g in e A fte r the g o v e rn o r has been a djusted , m easure the
p e r fo r m a n c e . M a lte s u r e t h a t th e in je c fu e l in je c tio n rate a da pta b le to the engine.
t io n a m o u n t is c a r e f u lly a d ju s t e d . (h) In spe ction o f fu el and oil leaks
2 . S in c e t h e in je c t io n a m o u n t v a r ie s o n Fuel leaks fro m d e liv e ry va lve a tta ch in g p osition
d if f e r e n t n o z z le s a n d p ip e s , m a k e s u r e and o th e r parts.
t h a t th e m e a s u r in g c o n d it io n s a re Oil leaks fro m o il seals and o th e r parts
o b s e rv e d .
(i) In spe ction o f parts
3 . I n je c t io n a m o u n t u n e v e n r a t io
Check parts fo r unu sua l noise and bearings fo r
M a x im u m in je c - A v e ra g e in je c
tio n a m o u n t in tio n a m o u n t of excessive heat.
U n e v e n ra tio ( ! ) -------------------------------------------------------------x 1 0 0 (% )
e a c h c y lin d e r
5 .1 .5 I n s t a lla t io n
< A D ty p e >
5 6
(T) In jectio n p u m p bracket

(2) In jectio n p um p
3 Oil pipe
4 O ve rflo w pipe
5 In jectio n pipe
6 Fuel hose B9147A (3.6 to 5.4 k g fm ) B9153A
13-57
SERVICE PROCEDURES
(1 ) A d ju s tm e n t o f In je c tio n P u m p B r a c k e t
C0603A 89148A
(a) Place In je ctio n Pum p C en te rin g T oo l (special to o l) (b) Slide the dial in d ic a to r o f the ce n te rin g to o l
on the in je c tio n p u m p bracket, h o ld a dia l in d ic a to r to to w a rd the a ir c o m p re s s o r (or in je c tio n p u m p drive)
the m a n d re l o f the ce n te rin g to o l, and p e rfo rm and m easure the p o s itio n s o f the co m p re s s o r crank
O -p o in t a d ju stm e n t. sh aft (or in je c tio n p u m p d riv e shaft) sh ow n in the
illu s tra tio n w ith the dial in d ica to r.
13-58
K eyw ay
(c) If the e cce n tricity betw een the m a n d re l and air (b) A t th is p o in t, check to ensure th a t th e keyw ay of
co m p re s s o r cran ksha ft is in excess o f the n o m in a l the cran ksha ft o f the a ir co m p re sso r (or in je ctio n
d im e n s io n , a djust by a d d in g o r re m o vin g in je c tio n p u m p drive) is in the u p p e rm o s t p o s itio n .
p u m p bracket shim s. If the keyw ay is n o t in the u p p e rm o s t p o s itio n , tu rn
S him In serting C o n d itio n the eng in e crankshaft.
The n u m b e r o f sh im s inse rted in to a sing le p o in t
m u st n ot exceed three.
The fro n t and rear sh im s m u s t be equal in
n um b e r.
e The d ifferen ce in n u m b e r betw een the to p and
b o tto m sh im s m u st n ot exceed one.
(d) A fte r a d ju s tm e n t, tig h te n the tig h te n in g b o lts to

the specified to rq u e befo re c o n firm a tio n .
(2 ) DnisiaSlaiSoiiti of InJecSorii P u m p
(c) A lig n the p o in te r o f the in je c tio n p u m p and the

inscribe d m ark o f the auto tim e r. (On e ngines w ith no
auto tim e r, a lign the in s c rib e d m ark on the p um p
bea rin g co ve r w ith th a t on the p u m p side c o u p lin g .)
(a) Crank th e eng in e to a djust the No. 1 c y lin d e r to

the fu el in je c tio n tim in g . For th is p urpo se, align the
angle scale inscribe d on th e o u te r p e rip h e ry o f the
fly w h e e l w ith the p o in te r o f the in sp e ctio n w in d o w o f
the fly w h e e l h ou sin g.
13-59
SERVICE PROCEDURES
(d) Install the d riv in g c o u p lin g on the cra n ksh a ft o f

the a ir co m p re sso r, and p u t it a little to w a rd the air
co m p re ssor. 5 .1 .6 B leeding th e FueB S ystem
Install the in je c tio n p u m p on th e in je c tio n p u m p Bleed the fuel system as described below .
bracket. M o ve the d riv in g c o u p lin g to w a rd the c o u
p lin g p late and tig h te n it w ith th e tim in g a d ju stin g
bolt.
Then tig h te n the co tte r b o lt to the sp ecified to rq u e to
reduce th e clearance b etw e en th e d riv in g co u p lin g
and c o u p lin g plate to less th an 0.5 m m .
IM 0TE:
A fte r th e in je c tio n pum p has b een in s ta l
led, be sure to c h e c k and a d ju s t th e fuel
in je c tio n s ta rt tim in g . (R e fe r to 5.11.7.)
(1) Loosen the air plu g o f the fu e l filte r.

(2) T urn the p rim in g p u m p knob o f th e in je ctio n
p u m p co u n te rc lo c k w is e to let the knob flo a t up.
13-60
5 .1 .7 In s p e c tio n and A d ju s tm en t off Fuel
In je c tio n S ta rt Tim ing
B5908A
(3) M ove the p rim in g p u m p knob up and d o w n by C0599A

hand to fo rce the fu e l o u t u n til no a ir b ub b le s com e
o u t fro m the air p lu g. (1) Crank the cran ksha ft m ore than 180 in n orm al
(4) A fte r air bub bles have ceased to co m e o u t in the d ire c tio n to alig n the fuel in je c tio n sta rt tim in g angle
fu el, firm ly tig h te n th e air plug. scale inscribe d on the p e rip h e ry o f th e fly w h e e l w ith
(5) M ove the p rim in g p u m p knob several tim e s up the p ointer.
and d o w n and tu rn d o w n the knob, w h ile pressing it
M O TE :
dow n.
Off th e en g in e is reve rs ed (by c ran k in g or
M OTE: w h en it is sto p p ed ), th e a u to m a tic tim e r
M a k e sure th a t fuel s p lit around is thor- w ill s ta y o p e ra te d in ad v an cin g d ire c tio n
uglily w ip e d a w a y . and w ill not re a d ily retu rn to norm al even iff
(6) O perate the sta rte r to e xh a u st the air fro m inside it is m ad e to resu m e norm al o p e ra tio n by
the in je c tio n p u m p and in je c tio n pipe. tu rn in g th e en g in e in norm al d ire c tio n ffor a
IM@T!s w h ile . M a k e sure th a t th e c ra n k s h a ft is
B not o p e ra te th e s ta rte r c o n tin u o u s ly (for c ra n k e d m ore th an 180 in norm al d ire c
m ore th an 15 seconds. tion by hand.
(2) If, u n d e r the c o n d itio n o f Item (1), the p o in te r o f

the In jectio n p u m p and the in scrib e d line o f the
a u to m a tic tim e r are in a lig n m e n t, th e in je ctio n start
tim in g is correct.
13-61
SERVICE PROCEDURES
[AD typ e in je c tio n p u m p ] 5 .1 .8 in s p e c tio n and A d ju s tm e n t of Mo-

load M inim um and M axim u m
S peeds
(1) RSV Typ e G overnor
[P typ e in je c tio n p u m p ]
(a) In spection and a d ju s tm e n t o f id lin g
Run th e eng in e at idle and check to ensure th a t the

c o n tro l lever to u ch e s the s to p p e r b o lt "A ", and
m easure the eng in e speed at th e tim e .
If the id lin g speed is n o t w ith in the sp ecified lim its,
adjust w ith the s to p p e r b o lt "A " .
(b) Inspection and a d ju s tm e n t o f no-load m a x im u m

speed
Push the c o n tro l lever u n til it to uch es the s to p p e r b o lt

"B ". If the engine speed is o u t o f the m a x im u m speed
(3) If the fu e l in je c tio n sta rt tim in g is n o t correct,
lim its , a djust w ith the s to p p e r b o lt "B ".
loosen the tw o tim in g a d ju s tin g b o lts and a djust the
tim in g by tu rn in g the a u to m a tic tim e r. NOTE:
T ig h te n th e a d ju stin g b o lts to the sp e cifie d to rq ue . A fte r idling a d ju s tm e n t, q u ic k ly m ove th e
Recheck the fu e l in je c tio n sta rt tim in g by the pro ce co n tro l lever from th e full load position to
dure describ e d in Item s (1) and (2). th e idling p o sition t verify th a t th e eng ine
does not s ta ll and no hunting occurs. Df
NOTE:
ab n orm al co n d itio n o ccu rs, m a k e a d ju s t
O not loosen any Slier p a rts th an th e
m e n t as fa r as th e s p e c ifie d idling lim its
ad ju stin g b o lts.
a llo w . If a d ju s tm e n t is im p ossible, dis
ass e m b le and in s p e c t th e in je c tio n pum p.
13-62
(2) RFD T yp e G overnor (e) In the above c o n d itio n (d), m easure the m a x im u m
speed to d e te rm in e w h e th e r it is w ith in the specified
lim its.
(f) If it is not w ith in the specified lim its , adjust the
fixe d p o s itio n o f the speed c o n tro l leve r w ith the
s to p p e r bolt.
M OTE;
1. Df th e fix e d position of th e full load
sto p p er bolt is chan g ed , th e am o u n t of
fuel in je c tio n w ill change. Be ca re fu l
not to ch a n g e th e fixed position .
2. C h eck to ensure th a t even if th e load
co n tro l lever is q u ickly re tu rn ed from
th e full load position to th e idling posi
(a) Check to ensure th a t the load c o n tro l lever is tion, th e en g in e does not stop and is
to u c h in g the idle s to p p e r bolt. fre e from hunting.
(b) In the above c o n d itio n (a), m easure the id lin g
speed to d e te rm in e w h e th e r it is w ith in the specified
lim its.
(c) If it is n ot w ith in the sp e cifie d lim its , a d ju s t w ith
the idle sto p p e r bolt.
(d) O perate the load co n tro l lever to the fu ll load
p o s itio n (u n til it to uch es th e fu ll load s to p p e r bolt).
13-63
SERVICE PROCEDURES
5.2 GOVERNOR
5 .2 .1 R S V T y p e G o v e rn o r
(1 ) D is a s s e m b ly , In s p e c tio n an d R e a s s e m b ly
Cracks, d e terio ra tion
24
1 C losing cover 11 T ension lever shaft 21 B ushing

U ng leich sp ring capsule 12 C on trol lever 22 Oil seal
3 Id lin g su b sp rin g capsule 13 C ollar 23 S w ive l leve r
4 T o rq u e sp rin g capsule 14 Shim 24 S top lever
5 G o ve rn o r cover 15 G o v e rn o r sp ring 25 Shim
6 S tart sp rin g 16 Tension lever 26 S p rin g cap
7 R ound nut 17 G uide lever assem bly 27 R eturn sp ring
F lyw e ig h t @ Sleeve 28 Bushing
9 G o ve rn o r hou sin g 19 F loating lever link 29 S lid in g lever
10 Plug 20 Snap ring 30 B olt
31 Snap ring
32 S p rin g
For disassem bly and reassem bly o f parts w ith an encircled num ber, 33 T o rq ue c o n tro l lever
see fo llo w in g items.
For reassem bly, reverse the ord e r o f disassem bly. 34 A d a p te r
B9150A
13-64
FU E L A N D ENGSNE C O N T R O L -
MOTE: (b) R em oval o f fly w e ig h t
1. 0 not d is a s s e m b le She s h a c k le and U sing Special W rench (special to ol), rem ove the
governor s le e v e from She guide lever,
rou nd n ut tig h te n in g the fly w e ig h t. A t th is tim e , hold
unless re p la c e m e n t is n e c essa ry .
the d rive side to pre ven t it fro m tu rn in g .
2. D not rem o ve th e governor housing
unless rem o va l is n e c e s s ita te d for c o r
re c tio n of oil le a k s , p a rts re p la c e m e n t,
e tc .
B efore rem oving th e housing, use T a p
p e t In s e rt (s p e c ia l tool} to s e p a ra te the
c a m s h a ft from th e ta p p e t.
Thread E xtractor (special to o l) into the fly w e ig h t.

A fte r th e b o lt end has to uch ed the cam shaft, lig h tly
strike the b o lt head and tu rn d o w n the b o lt to rem ove
the fly w e ig h t.
M O TE ;
Do not a tte m p t d isassem b ly to rem ove the
s w iv el le v e r e x c e p t when re p la c e m e n t of
(a) R em oval o f u ng le ich s p rin g a ssem bly
parts is n e c e s s a ry or when unsm ooth op
U sing Socket W rench (special to o l), loosen the nut era tio n is violent. In ad d itio n , d is a s s e m
tig h te n in g the u ng le ich s p rin g a ssem bly to th e te n bly of p arts for th e stop d e v ic e and torque
sion lever, and rem ove the u n g le ich sp ring capsule.
spring m ech a n is m of th e governor is not
g e n e ra lly required.
13-65
SERVICE PROCEDURES
(c) R eplacem ent o f sleeve o r guide lever a ssem bly 6) W hen the s h im has to be replaced, assem ble all
related parts c o rre c tly and select th e rig h t sh im
1) Rem ove the bearing fro m insid e th e sh ifte r, using
thickness to m ake sure th a t the d im e n s io n fro m the
a press.
end o f the h o u sin g to the s h ifte r c o m p lie s w ith th e
2) U sing a press, rem ove the s h ifte r o f the guide
specified value.
lever assem bly fro m the bearing.
Shim thickness (6 typ es):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 m m
M OTE:
M easu re th e a s s e m b ly dim en sio n w ith o u t
liftin g th e fly w e ig h ts .
3) Install the bearing in the sleeve.

4) Then in sta ll the s h ifte r o f the g u id e lever a ssem
b ly in the bearing.
5) Check to ensure th a t the sleeve rotates sm o o th ly .
MTE:
1. Do not re p la c e th e shim , as it has a
th ic k n e s s d e te rm in e d by a d ju s tm e n t of
Ite m 6).
2. During th e rem o va l and in s ta lla tio n op
e ra tio n s , use c a re not to d am ag e th e
c h ro m e p la te d s u rfa c e of th e s h ifte r.
13-66
5 .2 .2 RIFO T yp e G overnor
(H ) D isassem bly, In s p e c tio n arad R eassem b ly
Cracks, de terio ra tion
16
< D is a s s e m b ly s e q u e n ce >
1 G o ve rn o r co ve r 15 G o verno r sp ring
Lock nut 16 Load c o n tro l lever
Id lin g sp rin g a ssem bly 17 Bushing
4 Cap n ut 18 Lever sh aft
5 Lock nut 19 S lidin g lever
6 D am per sp rin g 20 Speed c o n tro l lever
7 G o ve rn o r co ver 21 Snap ring
8 S tart sp ring 22 Bushing
9 T ension lever plug 23 S w ivel lever
10 T ension lever sh a ft @ Round nut
G uide lever a ssem bly @ F lyw e ig h t
Sleeve (26) G o ve rn o r housing
13 Floating leve r link
For disassem bly and reassem bly o f
14 T ension lever see fo llo w in g items.
For reassem bly, reverse the ord e r o f disassem bly.
B9155A
13-67
13 F U E L A N D E N G IN E C O N T R O L -
NOTE: (b) R em ove the fly w e ig h t by the fo llo w in g procedure.

H. Oo not d is a s s e m b le th e s h a c k le and U sing Special W re nch (special to o l), rem ove the
sle e v e from th e guide lever, unless ro u n d n ut o f the fly w e ig h t.
re p la c e m e n t is n e c e s s a ry .
2. B not rem ove th e g overnor housing
unless rem oval is n e c e s s ita te d for c o r
re c tio n of oil le a k s , p a rts re p la c e m e n t,
e tc .
B efore rem oving th e housing, use T a p
p e t In s e rt {sp ec ial to o l) to s e p a ra te th e
c a m s h a ft from th e ta p p e t.
U sing E xtra cto r (special to o l), rem ove the fly w e ig h t.
(a) Rem ove the lock n ut w ith Socket W rench and

H andle (special tools).
F urth erm ore, rem ove the idle s p rin g capsule.
Tappet Pin
NOTE: 157931-7320 < fo r AD type p u m p >
Tappet H older
C h eck th e speed s e ttin g Sever. If th e re is 1 5 7 9 3 1 -4 7 0 0 < fo r P ty p e p u m p > B9159A
nothing w rong, do not d is a s s e m b le it.

(c) R em ove the g o v e rn o r h o u sin g by the fo llo w in g
pro ced ure.
U sing T ap pe t H old er o r T ap pe t Pin (special to o l),

d is c o n n e c t the ta p p e t fro m the cam shaft.
Then rem ove the g o v e rn o r h ou sin g tig h te n in g b olts,
and rem ove the g o v e rn o r h o u sin g , w h ile s trik in g w ith
a p la stic h am m e r, etc.
NO TE:
B@ not rem o ve th e stop le v e r ass em b ly on
th e top off th e govern o r housing from tin
governor housing.
13-68
Sleeve
(d) R eplacem ent o f sleeve o r g u id e lever a ssem bly (e) A sse m b ly d im e n s io n o f sh ifte r
To d isassem ble the s h ifte r and sleeve, rem ove the W hen the s h ifte r and sleeve are assem bled, be sure
snap ring in the sleeve, and th e s h ifte r and sleeve can n ot to change the a d ju s tin g sh im , as the a ssem bly
be separated. d im e n s io n o f the s h ifte r has been a djusted by the
shim .
If re a d ju s tm e n t is necessary, assem ble all related
parts c o rre c tly and select the rig h t sh im thickness to
make sure th a t the d im e n s io n fro m the hou sin g end
to the s h ifte r c o m p lie s w ith the sp ecified value.
S him thickness (6 typ es):

0.2, 0.3, 0.4, 0.5, 1.0, 1.5 m m
IM0TE:
M e a s u re th e a s s e m b ly d im e n s io n w ith a ll
fly w e ig h t lifte d .
D2024A
Use a press to rem ove the s h ifte r and b ush in g.
M O TE:
W h e n th e s h ifte r a n d b u s h in g a re in s ta lle d ,
u s e c a r e n o t to d a m a g e th e c h ro m e p la te d
s u r fa c e o f th e s h ifte r.
13-69
SERVICE PROCEDURES
5.2.3 Adjustment after Reassembly

HJRSV Type Governor
For g o v e rn o r p e rfo rm a n ce curve, see Service In
fo rm a tio n p ub lish ed separately.
A d ju stm e nt o f speed
regulation
A d ju stm e n t o f torque
spring
A d ju stm e n t o f high speed

A d ju stm e nt o f id lin g sub co n tro l
spring
A d ju stm e nt of id lin g
spring o r ungleich
spring
A d ju stm e nt o f sto p pe r
bolt
NO TE:
1. S u p p ly e n g in e o il to th e in je c tio n p u m p c a m c h a m b e r.
2. L o o se n th e a d ju s tin g le v e r s to p p e r b o lt.
3. R e m o v e th e id lin g sub s p rin g .
A d ju stm e nt o f in te rm e d ia te 4. Do n o t a llo w th e U n g le ic h s p rin g o r id lin g sub spring
speed control and to rq u e s p rin g to w o rk .
B9163A
(a) " 0 " p o s itio n se ttin g o f c o n tro l rack

[Refer to Item (1) (b) o r (2) (b), S e ction 5.1.4.1
(b) Install the angle scale plate fo r fix in g the a d ju stin g
lever.
A d ju s t the re la tio n sh ip b etw e en p u m p speed and the

rack p o sitio n to sp e cifie d g o v e rn o r p e rfo rm a n ce
curve by the fo llo w in g procedure.
13-70
Full p o sitio n
(c) T e m p o ra ry a d ju s tm e n t o f hig h speed c o n tro l (e) A d ju s tm e n t o f U n g le ich sp ring (g o v e rn o r w ith

U ng leich sp ring o nly)
W ith the a d ju stin g lever in fu ll p o sitio n , adjust the
m a x im u m speed sto p p e r b o lt so th a t high speed 1) Keep the p um p ru n n in g at a speed w h ic h is a
co n tro l starts to w o rk w he n th e p u m p speed is "N d ". little r lo w e r than "N a " (speed at w h ic h U ng leich
sp ring starts to w ork).
2) Fix the a d ju s tin g lever at the fu ll p o sitio n .
3) U sing the special to o l, Special W re nch , tig h te n
the U ng leich sp ring so th a t the rack w ill m ove fro m
"R c " to "R a ". Fix the s p rin g w ith lock nut.
4) Check th a t the p u m p speed is "N a " and "N b "
w hen the rack p o s itio n is "R a " and "R b ", respectively.
(d). A d ju s tm e n t o f in te rm e d ia te speed c o n tro l
W ith the p u m p speed at "N c " ( c p o in t) w h ic h is a little

lo w e r than "N d ", a djust the fu ll load sto p p e r b o lt so
th a t th e rack is p o sitio n e d at "R c".
(f) A d ju s tm e n t o f id lin g s p rin g (g o v e rn o r w ith id lin g

s p ring only)
A d ju s t the id lin g s p rin g so th a t the rack starts to m ove

fro m "R c " to d ire c tio n to increase fu el rate at p o in t k.
13-71
13 FUEL AND ENGINE C O N T R O L -
SERVICE P R O C E D U R E S
(g) A d ju s tm e n t o f lo w speed co n tro l
B9170A
(i) A d ju s tm e n t o f speed re g u la tio n
Check th a t the rack is p u lle d back to p o s itio n "R e "

1) A d ju s tm e n t o f sto p p e r b o lt w h e n the p u m p speed is increased fro m "N d " to
"N e ".
A d ju s t the sto p p e r b o lt so th a t th e rack is p o s itio n e d
at "R g " w he n the a d ju stin g lever is set at id lin g
p o sitio n w ith the p u m p sta tio n a ry . G overnor spring
D3482A
If th e p u m p fa ils to do so, a d ju s t tig h te n in g a m o u n t o f

the s w ive l lever a d ju s tin g screw .
T ig h te n in g gives b e tte r speed re g u la tio n .
Loosening give s p o o re r speed re g u la tio n .
2) A d ju s tm e n t o f id lin g sub sp rin g
Ne - Nd
Speed re g u la tio n ------------- ------------- x 100 (%)
A d ju s t the id lin g sub s p rin g so th a t the rack is
p o sitio n e d at "R i" w he n th e p u m p speed is " N i" . NO TE:
Check th a t the rack is p o sitio n e d at "R h " w h e n the 1. Ilf the speed regulation is poor, the
p u m p speed is fu rth e r increased. engine will exceed the specified m ax
(h) A d ju s tm e n t o f high speed co n tro l imum speed at no load and will enter a
hazardous condition.
A d ju s t as in (c) and fix the m a x im u m speed s to p p e r
2. The maximum extent to which th ad
b o lt in p osition .
justing screw can he loosened is 20
notches (5 turns) from the fully tight
ened position. Loosening it any further
can be dangerous.
3. Iff the adjusting screw is adjusted, the
tension of the governor spring will
change and the high speed control start
point will change. Be sure to readjust
the high speed control in accordance
with (h).
13-72
1) Fix the a d ju stin g leve r at the fu ll p o s itio n and set
the p u m p speed at "N k ".
2) S crew in u ntil the to rq u e s p rin g co nta cts the lever
and fix te m p o ra rily .
3) A d ju s t the to rq u e s p rin g so th a t the rack is
p o s itio n e d at "R 7 " w he n the p u m p speed is lo w e re d
to " N / " .
4) Check th a t the p u m p speed is " N j" w he n the
p u m p speed is lo w e re d to p o s itio n the rack at "R c".
5) A fte r the a d ju s tm e n t, check th a t the rack p o s itio n
Norm al is as sp ecified at each p u m p speed.
p o s itio n B9171A If the rack p o s itio n is o u t o f sp e c ific a tio n , rea dju st the
to rq u e s p rin g and fu ll load s to p p e r bolt.
(j) Stop lever o p e ra tio n check
(m) A d ju s tm e n t o f a d a pta tio n to eng in e
W ith the a d ju stin g lever fixe d at the fu ll p o s itio n , pull
A fte r the g o v e rn o r has been a d ju ste d , m easure
the stop lever all the w ay to the stop side and check
o ve ra ll in je c tio n a m o u n t at the sam e lever angle as in
th a t the rack is p o sitio n e d at 0 m m .
the hig h speed c o n tro l and In accordance w ith the
(k) A d ju s tm e n t o f fu ll load a d ju s tm e n t standard and re a d ju st as necessary.
(n) Locking w ith w ire
1) Install the lever to the g o v e rn o r cover.

2) W ith the a d ju stin g lever at the fu ll p o s itio n , adjust A fte r a d ju s tm e n ts , lock th e g o v e rn o r w ith w ire s.
the fu ll load sto p p e r b o lt so th a t the rack is p o s itio n e d
NOTE;
at "R c".
Locking f toe sections marked with *
(I) A d ju s tm e n t o f to rq u e sp rin g
must Coe done after adjustment of no-load
minimum arid maximum speeds.
13-73
SERVICE PRCEDURES
(2) RFD Type Governor

For g o v e rn o r p e rfo rm a n ce , curve, see S ervice In
fo rm a tio n p ub lish e d separately.
S etting p o sitio n 0 o f co n tro l rod
B9174A
MOTE: A d ju s t the re la tio n b etw e en p u m p speed and the rack

1. Remove the damper spring. p o s itio n to sp e cifie d g o v e rn o r p e rfo rm a n c e curve by
2. Remove the idling spring. the fo llo w in g pro ced ure.
3. Keep the stopper holt of the speed (a) " 0 " p o s itio n se ttin g o f c o n tro l rack
control lever loosened. [R efer to Item (1 >(b) o r (2) (b), S ection 5.1.4.]
' 4. Keep the stopper bolt of the load con (b) Install the angle scale p late fo r fix in g the c o n tro l
trol lever loosened. lever.
5. Supply engine oil to the injection pump
cam chamber.
13-74
S E R V IC E P R C E D U R E S 13
Pum p speed (rp m ) ----------- -

B4061A
(c) A d ju s tm e n t o f fly w e ig h t lift and fu ll load p o s itio n 3) L ow er th e p u m p speed to "N u " and a d ju s t the
D ivide the fly w e ig h t fu ll lift in to the lift necessary fo r high speed lift " L " w ith the stroke a d ju s tin g screw .
high speed 'control and the lift necessary fo r id lin g (d) A d ju s tm e n t o f high speed c o n tro l
co n tro l.
1) W ith the load co n tro l lever fixe d at the fu ll load
p o sitio n , te m p o ra rily set the speed c o n tro l lever so
th a t high speed co n tro l w o rks w he n the p u m p speed
is 700 to 800 rpm .
Set the c o n tro l lever at the fu ll load p o s itio n and set

the speed c o n tro l lever at th e m a x im u m speed
p o sitio n .
Increase the p u m p speed s lo w ly and a d ju st the speed
2) Increase the p u m p speed s lo w ly and a d ju s t the c o n tro l leve r s to p p e r b o lt so th a t the rack starts to
fu ll load s to p p e r b o lt so th a t the rack is p o s itio n e d at m ove fro m "R a " to w a rd fu el decreasing d ire c tio n
"R t" w hen the p u m p speed reaches "N t" . w h e n the p u m p speed reaches "N a ".
13-75
SERVICE PRCEDURES
2) Check o f speed re g u la tio n 2) L o w e r th e p u m p speed to "N e " and a d ju s t the
Increase the p u m p speed s lo w ly u n til the c o n tro l rack Id lin g s p rin g using the special to o l, W rench so th a t
is pulled back to "R b " p o s itio n . the rack is p o s itio n e d at "R e ".
3) W hen th e p u m p is sto p p e d th e rack sh o u ld be at
U pon reaching "R b " p o s itio n , check th a t the p um p
speed is "N b ". "R f" o r h ig h e r p o s itio n . A lso check th a t th e rack Is
p o s itio n e d at "R c " w h e n the p u m p speed is increased
F urther increase the p u m p speed and check th a t the
rack pull back a m o u n t " L " is as sp ecified. to " N d " .
IMOTE:
1. Df fthe speed regulation check point
(point b) is where the damper spring
acts, check the speed regulation a fte r
idling and damper spring adjustment.
2. Of the value is out of specification,
replace the governor spring.
(e) A d ju s tm e n t o f id lin g s p rin g (g o v e rn o r w ith id lin g
sp ring only)
D4506A
1) Set the p u m p speed at " N c " (Nd + 100 rpm ) and

a d ju st the s to p p e r b o lt so th a t the rack Is p o s itio n e d at
"R c".
13-76
(f) A d ju s tm e n t o f U ng leich sp ring
(Vehicles w ith U ngleich s p rin g only)
B4317A
3) S lo w ly increase the p u m p speed fro m " N f" to
"N g " and a d ju s t th e screw p o s itio n so th a t the
1) Set the p u m p speed at " N f" and place the load U ng leich s p rin g w ill sta rt w o rk in g .
c o n tro l lever in the fu ll load p o sitio n . 4) Increase the pum p speed to check th a t the
2) Using th e special to o l. Special W re nch , a djust the U ng leich s p rin g sto ps w o rk in g at " N h " .
U ngleich sp rin g capsule p o s itio n so th a t th e U ngleich 5) Change the p u m p speed betw een " N f" and "N a "
stroke C in the state o f Step 1 w ill have the specified to check th a t the U n g le ich stroke has th e specified
value. A fte r th e a d ju stm e n t, fir m ly tig h te n it w ith the values.
lock nut. M@TEs

1. Df th e U n g le ic h s tr o k e 5s owt o f s p e c i
fic a tio n , r e a d ie s t th e U n g le ic h s p rin g
capsulle p o s itio n .
2 . If th e s p e e d a t w h ic h th e y n g ie ic h
s p rin g s to p s w o rk in g is o u t o f s p e c ific a
tio n , r e p la c e th e U n g le ic h s p rin g c a p
s u le .
13-77
SERVICE PRCEDURES
(g) M ea su re m e n t o f load c o n tro l lever angle
Check th a t w h e n the load c o n tro l lever is held at the

id lin g p o s itio n -a n d the fu ll load p o s itio n , the lever
angle at the respective p o s itio n s is up to sp e cifica tio n .
If the lever angle is o u t o f sp e cific a tio n , replace the
shim in sta lle d betw een th e s h ifte r and sleeve.
SMOTE:
If She s h im w a s r e p la c e d , r e p e a t a d ju s t
m e n t o f th e g o v e rn o r fro m th e b e g in n in g .
(h) A d ju s tm e n t o f d a m p e r sp rin g
2) A d ju s t the d a m p e r s p rin g tig h te n in g a m o u n t so

th a t the rack is p o s itio n e d at "R g - 0.1 m m ".
1) H o ld in g the load c o n tro l leve r at the idle p o s itio n

(p o in t e) and s lo w ly increase the p u m p speed fro m
"N e " u n til the rack is p o s itio n e d at "R g - 0.2 m m ".
H old the p u m p speed " N h " w h e n the rack is so
p o sitio n e d . 3) A fte r a d ju s tm e n t, s to p th e p u m p and loosen and
a d ju st the s to p p e r b o lt so th a t the rack is p o s itio n e d at
"R i".
13-78
F U E L A M D E N G IN E C O N T R O L
S E R V IC E P R C E D U R E S
-
13
(i) A d ju s tm e n t o f rack lim it A fte r a d ju s tm e n t, in sta ll the cap n u t securely.
1) Cap typ e 2) S crew typ e
a) R em ove the g u id e screw fro m the back o f the a) Place the load c o n tro l lever in the fu ll load
p um p hou sin g and install th e special to o l, G uide p o s itio n and keep th e p u m p speed at " N v " .
Screw. b) A d ju s t the screw o f the rack lim ite r so th a t the rod
p o s itio n and fuel in je c tio n (p o in t E) w ill be up to
s p e c ific a tio n , and secure it w ith th e lock nut.
(j) A d ju s tm e n t o f s ta rt b o o s te r (sm oke set assem bly)
B3768A
b) U sing a depth gauge, m easure th e rack cap depth.
c) A d ju s t the a d ju stin g n u t m o u n te d to the tip o f the

rack fo r the same d epth as the rack cap depth
m easured above. Fix the n u t in p o s itio n w ith the lock
nut.
13-79
SERVICE PRCEDURES
1) W ith the load c o n tro l lever set at th e fu ll load (I) Locking w ith w ire
p o s itio n , set the sm oke set a sse m b ly a d ju stin g n ut at
0 to 4 m m fro m the sto p p e r tip.
2) A d ju s t to m ake sure th a t w h e n the p u m p speed is
chan ge d to " N d " , the rack p o s itio n w ill change fro m
T o be lo c k e d w ith w ire fe v P P r
"R a " to "R a "'.
N^ l t \ r S S
""
SP'
\
v -x- T o be lo cke d
/ w ith cap
T o be ca p lo cke d
B4320C
A fte r a d ju s tm e n ts , lock th e g o v e rn o r.
MOTE;
L o c k p a rts m a r k e d w ith * a f t e r a d ju s tm e n t
o f no Hoad m a x im u m s p e e d .
3) Set and fix th e n u t so th a t the rack is p o s itio n e d at 5 .2 .4 In s p e c tio n a n d A d ju s tm e n t off Mo-

"R u " w he n the p u m p speed is " N u ". lo a d M in im u m an d M a x im u m
(k) A d ju s tm e n t o f a d a p ta tio n to eng in e Speeds
A fte r the g o v e rn o r has been a djusted , m easure [R efer to 5.1.8.)
o ve ra ll in je ctio n a m o u n t at the sam e lever angle as in
the high speed c o n tro l and in accordance w ith the
a d ju s tm e n t sta nd ard and re a d ju st as necessary.
13-80
5 .3 FE E D P U M P
5 .3 .1 D is a s s e m b ly , In s p e c to ra a n d R e a s s e m b ly
1 Eye b o lt (suctio n side: w ith gauze filte r) 7 Plug

2 Eye b o lt (d e live ry side) 8 Piston s p rin g
3 P rim ing p u m p 9 Piston
4 Check va lve plug 10 Snap ring
5 Check valve sp rin g 11 T ap pe t
6 Check valve 12 Feed p u m p h o u sin g
For reassem bly, reverse the o rd e r o f disassem bly.
NOTE:
B e fo re d is a s s e m b ly , k n o w th e tro u b le s p o ts th ro u g h ly by
m a k in g te s ts .
B9175A
13-81
SERVICE PRCEDURES
5 .3 .2 T e s t a n d A d ju s tm e n t
The feed p u m p tests are as fo llo w s .
L iftin g capacity A ir tig h tne ss test

C ondition
No. o f strokes
req u ire d before No leaks from
A ir
liftin g w hen push rod sliding
pressure area
operated at
60 to 100 195 kPa
strokes per (2 kg f/cm 2)
m in ute
D e liv e ry NV 25 strokes
C o n d itio n o r less Feed pum p
Fuel passed th ro u g h 1.54-dia.
nozzle fo r 15 seconds w hen
p u m p is operated at 1 000 rpm
NV Refer to 3.1 Service S tandard Table.
Test co n d itio n s
Fuel pipe
I.D. 8
Length 2 000
Cam lift
6 (eccentric cam ) [KE type)
4 (double cam ) [K type] 1 m
Height fro m o il level 1 000
Test bench FPT-1
Test oil
SAE Standard Test Oil (SAE J967c)
D6401A
13-82
SERVICE PRCEDURES 13
5 .4 A U T O M A T IC TAMER
5 .4 .1 SA T y p e A u to m a tic T im e r
(1 ) D is a s s e m b ly a n d D nspection
For d isa sse m b ly and re a ssem bly o f the a u to m a tic
tim e r, use SA Type A u to m a tic T im e r Special T ool
(105790-5010).
W ear of
pin section
Round nut
2 T im e r plug
@ T im e r case
4 O il seal
5 Flange
6 Oil seal
7 S pring
8 S him
9 F lyw e igh t
10 Flolder
W ear,
dam age
item s.
D3152A
(a) R em ove the c o u p lin g fro m the a u to m a tic tim e r.
13-83
(b) M o u n t Special S p an n er (special to o l) in the c o u (e) R em ove the tim e r plu g and place the a u to m a tic
p lin g m o u n tin g th re ad e d hole to p re ve n t tu rn in g , and tim e r on Base (special to ol).
rem ove the ro u n d nut. MOTH;
Lone up fidie hole in tine tim er plug with the
pin f the base.
(c) W h ile h o ld in g the a u to m a tic tim e r w ith Special

S panner (special to o l) to p re ve n t it fro m tu rn in g ,
rem ove th e a u to m a tic tim e r w ith E xtra cto r (special (f) U sing Hand S p an n er (special to o l), rem ove the
to ol). tim e r case by tu rn in g clockw ise.
(d) M o u n t Base and G uide B o lt (special to o ls ) in th e

vice.
13-84
(2) Reassembly
9 3
D3153A
(a) M o u n t Base and G uide B o lt (special to o ls) in a (b) Install th e o il seal in th e flange.
vice. 1) M o u n t Block (special to o l) to th e base.
2) Put th e fla n g e so th a t its pins w ill fit in th e holes in
the block.
3) A p p ly NEJI LOCK to the o il seal in s ta llin g hole in
the flange.
4) Put the oil seal in the hole in the fla n g e . Install the
o il seal by tu rn in g d o w n T h ru s t B ushing (special to o l)
w ith G uide B ushing (special to o l) in betw een.
13-85
(e) A fte r placing S u p p o rt (special to o l) on the

fly w e ig h t, install the sh im and sp rin g .
Thread G uide (special to o l) o n to the g u id e bolt.
M O TE :
Select the proper shim thickness so it a hie
for the advance angle of the automatic
timer.
(c) Install the o il seal in th e tim e r case.
1) M o u n t Block and G uide (special to o ls) to the base.

2) Put the tim e r case on th e g uide.
3) A p p ly NEJI LOCK to the o il seal in s ta llin g hole in
th e tim e r case.
4) Put the o il seal in the hole in the tim e r case. Install
the o il seal by tu rn in g d o w n T h ru s t B ushing (special
to o l) w ith G uide B ushing (special to o l) in betw een. (f) Put the fla ng e so th a t the pin o f the fla n g e w ill
to uch one end o f th e sp rin g .
M o u n t Special S p an n er (Special to o l) to the co u p lin g
m o u n tin g hole o f the flange.
F urth e rm o re , m o u n t T h ru s t B ushing (special to o l)
w ith a bolt.
(d) Place the h o ld e r on Base (special to ol).
(g) A fte r placing Oil Seal G uide (special to o l) on the

fla ng e, in s e rt the tim e r case
13-86
(i) Inject app ro x. 150 g o f a u to m a tic tim e r grease
fro m the tim e r plu g hole.
Hand Spanner A fte r grease has been Injected, tig h te n the tim e r plug.
(h) A fte r the oil seal g u id e has been rem ove d, tu rn

d o w n the tim e r case o n to th e h o ld e r w ith Hand
S panner (special to o l), and punch It.
MOTE: (j) A fte r the a u to m a tic tim e r has been In stalled on
Turn down She tim er case rato! She imjee the ca m sh aft, fit Special S panner (special to o l) Into
Sion start timing lines inscribed on the the c o u p lin g m o u n tin g hole. W h ile h o ld in g it to
timer case and Mange are in alignment. p re v e n t tu rn in g , tig h te n the rou nd n u t to th e sp ecified
to rq u e .
13-87
SERVICE PRCEDURES
5 .4 .2 SP T y p e A u to m a tic T im e r
(1 ) D is a s s e m b ly amid In s p e c tio n
For d isa sse m b ly and rea sse m b ly o f the a u to m a tic
tim e r, use th e special to o l, SP Type A u to m a tic T im e r
Special T ool (105790-5050).
1 Cap screw
@ Round nut
3 Cover
4 Oil seal
Washer
Roller
Bushing
8 Flange
9 Retainer
10 Timer spring
11 Spring seat
12 Shim
13 Flyweight
14 Timer housing
For d isa sse m b ly o f parts w ith an encircled n um b e r, see fo llo w in g item s.
D3103A
(a) Rem ove the c o u p lin g fro m the tim e r.
(c) M o u n t Special S panner (special to o l) by taking

a dvantage o f the c o u p lin g m o u n tin g thread. W h ile
(b) Rem ove the cap screw o f the tim e r. W h ile using
h o ld in g it to p re ven t tu rn in g , rem ove the tim e r fro m
Box S panner (special to o l), rem ove the ro u n d nut
the in je c tio n p u m p , using E xtra cto r (special tool).
w ith Box W rench (special to ol).
13-88
(d) M o u n t Base (special to o l) in a vice. (f) M ount Special S panner (special to o l) to the
flange. W ith th e tim e r sp ring com pressed, rem ove the
w asher, ro lle r and b ushing.
(e) Fix the tim e r to Base (special to o l)
13-89
SERVICE PROCEDURES
(2 ) R e a s s e m b ly
(a) M o u n t Base (special to o l) in a vice and secure the (b) M o u n t Special S panner (special to o l) to the
tim e r h o u sin g to th e base. flange. W ith the tim e r sp ring co m p re ssed , install the
b ush in g, ro lle r and w asher.
13-90
Cover side
R oller side
D3113A
SMOTE: (d) R em ove the plu g at the rear end o f the tim e r and
W h e n th e w a s h e r is in s ta lle d , d ir e c t it as s u p p ly 250 to 270 cc o f e ng in e oil.
show n.
(c) Install the key to the in je c tio n p u m p ca m sh aft and

install the a u to m a tic tim e r. W h ile using Special
S panner (special to o l) to p re ve n t tu rn in g , tig h te n the
ro u n d n ut to the sp ecified to rq u e .
13-91
13-92
5 .5 P U M P 1 D R IV E C A S E For rem ova l and in s ta lla tio n o f the p u m p d riv e case,
5 .5 .1 R em oval and I n s ta lla tio n refer t0 5-1-1 in G ro u P 61 Special E q uip m e nt.
5 .5 .2 D i s a s s e m b l y a ra d I n s p e c t i o n
13-93
SERVICE PROCEDURES
5.5.3 Reassem bly
In stallation of llnjection Pump Clear
Install th e in je ctio n p u m p gear, se nso r plate and nut

as sh ow n.
13-94
5 .6 IM JECTIO M WOZZLE 5 .6 .2 D isassem bly
5.6.1 R em oval and In s ta lla tio n ____________________
(1-spring nozzle)

1
of t '
2
. 3 Settling
W ear 4 .....
TJ
9
7 W ear
f g Carbon
deposited
0 ' 6
>

1 Cap nut 5 C onnector

2 A d ju s tin g screw 6 R etaining n ut
3 S pring 7 Needle valve
4 Push rod 8 Nozzle
9 Nozzle h o ld e r D7027A
(2-spring nozzle)
1 Cap nut
2 A d ju s tin g screw
3 Lock nut
Cracks,
d e te rio ra tio n 4 4 No. 2 spring
5 Set screw
6 No. 2 push rod
7 Spacer
8 No. 1 spring
9 No. 1 push rod
10 R etaining nut
11 Nozzle
12 Needle valve
13 Nozzle h o ld e r
14 C onnector
D7015A
13-95
SERVICE PROCEDURES
5 .6 .3 C lean in g and (Inspection

(1) C leaning
(b) Insert, w h ile tu rn in g , a clea nin g needle in to the

in je ctio n o rific e o f the nozzle to re m o v e ca rb on . Use
the needle o f p ro p e r size fo r in je c tio n o rifice .
A fte r w a sh in g the nozzle in gas o il, rem ove dep osite d
carbon using the Nozzle C leaning T ool (special to ol)
MOTE;
M ever ch a n g e th e co m b in a tio n of th e n o z
zle and n ee d le valve.
(c) Clean the nozzle seat using th e clea nin g needle.

(d) To rem ove b u rn t and h arde ne d ca rb on , use FUSO
Carbon R em over or e qu iva len t.
(2) Inspection
(a) R em ove the needle va lve fro m the nozzle and

clean the needle va lve w ith th e needle va lve cleaning
w o o d piece.
Clean and im m e rs e the nozzle in gas o il, slide the

needle va lve and check th a t it m oves sm o o th ly .
13-96
Next, pull up the needle va lve v e rtic a lly a bo ut 1/3 o f (1) In je c tio n P ressure
its e ntire stroke and check th a t it fa lls u nd er its ow n
w e ig h t. If it does n o t fa ll, replace the nozzle.
5 .6 .4 R e asse m b ly and A d ju s tm e n t in
spiring nozzle)
(a) Rem ove the cap n ut and install to the nozzle

tester.
(b) Loosen the a d ju stin g screw and operate the
nozzle te ste r tw o o r th re e tim e s fo r bleeding.
(c) O perate the nozzle te ste r at sp ecified speed,
a d ju stin g the a d ju stin g screw fo r sp ecified in je ctio n
pressure.
M OTE;
Met/er Bet you rself exp o sed d ire c tly to th e
a to m ize d fuel in je c te d from th e nozzle.
D7008A
(d) A fte r a d ju s tm e n t, tig h te n the cap n ut to specified

to rq u e . Fix the a d ju s tin g screw w ith a s c re w d riv e r
inserted th ro u g h th e cap n u t hole to p re ven t tu rn in g
o f the a d ju stin g screw .
(e) A fte r tig h te n in g the cap nut, check again the
in je c tio n pressure.
13-97
SERVICE PROCEDURES
(2) Spray Condition 5.6.5 Reassem bly and A djustm ent (2-
spring nozzle)
A d ju s t w h ile a s s e m b lin g th e p arts b y the fo llo w in g
procedures.
As the p re lift is adjusted in 1/100 m m in cre m e n ts, use
clean d e te rg e n t to th o ro u g h ly re m o ve d u s t and d irt
befo re a d ju stm e n t.
For a d ju s tm e n t, th e fo llo w in g special to o ls are re-
q uire d .
Special to o l Diesel Kiki p art No.
Nozzle tester (500 kg /cm 2) 105785-1010
A d ju s tin g device 105789-0500
W hen a d ju stin g the pressure w ith a nozzle tester,

check also fo r clog ge d in je c tio n o rifice s, sp ra y c o n d i
tio n , and fu el leaks fro m the o rifices. Replace the
nozzle if defective.
(3) Fuel Tightness Test
1 A d ju s tin g device a ssem b ly 157892-0220
2 Dial gauge 157954-3800
3 Pin, ( - 50 m m 157892-1200
4 Pin, / = 60.5 m m 157892-1100

Install a nozzle th a t has been adjusted to sp ecified
5 C onnector assem bly 157892-1320
in je ctio n sta rt pressure to the nozzle tester. S lo w ly
6 Base 157892-1800
increase th e pressure to the te st pressure and keeping
th is c o n d itio n , check fo r fuel leaks fro m the b o tto m o f 7 Gasket (fo r re ta in in g nut) 157892-1500
th e nozzle. The nozzle is fu n c tio n in g n o rm a lly if th ere 8 R etaining n ut fo r a d ju s tm e n t 157892-1420
is no leak. 9 Gasket (fo r b o lt o f re ta in in g nut) 026508-1140
13-98
(1) A d ju s tm en t of M ozzle Waive pening
P ressure
A d justing step s D7017A
0 A d ju s tm e n t o f nozzle o p e n in g pressure
(2) S election o f p re lift a d ju stin g shim s (a) U sing the R etaining N ut fo r A d ju s tm e n t (special
(3) A d ju s tm e n t o f 2-spring a d ju stin g pressure to o l) in sta ll the nozzle and needle va lve to the nozzle
* 0 Check o f needle va lve fu ll lift holder.
(5) In sta lla tio n o f p re lift sh im s MOTE:
*(6) Checking o f p re lift H. M a k e sure th a t th e kn o c k pin has s e a
* 0 C hecking o f 2-spring a d ju stin g pressure te d c o m p le te ly in th e no zzle b efo re
0 ' Inspection tig h te n in g th e re ta in in g nut fo r adjust-
In spe ction m ake o p e ra tio n s m arked w ith * as neces orient. T ig h ten th e re ta in in g nut fin g er
sary fo r insp ectio n o r c o n firm a tio n . tig h t and th en tig h te n to s p e c ifie d to r
que using a to rq u e w re n ch .
2. IRemove th e bolt fro m th e tip of th e
re ta in in g nut.
13-99
SERVICE PROCEDURES
NOTE:
1= W hen using a shim , be sure So c h e e k its
th ic k n e s s by a m ic ro m e te r.
2. U se s am e shim for p re lift a d ju s tm e n t.
3. U se of a 0 .0 2 m m th ic k shim ch a n g es
th e v a lv e opening p ress u re by ab o u t
2 3 5 kP a (2 .4 k g f/e m 2}
(2) S e le c tio n of PrellifS A d justing Shim

(a) 0 p o in t a d ju s tm e n t o f a d ju s tin g device
Dial Gauge
(b) Insert 1st push rod 1st sp rin g , va lve o pe ning

pressure a d ju stin g sh im (firs t use a b o u t 1 m m thick
one) and spacer to the nozzle holder.
Then tig h te n the setscrew to sp ecified to rq u e .
Install th e Dial Gauge (special to o l) to the A d ju s tin g

Device (special tool).
Install the 2nd push rod to the Base (special to o l) and
install the assem bly to a vice.
Set the pin and a d ju s tin g device as ind icate d in the
above illu s tra tio n and a d ju s t 0 p o in t o f the dial gauge.
Use a 60.5 m m lon g pin.
(c) Install the nozzle h o ld e r to the Nozzle Tester (b) Install the 2nd push rod to the nozzle holder.
(special to o l) and a d ju st the sh im th ickne ss fo r NOTE;
n o m in a l in je ctio n pressure. O not in s ta ll th e 2nd spring and p re lift
Shim types: ad ju stin g shim .
0.50 to 1.54 m m (by 0.02 m m )
13-100
(e) Rem ove th e a d ju s tin g device fro m the nozzle
holder.
{3) A d ju s tm en t off 2-spring A d justing Press-

ure
Install th e 2nd s p rin g , a d ju s tin g screw and lock n u t to

the nozzle holder.
Bo mot in s ta ll th e p re lift ad ju stin g shim .

(c) Install the a d ju stin g device to th e set screw using
its in te rm e d ia te screw.
A fte r in sta lla tio n , h o ld in g th e dial gauge at its h older,
m ove it up and d o w n to check th a t the gauge operates
sm o o th ly .
Push d o w n th e gauge, h o ld in g its h o ld e r and read its
lift h.
MOTE?
R ead t 1 / 1 0 0 m m .
(d) S election o f p re lift a d ju stin g sh im
t = ( + h
W here t: Shim thickness (m easured)

A d ju s t the 2-spring a d ju s tin g pressure (open press
C\ P re lift (0.10 + 0.02 m m )
ure) to the n o m in a l value, using the a d ju s tin g screw
h: D im e nsio n selected in (c) and nozzle tester.
T = t 0.015 m m A fte r a d ju s tm e n t, tig h te n the lock n u t to specified
to rq ue .
T: Thickness o f sh im to be used
Type o f sh im s
0.75 to 1.50 m m (by 0.01 m m )
13-101
(4) C h eckin g Full Lott off M eele V a lv e MOTEs

M ever loosen tine lo c k nut as loosening it
c h a n g es th e 2-spring a d ju stin g pressure.
(b) Install the p re lift sh im selected in (2) betw een the
spacer and 2nd push rod.
(c) In sta ll th e 2nd push rod and 2nd sp ring and
tig h te n th e setscrew , lock n u t and a d ju s tin g screw as
an a sse m b ly to sp e cifie d to rq u e .
(d) Check again th a t the needle va lve fu ll lift d im e n
sion "S " w ith th e dial gauge by the p ro ced ures
describ e d in (4).
() C h eckin g P re lift
Check th e p re lift based on d im e n s io n " L " m easured
in (4) and d im e n s io n "S " m ea sured in (5).
(a) Install the special to o ls ind icate d in above illu s tra
tio n and set 0 p o in t o f the Dial Gauge. L - S = A('
(b) Install the nozzle to th e nozzle te ste r and operate w h e re ( 0.02 < AC < (' + 0.02 m m
the tester le v e rto bleed the insid e o f th e re ta in in g nut.
At : P re lift (m easured)
A lso check fo r fu el leaks.
( : P re lift (0.1 m m )
(c) O perate the te ste r lever to increase th e pressure
L: N eedle valve fu ll lift d im e n s io n (m ea
to a b o u t 34.5 to 44 MPa (350 to 450 kg f/c m 2) so th a t
sured)
the needle valve o f th e nozzle is fu lly lifte d . Read th is
S: N eedle valve lift d im e n s io n (m easured)
lift d im e n sio n " L " o ff the dial gauge.
w ith p re lift su btracted
(d) R em ove the Dial G auge, C on ne cto r and Pin
If A ( is o u tsid e o f sp e cifie d d im e n s io n C 0.02
(special to ol).
m m , replace the p re lift a d ju s tin g s h im as d e
{) In s ta lla tio n f P re liff Shim scrib ed in (5) and repeat steps (4) and (5) so th a t
A ( w ill fa ll w ith in C 0.02 m m .
S elect th ickne ss t' o f sh im to be used as fo llo w s .
t' s= t + [C - AC)
T = t ' 0.015 m m
w h e re t: T hickness o f e x is tin g s h im
t': S him thickness
T: Thickness o f sh im to a ctu a lly replace
e x is tin g s h im
C: P re lift (0.1 m m )
(a) Rem ove the setscrew , lock n u t and a d ju stin g

screw as an a ssem bly fro m th e nozzle holder.
13-102
F U E L A M D E M G IM E C O N T R O L -
1?) C h e c k in g A d ju s tin g A llo w a n c e o 2- (b) S pray co n d itio n
s p rin g
(a) A fte r checking the p re lift in Item (6), increase the

pressure again to a bo ut 34.5 to 44 MPa (350 to 450
kg f/cm 2) so th a t the needle va lve o f the nozzle is fu lly
lifted.
NOTE:
T h e R e ta in in g N u t fo r A d ju s tm e n t {s p e c ia l
to o l} m u s t h a v e a h o lt fit t e d a t its tip .
(b) W hen the nozzle tester lever o p e ra tio n is stopped
w ith the nozzle needle valve fu lly lifte d, the pressure
W hen a d ju s tin g th e pressure w ith a nozzle tester,
w ill sta rt to d ro p and the needle va lve w ill go dow n.
check also fo r clo g g e d In je c tio n o rifice s, sp ra y c o n d i
(c) A t the m o m e n t the nozzle lift has d ro pp ed to 0.05
tio n , and fuel leaks fro m the o rifices. Replace the
m m , read the pressure gauge in d ica tio n .
nozzle If defective.
(d) If the 2-spring a d ju stin g pressure (cover pressure)
(c) Fuel tig h tn e s s test
is o u t o f sp e cifica tio n , a djust th e 2-spring adjustin g
pressure as described in (3).
M O TE:
A d ju s t w ith o u t in s ta llin g p r e lift s h im .
(e) Rem ove special tools.
{8} In s p e c tio n
(a) T igh ten the reta inin g n ut and cap n u t to specified
torque.
M O TE:
1. M a k e s u re th a t th e k n o c k pin h as s e a -
te d c o m p le te ly b e fo re tig h te n in g th e
r e ta in in g n u t.
2 . T ig h te n th e re ta in in g n u t fin g e r fig h t
Install a nozzle th a t has been a d ju ste d to specified
an d th e n tig h te n to s p e c ifie d to rq u e
Injection sta rt pressure to the nozzle tester. S lo w ly
u sin g a to rq u e w re n c h .
increase the pressure to the te st pressure and keeping
th is c o n d itio n , check fo r fuel leaks fro m th e b o tto m o f
the nozzle. The nozzle is fu n c tio n in g n o rm a lly if there
is no leak.
13-103
SERVICE PROCEDURES
5 .7 F U E L F IL T E R
< S ta n d a rd > < O p tio n >

C racks, d a m a g e d
25 Nm th re a d e d p o rtio n
(2.5 kgfm )
MOTE:
1. W h e n re m o v in g th e e le m e n t, c h e c k fo r
th e g a s k e t le f t b e h in d on th e h e a d s id e .
2 . T o m o u n t, a p p ly a th in c o a t o f e n g in e oil
to th e g a s k e t, a n d th e n s e c u re th e
e le m e n t by tig h te n in g % to 1 tu rn a fte r
th e g a s k e t c o m e s in c o n ta c t w ith th e
fu e l f ilt e r h e a d .
3 . A fte r in s ta lla tio n , b le e d th e fu e l sys-
te rn .
4 . A fte r b le e d in g th e a ir, s ta r t th e e n g in e
a n d c h e c k fo r fu e l le a k s .
To rem ove the e le m e n t, use F ilter W re nch (special

tool).
13-104
5 .8 W ATER SEPAR ATO R
1 Drain plug
2 Ring nut
3 Case
4 Baffle plate
5 Isolation plate
6 Screen assem bly
7 W ater level ring
8 Cover
1 ------- )
D7405C
If the red w a te r level ring in the tra n s lu c e n t case rises

to the level o f the red line m arked on th e o u te r
c ircu m fe re n ce o f the case, im m e d ia te ly loosen th e
d ra in plu g to disch arg e w a te r.
It is not necessary to c o m p le te ly re m o ve the d ra in
p lu g, as w a te r is d isch a rg e d g ra d u a lly th ro u g h the
g ro o ve o f the loosened p lu g.
MOTE:;
A fte r d ra in in g , tig h te n firm ly th e d ra in p lu g
b e fo re b le e d in g th e fu e l s y s te m .
13-105
13 FUEL A N D E N G IN E C O N T R O L - T R O U B L E S H O O T IN G
TR O U B LES H O O TIN G
S ym p to m Probable cause R em edy Ref. g rou p
Engine is D efective feed p u m p

hard to start Clean
C logged gauze filte r
Check va lve ino p e ra tive Replace
B ind in g o r w o rn p iston Replace
B ind in g push rod Replace
W o rn ta p p e t Replace
D efective in je c tio n p um p
B ind in g o r w o n p lu n g e r Replace
B ind in g co n tro l rack o r c o n tro l rod Replace
B in d in g d e live ry va lve Replace
W o rn ta p p et Replace
W o rn ca m sha ft Replace

B ind in g needle va lve Replace
V alve o p e n in g p ressure to o lo w A d ju s t
C logged in je ctio n o rifice Clean
Nozzle n ot a ir-tig h t C orre ct o r replace
Fuel tank e m p ty S u p p ly fuel
C logged fu e l p ip e o r fu e l leak fro m c o nn e ctio ns C orre ct o r replace
A ir o r w a te r tra p p e d in fu e l system Bleed or replace G ro u p 11
C logged fuel filte r o r se con d a ry filte r Replace
Engine stops C logged fu e l filte r o r se con d a ry filte r Replace

im m e d ia te ly
a fte r starting A ir o r w a te r tra p p e d in fuel system Bleed o r replace G ro u p 11
D efective feed p um p Check
Engine knocks In je ctio n tim in g to o early A d ju s t

V alve o pe n in g p ressu re to o high A d ju s t
C logged in je c tio n o rifice Clean
Nozzle n ot a ir-tig h t C orre ct o r replace
Poor q u a lity fuel in use R eplace
S m oky exhaust gas D efective in je c tio n p u m p

and engine
In co rrect in je c tio n tim in g A d ju s t
knocking
W o rn p lu n g e r Replace
D efective v a lve seat o f d e liv e ry valve Replace
13-106
FUEL AND ENGINE CONTROL - TROUBLESHOOTING 13
S m oky exhaust gas Poor q u a lity fuel in use Replace

and engine
knocking Defective in je c tio n nozzle
Valve o p e n in g pressure to o lo w A d ju s t
Broken sp rin g Replace
U nstable D efective in je ctio n p u m p

e ngine o u tp u t
In su fficie n t p lu n g e r s lid in g stroke Replace
Broken p lu n g e r sp rin g Replace
C on tro l rack o r c o n tro l ro d n ot s lid in g s m o o th ly C orrect
W o rn or sticky tappet Replace
Broken d e live ry valve sp rin g Replace
Loss o f a ir-tig h tn e s s due to loose d e liv e ry va lve h o ld e r C orrect
D elivery va lve n o t fu n c tio n in g n o rm a lly Replace
Defective in je ctio n nozzle

Needle va lve n o t s lid in g s m o o th ly Replace
V alve o p e n in g pressure to o lo w A d ju s t
D efective feed p u m p
Check va lve n ot fu n c tio n in g n o rm a lly Replace
W orn p iston Replace
A ir o r w a te r tra p p e d in fuel system Bleed o r replace G ro u p 11
C logged fuel filte r o r se condary filte r Replace
Incorrect in je ctio n tim in g A d ju s t
C on tro l lever n o t in co nta ct w ith fu ll speed set b o lt A d ju s t
Loss o f D efective in je c tio n nozzle

eng in e o u tp u t
Nozzle n ot a ir-tig h t C orrect o r replace
Defective in je ctio n p u m p
W o rn p lu n g e r Replace
(Broken) D am aged d e liv e ry va lve sp rin g Replace
Defective d e liv e ry va lve seat Replace
Loss o f a ir-tig h tn e ss due to loose d e liv e ry valve h o ld e r C orrect
Loss o f D efective g o ve rn o r
e ngine o u tp u t
Too e arly ro ta tio n c o n tro l due to w eak g o v e rn o r sp rin g A d ju s t
Faulty fu ll load sto p p er p o sitio n A d ju s t
A d ju stin g leve r (o r load c o n tro l lever) p o o rly adjusted A d ju s t
Poorly adju ste d in je c tio n tim in g A d ju s t
Incorrect tim in g advance o f a u to m a tic tim e r A d ju s t
Poor q u a lity fuel in use Replace
13-107
13 FUEL A N D E N G IN E CONTROL - T R O U B L E S H O O T IN G
Engine ca nn o t D efective g o v e rn o r
deve lo p m a xim u m A d ju s t
G o ve rn o r sp rin g to o w eak
speed
A d ju s tin g leve r (o r load c o n tro l lever) p o o rly adjusted A d ju s t

Nozzle n ot a ir-tig h t C orrect or replace
Valve o p e n in g p ressu re to o lo w A d ju s t
Engine m a x im u m In je ctio n p u m p c o n tro l rack o r c o n tro l rod n ot s lid in g s m o o th ly C orrect

speed to high
D efective g o v e rn o r
G o ve rn o r sp rin g to o w eak A d ju s t
F lyw e ig h t n o t fu n c tio n in g e ffe c tiv e ly C orrect
Idling is not D efective in je c tio n p u m p

sm o oth
B in d in g , sticky o r w o rn p lu n g e r Replace
Loose co n tro l p in io n C orrect
P lunger sp rin g n ot seating c o rre c tly Replace
D elivery va lve h o ld e r to o tig h t C orrect
o U neven fu e l in je ctio n rate a m o n g c y lin d e rs A d ju s t
Broken p lu n g e r sp rin g Replace
A ir o r w a te r tra p p e d in fuel syste m Bleed o r replace G ro u p 11
D efective g o v e rn o r
Id lin g sp rin g to o w eak A d ju s t
Bent linkage C orrect
Large fric tio n o r pla y in linkage Replace
Loose ro un d n ut C orrect
P o o rly a dju ste d id lin g set b o lt A d ju s t
Id lin g is not D efective feed p um p

sm o oth
D efective check valve Replace
W o rn p iston Replace
C logged gauze filte r Clean
C logged fuel filte r o r se con d a ry filte r Replace
P o o rly a dju ste d in je c tio n tim in g A d ju s t
D efective a u to m a tic tim e r C orrect

W eak sp rin g Replace
Nozzle n o t a ir-tig h t C orre ct o r replace
Engine w ill Broken o r e lo n g ated e ng in e sto p cable Replace

n o t stop
E ngine sto p cable p o o rly adju ste d A d ju s t
Dam aged g o v e rn o r sto p m e cha n ism Replace
P oor su p p ly Cracked fu e l hose o r pipe Replace

o f fuel
Fuel tank n ot a ir-tig h t Replace
13-108
14
CO O LIN G
CONTENTS
1. G E N E R A L ........... ..................... . 2 5 .4 FA N D R IV E ............... 3

2. S P E C IF IC A T IO N S ................................. 3 5 .4 .1 D is a s s e m b ly a n d Onspec-
3. S E R V IC E S T A N D A R D S .................. 4 tio n .......................... . 9
3.1 S E R V IC E S T A N D A R D T A B L E ..... 4 5 .4 .2 R e a s s e m b ly ......... 9
3.2 T IG H T E N IN G T O R Q U E T A B L E ... 4 5 .5 T E N S IO N P U L L E Y ...................... 9
4 . S P E C IA L T O O L ....................... . 4 5 .5 .1 D is a s s e m b ly a n d In s p e c -
5. S E R V IC E P R O C E D U R E S .................. 5 tio n ......................................... 9
5.1 R E M O V A L A N D IN S T A L L A T IO N 5 .5 .2 R e a s s e m b ly ............................ 10
OF C O O L IN G FA N .............................. 5 5 .6 R A D IA T O R ................................. 10
5.2 W A T E R P U M P ............................ 5 5 .6 .1 In s p e c tio n .............................. 10
5.2.1 R e m o v a l a n d In s ta lla tio n ....... 5 5 .7 IN S P E C T IO N A N D A D J U S T M E N T
5 .2 .2 D is a s s e m b ly a n d [Inspec O F V -B E L T T E N S IO N .................. 11
tio n ................................................. 5 5 .8 C L E A N IN G O F C O O L IN G
5 .2 .3 R e a s s e m b ly ............................ 7 S Y S T E M ..................................... 11
5.3 T H E R M O S T A T ...................... 8 5 .9 G A S L E A K T E S T ......................... 14
5.3.1 R e m o v a l a n d In s ta lla tio n ....... 8 5 .1 0 B L E E D IN G T H E C O O L IN G
5 .3 .2 In s p e c tio n .............................. 8 S Y S T E M ..................................... 14
6 . T R O U B L E S H O O T IN G .................... 15
14-1
14 C O O L IN G - GENERAL
1. G E N E R A L (2) T h e rm o s ta t
The e n g in e is co o le d by fo rce d c irc u la tio n o f c o o la n t
by the w a te r p um p. The illu s tra tio n b e lo w sh o w s the
co o la n t flo w .
i l } W a te r P o m p
The th e rm o s ta t is a b o tto m bypass ty p e w ith a special

w a x enclosed in a pellet. W hen the w a x is heated, it
changes fro m s o lid to liq u id and its v o lu m e also
changes. T his change in v o lu m e changes the o pe ning
o f the valve and changes the q u a n tity o f c o o la n t
flo w in g into th e ra d ia to r and w a te r p u m p (bypass
side), th e re b y c o n tro llin g the c o o la n t te m p e ra tu re .
(3) R a d ia to r
The w a te r p u m p is a c e n trifu g a l p u m p . M o u n te d on
the le ft side o f th e crankcase, the p u m p is d riv e n by
the cran ksha ft p u lle y via a V -belt.
An im p e lle r having a blade is m o u n te d at one end o f
the w a te r p u m p sh a ft and c o o la n t is sealed o ff by a
u n it seal.
For lu b ric a tio n o f th e w a te r p u m p , refe r to "G ro u p 12
L u b ric a tio n ".
The ra d ia to r c o o lin g ca pa city va rie s d e p en din g on

a p p lic a tio n s (in s ta lla tio n in an enclosed g en e ra to r
ro o m o f a b u ild in g , o p e ra tio n in s ta tio n a ry state, etc.).
14-2
COOLING - GENERAL, SPECIFICATIONS 14
C o n side ra tion s are, th e re fo re , paid to the fan d ia The pressure cap regulates th e pressure in the
m eter, ra d ia to r ca pacity and o th e r factors. Som e u nits c o o lin g system . W hen the pressure b u ild s up in the
fo r co n stru ctio n p lants are e q u ip p e d w ith an oil co oler system th a t exceeds a p re d e te rm in e d level, the
to cool h y d ra u lic oil. pressure va lve co m p re sses the pressure s p rin g , re
(4) Pressure Cap leasing the excessive pressure th ro u g h the o v e rflo w
pipe in to the a tm o sph e re .
If e q u ip p e d w ith a reserve tank, the c o o la n t th a t has
o v e rflo w e d is ch anneled in to it.
W hen the c o o la n t te m p e ra tu re d ro p s and negative
pressure b u ild s up in the syste m , the v e n t valve
opens to take in a ir to p re ve n t the ra d ia to r fro m
b e co m in g d e fo rm e d .
If e q u ip p e d w ith a reserve tank, c o o la n t is taken fro m
the reserve tank to p re v e n t the ra d ia to r fro m b e c o m
ing d e fo rm e d and to keep the q u a n tity o f c o o la n t in
the syste m co nsta nt.
If e q u ip p e d w ith a pressure release leve r on the cap,
raising the lever u p rig h t o pe ns the pressure va lve and
releases the pressure in th e c o o lin g system .
2. S P E C IFIC A TIO N S
Item S p e cifica tio n
C ooling m eth o d W a te r-co ole d , fo rce d c irc u la tio n

C oo lin g w a te r q u a n tity (Engine proper) 6D22, 6D22-T: 22 lit.
6D22-TC: 24 lit.
W a te r p um p Type C e n trifu g a l type
Drive V -belt d riv e
V -belt Type x q u a n tity (W ith fan|
L ow edge c o gg e d B ty p e x 1 (fo r w a te r p um p )
Low edge co gg e d C ty p e x 2 (fo r fan d rive )
(W ith o u t fan]
L ow edge co gged C ty p e x 1 (fo r w a te r p um p )
T h e rm osta t Type W ax p elle t, b o tto m bypass
Valve o p e n in g te m p e ra tu re x q 'ty 76.5"C x 2
Fan Type P usher typ e o r su ctio n type
R adiator Type Tube and c o rru g a te d fin typ e o r tu b e and plate fin type
14-3
14 C O O L IN G - S E R V IC E S T A N D A R D S , S P E C IA L T O O L
3. S i r a C E SYAMDAKOS
3.1 SE R V IC E STAM DARB TABLE
U n it: m m
D escrip tion N o m in a l va lue L im it C orrection and rem arks

[Basic d ia m e te r]
Th e rm osta t V alve o p e n in g sta rt 74.5 to 7 8 .5 X Replace.

te m p e ra tu re
Valve lift/te m p e ra tu re 10 o r m ore/90C
W a te r p um p In te rfe re n ce betw een p u m p [25] R eassem bling up

sh a ft and fla ng e 0.05 to 0.08 to tw o tim es
In te rfe re n ce betw e e n p u m p 111.8]

sh a ft and im p e lle r 0.03 to 0.06
R adiator pressure va lve o p e n in g p ressure 39 to 59 kPa - Replace pressure

(0.4 to 0.6 k g f/c m 2) cap.
R adiator check pressure 98 kPa - C orrect o r replace.

(1.0 k g f/c m 2)
T e nsion o f V -belt w /fa n d rive 10 to 15 - A d ju st.

(d efle ctio n of V -belt
w he n pressed d o w n at w /o fa n d rive 17 to 22
m id d le u n d e r app ro x.
98 N (10 kgf) pressure)
3 .2 TIGKITEKIOMQ TO R Q U E TA BLE
D escrip tion Thread size T ig h te n in g to rq u e Rem arks

mm
Fan d riv e fla ng e n ut M 20 x 1.5 145 (15)
Tension p u lle y shaft nut M 16 x 1.5 98 (10)
4. SPECIAL TOOL
U n it: m m
14-4
C O O L IN G - S E R V IC E PROCEDURES 14
5. SERVQGE PROCEDURES 5.2 W ATER PU M P
5.1 REM O VAL ANB IN S T A L L A T IO N OF 5 .2 .1 Removal! arnci OiiDStaSlatiiorTi
CO O LIN G FAN
5 .2 .2 D isassem b ly and In s p e c tio n
clogged oil hole
< D is a s s e m b ly s e q u e n c e >
1 W a te r p u m p p u lle y W a te r p u m p sh a ft
Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 W a te r p u m p co ver 13 U n it seal
Im p e lle r 14 W a te r p u m p case
For parts w ith an encircled num ber, refer to Disassem bly and
Inspection Procedures that fo llo w . D0044C
14-5
14 COOLING - SERVICE PROCEDURES
D is a s s e m b ly a n d In s p e c tio n P ro c e d u re s
(3 ) Im p e lle r to W a te r P u m p S h a ft T ig h te n
ing M a rg in
(1 ) R e m o v a l o f D m peller
If the tig h te n in g m a rg in exceeds sp e c ific a tio n , replace
U sing tw o th re ad e d holes (M 8 x 1.25) in the im p e lle r
th e im p e lle r o r w a te r p u m p shaft.
and the W a te r Pum p Im p e lle r P uller (special to o l), pull
o ff the im p e lle r. NOTE:
Do n o t re a s s e m b le m o re th a n th r e e tim e s
e v e n w h e n th e s p e c ific a tio n is m e t.
(2 ) F la n g e to W a te r P u m p S h a ft T ig h te n in g
M a rg in
If the tig h te n in g m a rg in exceeds sp e c ific a tio n , replace
the fla ng e or w a te r p u m p shaft.
NOTE:
Do n o t re a s s e m b le m o re th a n th r e e tim e s
e v e n w h e n th e s p e c ific a tio n is m e t.
14-6
C O O L IN G - S E R V IC E P R O C E D U R E S 14
5 .2 .3 R e a s s e m b ly
A p p ly e n g in e
o il to lip s .
12
1. A fte r re a s s e m b ly , tu rn th e w a te r p u m p p u lle y by h an d
to m a k e s u re th a t th e im p e lle r is n o t in c o n ta c t w ith
th e c a s e a n d c o v e r.
2. W h en p re s s -fittin g th e im p e lle r a n d fla n g e , m a k e s u re
t h a t th e y c a n n o t b e in s ta lle d w ith a lo a d of 4 .9 kM (5 0 0
D0047D
OiatallatiiQfi) f Praoi S e a l To in sta ll th e u n it seal, use th e p re s s -fit jig as sh o w n

and p re ss-fit th e u n it seal u n til the in sta lle d d im e n
sions sh o w n are o b ta in e d .
14-7
5 .3 THERM OSTAT A g ita te w a te r in the c o n ta in e r w ith the s tirre r to

o b ta in u n ifo rm te m p e ra tu re . For the in sp e ctio n , use
5 .3 .1 R e m o v a l a n d In s ta lla tio n
the fo llo w in g procedures.
(1) S lo w ly heat w a te r to th e th e rm o s ta t valve o p e n

ing te m p e ra tu re .
The valve o p e n in g te m p e ra tu re is sta m p ed on the
th e rm o s ta t. Its n o m in a l va lu e is the sta m p ed te m p e r
a ture 2C.
Keep th is c o n d itio n fo r a b o u t fiv e m in u te s and m ake
sure th a t the va lve is open.
(2) Raise the te m p e ra tu re fu rth e r to heat the w a te r to
the va lv e lift m e a su rin g te m p e ra tu re co rre s p o n d in g
to th e va lv e o p e n in g te m p e ra tu re . (See the table
above.)
Keep th is state fo r fiv e m in u te s and m easure the
bypass va lve lift.
5 .3 .2 In s p e c tio n (3) L o w e r te m p e ra tu re d o w n to 65C or b e lo w and
ensure th a t th e va lve is fu lly closed.
If the th e rm o s ta t is fo u n d defe ctive in any o f th e
Therm ostat stam ping 76.5 above ite m s, replace it w ith a new one.
Valve opening 74.5 to 78.5 MOTE:

tem perature (C)
S u p p o rt th e th e r m o s ta t so th a t th e h e a t
Valve lift/ M ore than 10/90 w ill mot d ir e c tly tr a n s fe r t it.
tem perature (mm/C)
Bypass valve lift

Valve opening T he rm o m e te r
S tirrin g rod
tem perature
stam ped p o sitio n
T herm ostat h older
T herm ostat _
Heat source
D0301B
14-8
C O O L IN G - S E R V IC E P R O C E D U R E S m
5.4 FAM DRIVE

5.4.1 Disassembly and Inspection
6 Spacer
7 Ball bearing
8 Bearing case
B9023D
5.4.2 Reassembly 5.5 TEMSOOM PULLEY

Sealing side to
be faced o u tw a rd .
To be packed w ith grease
(m u ltip u rp o se grease)
6 Rotating co n d itio n
< A sse m b ly sequence> 1 A d ju s tin g b o lt

8 5 > 3 > 2 > 1 2 T en sion p u lle y bracket
4 _ 7 -> 6 -t 3 Snap ring
4 T en sion p u lle y sh aft
B9024D 5 T en sion p u lle y
6 Ball bearing B9023E
14-9
5 .5 .2 R e a s s e m b ly
(2) C onnect a hose to one o f the ra d ia to r p orts, cap

the o th e r port, and im m e rs e the ra d ia to r into w ater.
U sing a ra d ia to r cap tester, fo rce the com pressed air
u nd er the specified in sp e ctio n pressure fro m the hose
end to check fo r leaks.
If th e re is a leak, reso ld e r the p o in t o f leakage or
replace the rad ia to r.
5 .6 R A 0 B A T 0R
5 .6 .1 In s p e c tio n
(3) In spection o f ra d ia to r cap
Check the s p ring te n s io n and sealing c o n d itio n o f the

pressure va lve and v e n t valve. If d efective, replace.
Check the pressure va lv e o p e n in g pressure, using a
D0402A ra d ia to r cap tester.
(1) U sing a co p p e r w ire o r s im ila r device, rem ove

d irt, m ud , and bugs fro m the fro n t o f ra d ia to r core
w ith care to pre ven t d am ag e to tu rb in g s .
14-10
COOLING - SERVICE PROCEDURES 14
5.7 IN S P E C T IO N AMD A D J U S T M E N T OF (a) A lte rn a to r section
V-BELT T E N S IO N S lig h tly loosen the a lte rn a to r m o u n tin g b o lt and
(1) In s p e c tio n a d ju s tin g b olt, then m ove the a lte rn a to r to rig h t or left
by in s e rtin g a to o l such as w re nch handle.
NOTE:
W hen m oving th e a lte rn a to r, try not to
d am ag e th e s ta to r co il s e c tio n b e tw e e n
th e fro n t and rear b ra c k e ts . The sam e
a p p lies to th e bolts.
A d ju s tin g b olt
(b) T en sion p u lle y section
Loosen the id le r p u lle y m o u n tin g nut, then a d ju st L

m o v in g the id le r p u lle y by m eans o f the adjustin g
A d ju s t the belt te n sio n to o b ta in the sp e cifie d belt bolt.
d e fle ctio n w h e n the ce nte r o f each belt is pressed
w ith a fo rce o f a p p ro x im a te ly 98 N (10 kgf). 5 .8 C L E A N IN G IP 0 L IM SY STE M
NOTE;
H A s la c k b e lt can be a c a u s e of o v e rh e a t-
ing and u n d e rc h a rg e .
2. An e x c e s s iv e ly tig h t b e lt m ay re s u lt in
d am ag ed b ea rin g s and b e lts .
(2) A d ju s tm en t
If the ra d ia to r is used fo r a long tim e , rust, scale, m ud,

etc. are d e p o site d inside, re s u ltin g in overheat. Clean
the c o o lin g syste m w ith c ity w a te r by using the
fo llo w in g p rocedures.
The city w a te r to be used sh o u ld have the fo llo w in g
pro pe rtie s.
R equired p ro p e rtie s o f c ity w a te r
14-11
(a) D ischarge co o la n t fro m th e rad ia to r, and cran k

Total hardness 300 p p m or less
case.
S ulfate SO 4 100 p p m o r less
(b) A fte r d ra in in g the system , fill it w ith tap w a te r
C hlo rid e Cl 100 p pm o r less (p re fe ra b ly h ot w ater) and, w ith the w a te r te m p e ra
Total disso lve d so lid s 500 p pm o r less tu re kept at a ro un d 90C, run the engine at idle fo r
PH 6 to 8 a b o u t 10 m in u te s. Then, disch arg e w ater.
C on tinu e flu s h in g u n til the d ra in e d w a te r runs clear.
K10TE: (2) W ashing w ith C lean in g S olution (W hen

1 U se a c le a n in g solutn If fthe ra d ia to r Is ra d ia to r clogging or c o o la n t c o n ta m in a
serio u sly o b s tru c te d or c o o la n t Is tio n a re serious)
serio u sly c o n ta m in a te d .
2. W hen th e co o lin g sys te m is c le a n e d or
w a s h e d w ith w a te r, m a k e sure th a t th e
c o o la n t te m p e ra tu re is m a in ta in e d a t
90C; th e c o o la n t te m p e ra tu re b e lo w
th e v a lv e o p ening te m p e ra tu re closes
th e th e rm o s ta t re s u ltin g in poor
c o o la n t c irc u la tio n .
3. For q u ic k e r rise of w a te r te m p e ra tu re ,
you m ay co v e r th e ra d ia to r fro n t w ith
c a rd b o ard , e tc .
4. Df m uch rust is found, w a te r m ay le a k
from th e ra d ia to r a fte r c le a n in g . C h eck
c a re fu lly e a c h s e c tio n of th e ra d ia to r (a) D ischarge co o la n t fro m the rad ia to r, crankcase,
a fte r c le a n in g . and reserve tank.
(b) Ready a m ix tu re of Fuso R adiator C leaner
C oo la nt in use C leaning interval

(Radipet-7 or e q u iv a le n t: 5 to 10%) and c o oling w ater.
Pour the specified am ount of m ix tu re into the
FUSO Diesel Long Life E very 2 years
C oolant radiator.
A n ti-ru st, anti-freeze A t tim e o f c o o la n t repla ce m en t o f
every 6 m o n th s o r before and
a fte r use o f anti freeze
I f } W ashing w ith W a te r
(c) Run the eng in e to raise the s o lu tio n te m p era ture

to aro un d 90C. Let the e n g in e run at idle fo r a nother
30 m in u te s, th en rem ove the so lu tio n .
14-12
C O O L IN G - S E R V IC E PROCEDURES m
Replace the c o o la n t once e very tw o years to retain its
anti-freeze and a n ti-ru s t effects.
For usage o f Long Life C oolant, refer to Its in s tru c tio n
m anual.
NOTE:
1. Be sure to use FUS B iesel Long Life
C o o lan t.
2. INIever m ix it w ith DIAQUEEM Long Life
C o o la n t or o th e r c o m m e rc ia l long life
c o o la n ts , a n ti-fre e z e s or a n ti-ru s ts .
B0426A
(d) A fte r d isch a rg in g the s o lu tio n , fill the system w ith

tap w a te r (p re fe ra b ly hot w a te r) and w ith the w a te r
te m p e ra tu re kept at a ro un d 90C, run the eng in e at
idle fo r a b o u t 10 m in u te s. Then, d ra in w ater.
C ontinue flu s h in g u n til d ra in e d w a te r runs clear.
E\ITE:
1. Iff Slue inside is h e a v ily sta in e d , w ashing
w ith ta p w a te r b efo re ch arg in g ra d ia to r
d e te rg e n t w ill be e ffe c tiv e . B13IU A
2. Running th e en g in e a t id le for longer
th an an hour w ith d e te rg e n t le ft in (b) W hen A n ti-ru s t and A n ti-fre e ze are
en g in e could c a u s e d a m a g e to th e c o o l used:
ing sys te m . Be sure to o b serve s p e c i
1) A fte r clea nin g, add Fuso R adiator A n ti-ru s t
fied c le a n in g tim e .
(Radipet-9B or e q u iva le n t) at a ra tio o f 5% to the
3. A fte r c le an in g w ith d e te rg e n t, fill w ith
co o la n t q u a n tity to p re ve n t c o rro sio n in su m m er.
c o o la n t as soon as possible.
(3) C ooling W ater
o .
B1322A
2) In w in te r, add th e Fuso A ntl-freeze o r e q u iv a le n t

at a ra tio o f 30 to 60% to p re ven t freezing.
(a) W hen Long Life C o o la n t is used: For usage o f a n ti-ru s t and anti-freeze, see respective
in s tru c tio n m anuals.
In o rd er to p re ve n t freezing o f co o lin g w a te r and
co rro sio n o f the co o lin g syste m , add FUSO Diesel KI0TE:
Long Life C oo lan t at a ra tio o f 30 to 60% o f q u a n tity o f W hen th e a n ti-ru s t or a n ti-fre e z e is used,
w ater. nev er use w ith o th e r long life co o lan ts.
14-13
5 .9 LEM C T E S T 5 .1 0 BLEEBOM T H E LOM S Y S T E M

A ir o r e xh a u st gas leaked in to the co o la n t p ro m o te s (1) W ith the pressure cap rem ove d fro m the rad ia to r,
co rro sio n and rust fo rm a tio n . P e rform the fo llo w in g let th e e ng in e run at idle w ith c o o la n t te m p e ra tu re o f
check and, if defects are fo u n d , take rem ed ial action. a bo ut 90C to bleed the system c o m p le te ly .
(2) A fte r the system has been bled o f air, add c o o la n t
to ra d ia to r and reserve tank as required.
(1 ) Onspectioin)
Rem ove the pressure cap fro m the ra d ia to r, and run
the e ng in e to raise th e c o o la n t te m p e ra tu re up to
a ro un d 90C.
If b ub bles co n tin u e fo rm in g in th e co o la n t u n d e r the
c o n d itio n , it ind icate s th a t a ir or e xh a u st gas has
leaked into the co olan t.
(2 ) C a u s e s
(a) If air is tra p p e d in co o la n t, check c y lin d e r head
b olts, w a te r p u m p m o u n tin g b olts, and hose and its
co n n e ctio n s fo r looseness. Check also hoses fo r
dam age.
'(b ) If the e xha ust gas has leaked in to co olan t, check
the c y lin d e r head gasket o r nozzle tu b e end stake fo r
dam age. Check also c y lin d e r head fo r cracks.
14-14
C O O L IN G - T R O U B L E S H O O T IN G 14
6. TR O U B LE S H O O T IN G
S ym p to m Probable cause Rem edy Ref. g ro u p
O verheating D efective V-belt

o Incorrect tension A d ju s t
Broken belt Replace
C logged co o lin g system Clean
D efective th e rm o sta t Replace
D efective w a te r p u m p
o Loose shaft to fla ng e e ng a g em e n t Replace
Loose shaft to im p e lle r e ng a g em e n t
o Incorrect im p e lle r to case clearance
D am aged im p e lle r
C logged ra d ia to r fins Clean
D am aged co o lin g fan Replace
L ow co o la n t level Replenish
O ve rco o lin g D efective th e rm o sta t Replace
Quick loss D efective ra d ia to r hose

o f co o la n t
P oor hose co nn e ctio n C orrect
Cracked o r d am aged hose Replace
D efective ra d ia to r
R adiator p ro p e r n ot a ir tig h t Replace
D efective pressure cap
D efective w a te r p u m p
o D efective u n it seal Replace
D efective o il seal
o Poor p u m p in s ta lla tio n (defective gasket)
D efective o il co ole r Replace G ro u p 12
Poor th e rm o s ta t case in s ta lla tio n (d efe ctive gasket) Replace
P oor th e rm o s ta t c o v e r in s ta lla tio n (defective gasket)
Poor bypass hose in s ta lla tio n
D efective heater hose

Poor hose co nn e ctio n C orrect
Cracked o r d am aged hose Replace
D efective c y lin d e r head gasket Replace G roup 11
14-15
15
INTAKE i B EX3MUST
CONTENTS
1. GENERAL ...................... ................ 2 5.3 ADR CLEANER ...................... 13

2. S P E C IF IC A T IO N S ........... ................. . 5 5.3.1 Disassem bly and
3. SERVDCE STA N D A R D S ................. 6 Reassem bly ......... 13
3.1 SERVBCE S TA N D A R D TA BLE .... 6 5.3.2 Inspection and Cleaning 14
3 .2 T IG H T E N IN G TO RQ UE 5.4 TURBOCHARGER ............... 15
TA BLE ............... ................................ 7 5.4.1 TD08 Type Turbocharger 15
4. SPEC IA L TO O L .................................... 7 5.4.2 4LF Type Turbocharger , 25
5. SERVBCE PR O C ED UR ES ............... . 8 5.4.3 3LM Type Turbocharger 30
5.1 REM O VA L AND IN S T A L L A T IO N 5.5 AFTER COOLER ................ 35
OF IN T A K E SY S TE M ......... 8 5.5.1 Disassem bly, Inspection
5 .2 REM O VA L AND IN S T A L L A T IO N and Reassem bly ........... 35
OF E X H A U S T SY S TE M ........ . 11 5.5.2 Air-pressure Test ......... .
6. TROUBLESHOOTING ..........
15-1
15 IN T A K E A N D EXHAUST - GENERAL
1. GENERAL
{US Air leaner
The air cleaner uses a filte r paper typ e e le m e n t.

Because o f p la stic co a tin g and heat tre a tm e n t, th e
e le m e n t is h ig h ly re sista n t to w a te r and o il. Even if it
is c o n ta m in a te d , its fu n c tio n s can be regained by
cleaning.
The intake air is g ive n a spin by th e e le m e n t vanes fo r
c e n trifu g a l se pa ra tion o f large p article s o f d u s t and
d irt. S m all p article s o f d u s t and d irt are filte re d o u t by
the filte r paper e le m e n t so th a t a clean a ir is d ra w n
in to the engine.
The standard air clea ne r is a sin g le e le m e n t typ e, and
the d o u b le e le m e n t typ e can be e ffe ctive o r o p e ra tio n
safety u nd er unu sua l c o n d itio n s w ith a lot o f d ust and
dirt.
(2) P re c le a n e r
The precleaner, c o u p le d w ith th e a ir cleaner, co lle cts

re la tiv e ly large p article s o f d u s t co n ta in e d in the a ir
d ra w n in by engine.
The a ir e nte rin g th e pre cle a ne r is m ade to spin by th e
g u id e vanes o f th e pre cle a ne r to c e n trifu g a lly sepa
rate large p article s o f d u s t befo re the a ir is d raw n in to
the a ir cleaner.
15-2
INTAKE AND EXHAUST - GENERAL 15
(3 ) V a c u a to r V a lv e A fte r the e le m e n t has been cleaned o r replaced,
depress the reset b u tto n on the top, and the signal
w ill return to its o rig in a l p osition .
\ \
A |
^ : n.
B0624A
The c e n trifu g a lly separated p a rticle s o f d u s t and d irt

are co lle cted at th e b o tto m o f the air cleaner. The
co lle cted p article s o f d ust and d irt are d ischarged In the e le ctric d ust in d ic a to r, its e le ctric c o n ta ct p oints
o u tsid e by p u lsa tio n s o f the va c u a to r valve m o u n te d close at a n eg ative pressure o f 6.23 kPa (635 m m H 20)
in the air cleaner. or 7.47 kPa (762 m m H 20 ) to tu rn on th e w a rn in g lam p,
In the eng in e speed increases (to 800 rpm or m ore), in d ic a tin g to th e d riv e r the tim e to clean o r replace the
th e v a cu a to r va lve w ill be closed by a high negative elem ent.
pressure in the air cleaner, so no o u tsid e air w ill be {5) T u rb o c h a rg e r
d ra w n in.
(4 ) D u s t (In d ic ato r
The d ust in d ic a to r is d ire c tly m o u n te d near the o u tle t

o f the air cleaner.
The d u st in d ic a to r operates on th e negative pressure
o f the air d ra w n in to the e n g in e p e rfo rm in g the
fu n c tio n o f in d ic a tin g the tim e to clean o r replace the
e lem ent.
If d ust is co lle cted in the e le m e n t, the suction
resistance increases. W hen th e n egative pressure
reaches 7.47 kPa (762 m m H 20 ), o r 6.23 kPa (635 The tu rb o c h a rg e r utilizes the e ne rg y o f the engine-
m m H 20 ) the signal is p ulled d o w n a gainst th e sp ring exha ust gas to feed m o re a ir into th e e ngine, th e re b y
pressure, and the tra n sp a re n t p o rtio n o f the body o ffe rin g a dvantages such as boosted e n g in e p o w e r
changes to red, in d ic a tin g the tim e to clean or replace o u tp u t, th riftie r fu e l c o n s u m p tio n , and reduced en
the e lem ent. gine noise. 1(-
15 IN T A K E A N D EXHAUST - GENERAL
The exha ust gases d isch arg ed fro m th e eng in e c y lin

ders are d e live re d th ro u g h the e x h a u st m a n ifo ld to
the tu rb o c h a rg e r, accelerated in th e tu rb in e h o u sin g ,
and b lo w n a ga in st the tu rb in e w h e e l. As a result, the
tu rb in e w h e e l tu rn s at a speed o f several tens o f
th o u s a n d s o f re v o lu tio n s per m in u te , w h ic h spins the
c o m p re s s o r w he el. As th e c o m p re s s o r w he el spins,
th e a m o u n t o f a ir fa r la rg e r th an th a t su p p lie d w h e n
no tu rb o c h a rg e r is in sta lle d is fo rc e d in to the e n g in e
c y lin d e rs , a llo w in g m o re fu e l to be b u rn t in th e
c y lin d e rs . This increases th e e ffe ctive pressure d u rin g
c o m b u s tio n (the pressure fo rc in g p isto n s d o w n ), th u s
b o o s tin g the p o w e r o u tp u t.
The tu rb o c h a rg e r is d iv id e d in to tw o basic sections:
the tu rb in e w he el th a t is d riv e n by th e exha ust gases
and th e c o m p re s s o r w h e e l w h ic h is s u p p o rte d by the
bea rin g and forces intake a ir in to c y lin d e rs . A th ru s t
bearing is m o u n te d on th e c o m p re s s o r end.
The lu b ric a tin g o il is s u p p lie d fro m the oil m ain
g a lle ry at the fro n t end o f the e n g in e and rou ted
th ro u g h oil holes in the bea rin g h ou sin g to lub rica te
th e bearings. The o il is then re tu rn e d to th e eng in e o il
pan th ro u g h the d ra in p o rt at the b o tto m o f th e
bea rin g h ou sin g.
[Refer to G rou p 12 L u b ric a tio n .]
15-4
IN T A K E A N D EXHAUST - G E N E R A L , S P E C 1 F S C A T IO N S 15
(6) After Oooller The intake air c o o le r system , in c o rp o ra tin g a plate-
a nd -c o rru g a te d -fin typ e heat e xcha ng er w ith a b u ilt-in
in le t m a n ifo ld , tran sfe rs heat fro m the intake a ir to the
engine coolant.
The system cools o ff the intake air, w h o s e te m p e ra
T u rb o ch a rg e r tu re has gone high due to co m p re ssio n by the
tu rb o c h a rg e r, th ro u g h heat e xch a n g in g w ith the
eng in e co olan t. This a llo w s the d e n sity o f intake air to
be increased, a d m ittin g m ore air in to the e ngine,
w h ic h in tu rn increases the fuel in je c tio n rate and
im p ro v e s the c o m b u s tio n efficien cy. Thus the fuel
e c o n o m y and o u tp u t are im p ro v e d and the e xhaust
gases are reduced to a m in im u m .
B0627A
2 . SPECDFflCATDOMS
A ir cleaner (N ippon D on a ldo so n Ltd. prod u ct)
Elem ent Type C yclone typ e pap e r e le m e n t
T u rb o ch a rg e r (6D22-T1 (6D22-TC)
(S tandard) (O ption)
M o de l M its u b is h i TD08 M its u b is h i S ch w itze r M its u b is h i TD08

3LM o r 4LF
A fte r co ole r Type E ngin e -coo lan t-coo led ,

w ith b u ilt-in in le t m a n ifo ld
15-5
15 INTAKE AND EXHAUST - SERVICE STANDARDS
3 SERFAGE S T A N D A R D S
3.1 SERVICE STASMOAKD TABLE
U n it: m m
D escrip tion N o m in a l va lue L im it C orre ctio n and rem arks

[Basic d ia m e te rl
T u rb och a rg er I.D. o f bearing in se rtin g p o rtio n - 19.06 Replace.

(3LM) o f bearing hou sin g
S haft and Bearing jo u rn a l - 11.18 Replace.

tu rb in e w heel O.D.
Shaft co n c e n tric ity - 0.015 Replace.
Piston ring open end clearance 0.015 to 0.18 - Replace insert.
Shaft and tu rb in e w h e e l to tu rb in e 0.53 to 1.04 - Replace.

h o u sin g clearance
Shaft and tu rb in e w he e l end play 0.05 to 0.13 - Replace.

in axial d ire ctio n
S haft and tu rb in e w he e l to tu rb in e 0.74 to 1.55 - Replace.

back plate clearance
T u rb och a rg er I.D. o f bea rin g in se rtin g p o rtio n o f - 20.506 Replace.

ITD-08) bearing hou sin g
Shaft and Bearing jo u rn a l - 11.996 Replace.

tu rb in e w heel O.D.
S haft co n c e n tric ity - 0.015 Replace.
Bearing O.D. 20.382 Replace.
I.D. 12.042
Length 11.94
C learance betw een co m p re sso r w heel 0.08 to 0.28 - Replace.

and co m p re sso r co ver
Piston ring end gap in insert 0.05 to 0.25 - Replace.

hou sin g clearance
S haft and tu rb in e w h e e l end play 0.075 to 0.155 - Replace.


back p late clearance
T u rb och a rg er Bearing Bearing inse rtin g - 22.268 Replace.

(4LF) housing area I.D.
Piston ring - 22.5

in se rtin g area I.D.
Shaft and Piston ring - 1.68 Replace.

tu rb in e w heel g ro o ve w id th
Bearing jo u rn a l - 14.254
O.D.
S haft co n c e n tric ity - 0.015
15-6
INTAKE AND EXHAUST - SERVICE STANDARDS
SPECIAL TOOL 15
U n it: m m
D escription N o m in a l value L im it C orre ctio n and rem arks

[Basic diam eter)
T u rb och a rg er Piston ring g ro o ve w id th o f flin g e r sleeve - 3.3 Replace.

(4LF)
S haft and tu rb in e w he e l to tu rb in e 0.84 to 1.75 - Replace.
hou sin g clearance
Shaft and tu rb in e w he e l end play 0.08 to 0.152 - Replace.

Shaft and tu rb in e w he e l to tu rb in e 0.43 to 1.05 - Replace.

back plate clearance
C learance betw e e n co m pre sso r co ve r and 0.15 - Replace.

co m p re sso r w he e l in d ia m e trica l d ire c tio n
Clearance betw een shaft and 0.15 Replace.

tu rb in e w he e l and tu rb in e hou sin g
in d ia m e trica l d ire ctio n
Piston ring end gap in insert 0.03 to 0.18 - Replace.
A fte r co o le r check pressure 6D22-TC 195 kPa - Replace.

(2 kg f/cm 2)
Dust in d ica to r o p e ra tin g resistance S tandard 7.47 0.57 kPa - Replace.

(762 58 m m H 20 )
O ption 6.23 0.57 kPa - Replace.

(635 58 m m H 20 )
3 .2 TOKIT EM I MG TO R Q U E TABLE
D escrip tion Thread size T ig h te n in g to rq u e Remarks

O.D. x Pitch N m (kgfm )
mm
Inlet m a n ifo ld b o lt < E xce p t 6D22-TC > M 10 x 1.5 35 (3.6)
E xhaust m a n ifo ld nut M 10 x 1.25 41 (4.2)
T u rb o ch a rg e r A ttach in g nut M 10 x 1.25 26 (2.7)

a tta ch ing nut
Lock n ut M10 x 1.25 35 (3.6)
T u rb o ch a rg e r Shaft and tu rb in e w heel - 17 to 20

(3LM) atta ch ing n ut (1.73 to 2.07)
C om p re sso r co ve r a tta ch ing cap screw - 6.9 (0.7)
T u rb in e h o u sin g a tta ch ing cap screw - 17 (1.7)
T u rb och a rg er C ou p lin g assem bly - 5.9 (0.6) A p p ly MOLYKOTE

(TD-08) grease or e q u iv a le n t
Shaft and tu rb in e w h e e l lock nut - 20 (2) to threads
T u rb och a rg er V c la m p a tta ch in g n ut - 11 (1.1) A p p ly MOLYKOTE

(4LF) grease or e q u iv a le n t
Shaft and tu rb in e w h e e l lock nut - 27 (2.8) to threads
4= SPEeOAL TOOL
15-7
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
5. SERVICE PRO CED U RES

5.1 REMOVAL AMB INSTALLATION IF INTAKE SYSTEM
< 6 D 2 2>
1 Earth plate
2 In let pipe
3 A ir heater
4 In let m a n ifo ld
NOTE:
1. R e m o v e a ll h a rn e s s e s b e fo re d is a s s e m b ly .
2. P a y a tte n tio n to th e a ir h e a t e r m o u n tin g d ir e c tio n .
3. F o r in s p e c tio n o f a ir h e a te r , s e e G ro u p 1 6 .
B4556A
15-8
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
< 6 D 2 2 -T >
1 Earth plate
2 Inlet pipe
3 R ubber hose
4 A ir heater
5 Inlet m a n ifo ld
N O TE :
2. P a y a tte n tio n to a ir h e a te r m o u n tin g d ire c tio n .
3. F o r in s p e c tio n o f a ir h e a te r, s e e G ro u p e 1 6 .
B4557A
15-9
15 IN T A K E A N D EXHAUST - SERVSCE P R O C E D U R E S
< 6 D 2 2 -T C >
1 In let pipe
2 A ir escape pipe
3 W a te r in le t pipe
4 W a te r retu rn pipe
5 A fte r c o o le r assem bly
6 Earth plate
7 A ir heater
8 R ubber hose
MOTE:
2. P a y a tte n tio n to a ir h e a te r m o u n tin g d ir e c tio n .
3. F o r in s p e c tio n of a ir h e a te r, s e e C ro u p e 1 6 .
B4558A
15-10
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
5.2 REMOVAL AND OMSTALLATOON OF E X H A U S T S Y STE M
<6D22>
1 Heat in s u la to r
2 Exhaust m a n ifo ld
3 Seal ring
4 E xpansion ring
5 C enter e xha ust m a n ifo ld
B4560A
The e xhaust m a n ifo ld m o u n tin g nuts sh o u ld be

tig h te n e d to the specified to rq u e th ro u g h use o f
Socket (special to o l: MH061242).
15-11
15 IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES
<6D22-T, TC>
35 Nm
(3.6 kgfm )
26 Nm
(2.7 kgfm)
41 Nm
(4.2 kgfm )
Stam ped m ark "TO P"

Seal ring
To be installed w ith
stam ped m ark to w a rd m an ifo ld
Install the seal ring so th a t the ends o f each ring are positioned
180 apart fro m those o f the other.
Install the expansion ring so th a t any one o f its crests is not
p o sitio n ed at the seal ring ends.
1 Heat in s u la to r
2 Oil pipe
3 Oil retu rn pipe
4 T u rb o c h a rg e r
5 E xhaust m a n ifo ld
6 Seal ring
7 E xpansion rin g
8 C enter e xha ust m a n ifo ld
B4561A
The e xhaust m a n ifo ld m o u n tin g nuts sh o u ld be

tig h te n e d to the sp ecified to rq u e th ro u g h use o f
Socket (special to o l: M H061242).
15-12
5 .3 A m CLEANER
5 .3 .1 D is a s s e m b ly a n d R e a s s e m b ly
'S in g le e le m e n t ty p e >
A s s e m b lin g d ire c tio n m ark
< D o u b le e le m e n t t y p e > D ust cup
Do n o t re m o v e th e in n e r e le m e n t w h e n c le a n in g th e o u te r
V acuator va lve e le m e n t. E0158
15-13
5 .3 .2 In s p e c tio n a n d C le a n in g (3 ) In s p e c tio n o f E le m e n t
(1 )W h e n th e r e os D ry O u s t on th e E le m e n t
C7209A
A fte r th e e le m e n t has been cleaned, p u t an e le c tric
If there is d ry d u st on the e le m e n t, clean th e d ust by la m p inside th e e le m e n t to check fo r d am ag e and pin
b lo w in g 685 kPa (7 kg f/cm 2) o r lo w e r co m p re sse d air holes. If th ere are th in p o rtio n s in the filte r paper,
a gainst the elem ent. replace the e le m e n t. If th e packing on the to p surface
B lo w th e co m p re ssed air fro m insid e the e le m e n t up o f th e e le m e n t is broken, replace th e packing.
and d o w n a lo ng the frills o f the filte r p ap er and clean H I G le a n in g of A ir C le a n e r B o d y

the w h o le e le m e n t evenly. Clean the in sid e o f the air clea ne r b o d y and d isch arg e
M OTE; the d ep osite d dust.
H. O n o t s tr ik e th e e le m e n t @r s tr ik e it (5 ) In s p e c tio n o f P u s t In d ic a to r
a g a in s t a h a rd o b je c t to lo o s e n th e
d u s t.
2 . 0 n o t c le a n th e in n e r e le m e n t.
{2) W h e n th e r e is M o is t D u s t on th e E le
m ent
If the e le m e n t is co n ta m in a te d w ith m o is t soot,
're p la c e it regardless o f th e sp ecified re p la ce m e n t
freq ue n cy.
S ta rt the e n g in e and close the in le t p o rt o f a ir cleaner

g ra d u a lly to increase n eg a tive pressure. If th e red
sign al is d is p la y e d at the d u s t in d ic a to r, o r w a rn in g
lam p lig h ts fo r the e le c tric typ e, the d u s t in d ic a to r is
n orm a l.
M@TE;
Perform th is in s p e c tio n a f t e r c le a n in g or
r e p la c e m e n t o f th e a ir c le a n e r e le m e n t if
th e e le m e n t is h e a v ily c lo g g e d .
15-14
5 .4 TURBOCHARGER
5 .4 .1 T D 0 8 T y p e T u rb o c h a rg e r
11) D is a s s e m b ly
Blade bend and dam age,

corrosion, m arks of
interference on back surface 6
Interference w ith 5
com pressor wheel
Interference w ith
tu rb in e w heel, cracks
due to overheat, pitch in g ,
d e form a tion
Blade bend and dam age,

co rro sio n , marks o f interference
on back surface
Interference w ith tu rb in e
w heel, dam age
Bearing hole surface roughness,

dam age, gas corrosion, tu rb in e
side flange d e form a tion
D isassem bly sequence

1 C ou p lin g a ssem bly 10 T h ru s t sleeve
(2) T u rb in e h ou sin g 11 T h ru s t bearing
3 Snap ring assem bly 12 T h ru s t ring
C om p re sso r co ver 13 S h aft and tu rb in e w he el
5 C om p re sso r w h e e l 14 Piston ring
6 Snap ring 15 T u rb in e back p late
Insert 16 Bearing
8 Piston ring 17 Snap ring
9 Oil d e fle cto r 18 Bearing h ou sin g
For parts w ith an encircled num ber, refer to D isassem bly

Procedure that fo llo w s.
C8965B
15-15
INTAKE AND EXHAUST - SERVICE PROCEDURES
D isas sem b ly P ro c ed u re (c) R em o val of co m p re s s o r c o v e r
(a) B efore d isa sse m b lin g th e tu rb o c h a rg e r, m ake R em ove the c o m p re s s o r co ve r by ta p p in g it w ith a

a lig n m e n t m arks on the c o m p re s s o r cover, bearing p la stic h a m m e r w ith the snap rin g loosened.
h o u sin g , and tu rb in e h o u sin g so th a t th e y can be NOTES
p ro p e rly reassem bled. U se c a re not to d a m a g e th e co m p res so r
(b) R em o val of tu rb in e housing w h e e l during th e rem o va l p ro ced u re.
(d) R em o val of c o m p res so r w h e e l
To rem ove the tu rb in e h o u sin g , re m o ve the c o u p lin g

a ssem bly and tap the h o u sin g w ith a p la stic h a m m e r 1) Fit the bea rin g h o u sin g into th e tu rb in e h ou sin g
o r s im ila r to o l to p re ve n t d am ag e to it. w h ic h is cla m p e d in a vise.
MOTEs
T h e tu rb in e w h e e l b la d e s a re ea s y to bend.
U se c a re not to d a m a g e th e m .
15-16
IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S 15
{e} R em o ve ftline in s e rt.
2) W h ile h o ld in g the sh aft and tu rb in e w he el boss,

rem ove the lock n u t th a t secures the c o m p re s s o r 1) R em ove the snap ring.
w heel.
M OTE;
[Retain th e snap ring by hand to p re v e n t it
from springing out w h en slip ping offff th e
snap ring p liers.
2) Fit the tip o f a s c re w d riv e r in to the p o rtio n o f the

inse rt sh o w n and c a re fu lly rem ove it fro m the bearing
h ousing.
15-17
(2 ) C le a n in g a n d In s p e c tio n
C8988B
15-18
(a ) C le a n in g
T u rb o c h a rg e r m a n u fa ctu re rs use a b la s tin g e q u ip
m e n t fo r cleaning parts at th e ir w o rk s h o p s . As an
a lte rn a tive e ffective m e th o d fo r o v e rh a u l at the
d ealer's w o rksh o p , use the fo llo w in g procedures.
W hen a c o m m e rc ia lly a va ila b le neutral d e te rg e n t is
used fo r cleaning, m ake sure th a t it does n o t co nta in
co rro sive co m p o n e n t.
1) Before clea nin g, v is u a lly check the c o n d itio n o f

the parts. Check fo r burns, w ea r, etc. w h ic h co uld n ot
be id e n tifie d after w a sh in g .
4) Clean d ep osits, using a p la stic scraper or bristle

brush.
M OTE;
(Use c a re So p re v e n t d a m a g e t p arts.
2) Im m erse all the parts in a n o n -in fla m m a b le s o l

ve n t (D aido kagaku K o g yo 's Dai C leaner T-30 o r
e qu iva len t) to clean o ily c o n ta m in a tio n .
5) B lo w clean co m p re sse d air again against the

e n tire in te rn a l and e xte rn a l surfaces.
MOTE:
T h e b ea rin g housing and tu rb in e w h e e l
s h a ft should be re -im m e rs e d in a non-
in fla m m a b le d e te rg e n t a fte r S tep 4). A fter
d ep o sits have b een re m o ve d , blow co m
p ressed air.
3) B lo w clean com p re ssed a ir a g a in st th e e ntire

inte rn a l and e xterna l surfaces.
15-19
15 IN T A K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S
2) M easure I.D., O.D., and len gth o f the bearing. If

the m easured values exceed the service lim it, replace
the bearing.
6) To p re ven t rust, a p p ly e ng in e o il to the e ntire

in te rn a l and e xterna l surfaces o f th e bea rin g h o u sin g ,
tu rb in e h ou sin g and tu rb in e backing plate and the
sh a ft p o rtio n o f th e sh a ft and tu rb in e w heel.
3) M easure the s h a ft and tu rb in e w he el jo u rn a l
(b) In s p e c tio n d ia m e te r. If the m ea sured d ia m e te r is less than the
lim it, replace the s h a ft and tu rb in e w heel.
C9034A
1) If th e bearing hole d ia m e te r and p is to n rin g hole

d ia m e te r are b e yo n d the lim it, replace the bearing 4) Set a dial in d ic a to r beside th e th re a d e d p o rtio n of
h ousing. the s h a ft to m easure the c o n c e n tric ity .
If the d e fle c tio n o f the dia l in d ic a to r is beyond the
lim it, replace th e tu rb in e w he el shaft.
NOTE:
Do not c o rre c t b u t re p la c e a b en t sh a ft.
15-20
5) Insert
Insert a new p isto n rin g securely in th e bore in the

in se rt and m easure the end gap o f the p iston ring.
If the end gap is o u t o f s p e cifica tio n , replace the
insert.
(3 ) R e a s s e m b ly
For parts w ith an encircled nu m b e r, refer to Reassembly

Procedure that follow s. C8974B
15-21
R e as s e m b ly Procedale (b) In s ta lla tio n off snap ring

(a) In s ta lla tio n f p isto n ring
Set the th ru s t sleeve in to the o il d e fle cto r, and install

th e p iston ring.
^ T E s
1. W hen m ounting pisto n ring to th e th ru s t
s le e v e , en s u re th a t th e ring is not e x
panded and ring ends a re not tw is te d .
2. Df th e piston ring is to be re p la c e d w ith a
n e w one, be sure to re p la c e also th e
th ru s t s le e v e and s h a ft a n il tu rb in e Install th e snap ring to the bearing hou sin g w ith its
w h e e l w ith n e w ones. ta p e r up.
A fte r in s ta lla tio n , using a s c re w d riv e r d rive the snap
ring in to the g ro o v e in the bea rin g hou sin g by
h u m m e rin g .
M OTE:
1. R e ta in th e snap ring fey hand to p reve n t
it fro m springing out w h en slipping off
th e snap ring p liers.
2. S p e c ia l c a re m ust be e x e rc is e d , w hen
ta p p in g th e snap ring in to position, to
p re v e n t d a m a g e to th e bearin g housing
fey th e s c re w d riv e r.
15-22
IN TA K E A N D EXHAUST - S E R V IC E P R O C E D U R E S 05
(c) M e a s u re m e n t off c le a ra n c e b e tw e e n 2) Coat th re ad s in the sh a ft and tu rb in e w h e e l w ith
sh aft and tu rb in e w h e e l and tu rb in e m o ly b d e n u m d is u lfid e base grease (NLGI N o .2) Li
housing s o a p a n d m o u n tth e c o m p re s s o r w he el o n to th e shaft.
3) H old in g th e boss on the tu rb in e w he el side,
tig h te n the c o m p re s s o r w he el lock n u t to the specified
to rq ue .
M OTE;
S e t th e bearing housing c a re fu lly to p re
ven t d a m a g e on th e tu rb in e wSneel blades-
Set the dial gauge on the sh aft and tu rb in e w he el end.

M ove the shaft and tu rb in e w heel in the axial
d ire ctio n and m easure th e clearance b etw een the
tu rb in e w he el and tu rb in e h ou sin g.
If the clearance is o u t o f sp e cifica tio n , d isassem ble
and isolate th e cause.
(d) In s ta lla tio n off c o m p res so r w h e e l (e) Set a dia l gauge on the sh aft and tu rb in e w heel
end.
W ith c o m p re s s o r w h e e l m o ve d in th e axial d ire ctio n ,
m easure the end play. If the p lay is o u t o f sp ecifica
tio n , d isassem ble and check to locate the cause.
(f) W ith the tu rb in e h o u s in g re m o ve d fro m the

bearing h ou sin g and c o m p re s s o r co ver installed,
m easure th e fo llo w in g .
1) H old in g the tu rb in e h o u sin g in a vice, set the

tu rb in e w he el side o f the bea rin g h o u sin g into the
tu rb in e h ou sin g.
15-23
U sing tw o thickness gauges, m easure the clearance (h) In s ta lla tio n of tu rb in e housing and co m
b etw een the tu rb in e back p late and tu rb in e w he el pressor cotter
back surface. If th e clearance is o u t o f sp e cifica tio n ,
d isa ssem b le and check to locate the cause.
NO TE:
lie sure to use tw o th ic k n e s s g au ges and
ta k e m e a s u re m e n t a t th e tip of th e blad es.
(g) S h aft and tu rb in e w h e e l to co m p res so r
cotter c le a ra n c e
Make sure th a t the a lig n m e n t m arks are a ligned and

secure the parts w ith the c o u p lin g assem bly and snap
ring.
Install the c o u p lin g a sse m b ly by the fo llo w in g proce
dures.
1) T ig h te n the c o u p lin g assem bly to specified to r

que.
Check by the fo llo w in g pro ced ures. 2) H am m er the c o u p lin g assem bly all around.
3) T ig h te n again the c o u p lin g assem bly to specified
1) M ove up and d o w n the co m p re s s o r w he el to
to rq ue .
m easure ru n o u t (R)
4) A fte r reassem bly, tu rn the tu rb in e w heel and
MOTE: co m p re sso r w he el by hand and check fo r sm o o th
0@ not m e a s u re runou t by turnin g th e ro ta tion .
co m p res so r w h e e l. If the w heels tu rn h ea vily, o r b in d , d isassem ble, and
2) M easure c o m p re sso r co ve r insid e d ia m e te r (D) locate the cause o f tro u b le .
and co m p re sso r w he el o u tsid e d ia m e te r (d) at places
ind icate d in the illu s tra tio n .
3) C alculate the clearance by th e e q u a tio n given
b elow .
If it is o u t o f sp e cifica tio n , d isa ssem b le and check
again.
Clearance = 1/2(D - d - R)
15-24
5 .4 .2 4LF Typ e T u rb o c h a rg e r
See pages d e scrib in g the TD08 tu rb o c h a rg e r fo r
disa ssem b ly, in sp e ctio n , clea nin g and rea ssem bly
procedures.
(1) D isassem bly
<Disassembly sequence> flange de form a tion
1 V-clamp 10 Piston ring 18 Bearing

2 Turbine housing 11 Flinger sleeve (ft) Snap ring
3 V-clamp 12 Oil deflector @ Snap ring
4 Compressor cover 13 Thrust ring 21 Oil control sleeve
5 Compressor wheel 14 Thrust bearing 22 Bearing
6 Shaft and turbine wheel 15 Sleeve @ Snap ring
7 Piston ring 16 Thrust ring 24 Turbine back plate
8 Snap ring 7) Snap ring 25 Bearing housing
9 Insert
For parts w ith an encircled nu m b e r, refer to D isassem bly Procedure
th a t follow s.
NOTE:
1 . M a k e a lig n m e n t m a rk s to c la rify th e p o s itio n a l r e la 2. T h e c o m p re s s o r w h e e l a n d tu rb in e w h e e l b la d e s a re
tio n s h ip s a m o n g th e c o m p re s s o r c o v e r, b e a rin g h o u s e a s ily b e n t. U s e c a re n o t to a llo w th e m to fa ll a n d n ot
ing a n d tu rb in e h o u sin g b e fo re d is a s s e m b ly . to s tr ik e th e m .
3. Do n o t re m o v e th e tw o p in s of th e b e a rin g h ou sin g.
B4265A
15-25
D is a s s e m b ly p ro c e d u re W hen the snap ring h o ld in g the bearing in p o s itio n is

to be rem ove d, use p lie rs (tip d ia m e te r 1 m m ) to
p re ve n t dam age to the insid e o f the bearing h ou sin g.
(2 ) C le a n in g a n d (In s p e ctio n
15-26
flai M e a s u re m e n t of piston ring groove (b) M e a s u re m e n t off flin g e r s le e v e groove
w id th w id th
Install a n ew p iston rin g in th e p isto n ring g ro o ve and M easure the p iston rin g g ro o v e w id th o f the flin g e r
m easure th e clearance. sleeve.
If the reading is m o re th an the lim it, replace th e sh aft If th e rea din g is m ore th an the lim it, replace the
and tu rb in e w heel. flin g e r sleeve.
15-27
(3 ) Reassreiis8y

25- 24$3>>2221 @
18(7)-
16 > 15 >(14)
N O TE : 6>7
1. T h e p is to n rin g s h o u ld a lw a y s b e re p la c e d w ith a n e w
13 12
o ne. 9>8>5>4>3>2>1
S in c e it is e a s ily b ro k e n , do n o t o p e n it m o re th a n 11 10
n e c e s s a ry .
2. A p p ly e n g in e o il to a ll s lid in g s u rfa c e s b e fo re in s ta lla On parts m arked o, refer to the assem bly procedure described
below.
tio n .
3. W h en th e c o m p re s s o r c o v e r and tu rb in e h ou sin g a re
in s ta lle d , m a k e s u re t h a t th e ir a lig n m e n t m a rk s a re in
a lig n m e n t w ith th e m a r k s on th e b e a rin g h ou sin g.
B4268A
15-28
A ssem bly P ro c ed u re (e]| M easuring c le a ra n c e s b e tw e e n sh aft
(a) In s ta llin g snap rings and tu rb in e w h e e l and tu rb in e housing,
and co m p resso r w h e e l and com pressor
cower in d ia m e tric a l d ire c tio n
Use pliers (tip d ia m e te r 1 m m ) in in s ta llin g snap rings.
MOTls
M easure each clearance w ith a thickness gauge to
QnstaDII e a c h snap ring w ith its round side
check th a t it is w ith in the n o m in a l value.
to w a rd th e b earin g .
MOTEs
(b) In s ta llin g th ru s t bearin g
W hen a c le a ra n c e is to be m eas u red , press
th e s h a ft in th e a x ia l d ire c tio n to m in im ize
th e c le a ra n c e .
To install the th ru s t b earing, a p p ly eng in e o il to the

th ru s t rece ivin g side. Press it in w ith its lo c a tin g hole
in a lig n m e n t w ith th e lo ca tin g pin o f the bearing
h ou sin g u n til it is in fla t co n ta ct w ith th e bearing
h ou sin g.
15-29
5 .4 .3 3 L M T y p e T urbocharges-
See pages d e scrib in g th e TD08 tu rb o c h a rg e r fo r
d isa ssem b ly, insp e ctio n , clea nin g and reassem bly
procedures.
Interference w ith
co m pre sso r w heel
2
>
Blade bends,
dam age, c o rrosio n ,
m arks o f interference
on back surface &
Interference w ith
tu rb in e w he e l, dam age
Interference w ith
tu rb in e w he e l, cracks
due to overheat,
12 p itc h in g , d e fo rm a tio n
Blade bends, dam age
c o rrosio n , m arks of
interfe re n ce on back surface,
dam aged seal rin g g ro o ve
B earing hole surface

roughness, dam age,
gas co rro s io n , tu rb in e
side fla ng e d e fo rm a tio n
(T) Turbine housing 6 Flinger sleeve 11 Bearing housing
@ Compressor cover 7 Piston ring 12 Shaft and turbine wheel
3 Compressor wheel 8 Oil deflector 13 Piston ring
4 Snap ring 9 Thrust ring 14 Turbine backing plate
5 Insert 10 Thrust bearing 15 Bearing
For parts w ith an e ncircled n um b e r, refer to D isassem bly P rocedure th a t
fo llo w s.
N O TE :
1. B e fo re d is a s s e m b ly , m a k e a lig n m e n t m a rk s to in d i
c a te th e p o s itio n a l re la tio n s h ip s a m o n g th e c o m p re s s
o r c o v e r, b e a rin g h ou sin g and tu rb in e h o u sin g .
2. T h e c o m p re s s o r w h e e l a n d tu rb in e w h e e l b la d e s a re
e a s ily b e n t. U s e c a re n o t to a llo w th e m to fa ll a n d n o t
to s tr ik e th e m .
3. Do n o t re m o v e th e tw o p in s o f th e b e a rin g h o u s in g .
B9029A
15-30
IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S 15
D isassem b ly P ro c ed u re
(b) Rem ove the c o m p re s s o r cover.
(a) Rem ove the tu rb in e h ou sin g.
MOTE:
0 not drop and s trik e th e compresses'
w h e e l and tu rb in e w h e e l, as th e ir blades
a re re a d ily b en t.
15-31
15 IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S
(2 ) C le a n in g a n d (In s p e ctio n
Bearing hole d iam eter

L 19.06
N O TE :
The p a rts m ay be c le a n e d by use of a b la s t
e q u ip m e n t o r a n y o th e r e ffe c tiv e m e th o d s , b u t a non-
c o rro s iv e n e u tra l d e te rg e n t sho uld b e u se d .
B9034B
15-32
IN T A K E A N D EXHAUST - SERVJCE P R O C E D U R E S 15
(3) Reassembly
Bend lock washer. S haft and tu rb in e w he e l to

N om in al Value A p p ly e ng in e oil.
17 N m (1.7 kgfm ) tu rb in e h o u sin g clearance
NV 0.53 to 1.04
S haft and tu rb in e w heel

N o n -ch a m fe red side a xial play
to w a rd insert NV 0.05 to 0.13
13 A p p ly e ngine o il.
17 to 20 Nm
(1.73 to 2.07 k g fm ) '
T u rb in e backing p late to
sh aft and tu rb in e w he e l clearance
NV 0.74 to 1.55
< A s s e m b ly se quence>
Gasket
11 14 13 12 15 do:
15 5 - ,1
A p p ly engine o il.
B ronze side to w ard
A p p ly grease or o il co m pre sso r w heel For parts w ith an e ncircled num ber,
to socket p o rtio n . re fe r to R eassem bly Procedure th a t fo llo w s .
NOTE:
1. T h e p is to n rin g sh o u ld a lw a y s b e re p la c e d w ith a n e w
o n e . S in c e it is e a s ily b ro k e n , do n o t o p e n it m o re th a n
n e c e s s a ry .
2. A p p ly e n g in e oil to a ll s lid in g s u rfa c e s b e fo re in s ta lla
tio n .
3. W h en th e c o m p re s s o r c o v e r and tu rb in e h o u s in g a re
in s ta lle d , m a k e sure th a t th e ir a lig n m e n t m a rk s a re in
a lig n m e n t w ith th e m a rk s on th e b e a rin g h o u sin g .
B9037A
15-33
15 IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES
R e assem b ly P ro c ed u re
(c) Install th e tu rb in e h o u sin g tig h te n in g the b olts to
(a) A p p ly engine o il to b oth sides o f the th ru s t the sp e cifie d to rq ue .
bearing and th ru s t rin g b efo re a ssem bling them on MOTEs

the tu rb in e w heel shaft. Then install th e o il deflector. Apply an a n ti-s e izu re a g e n t to th e cap
MOTEs s c re w .
[Install th e th ru s t bearin g w ith th e bronze
side up.
(b) Install the c o m p re sso r co ver by tig h te n in g the

b olts to th e specified to rq u e .
15-34
S .5 A F T E R C O O LE R
5 .5 . H D is a s s e m b ly , In s p e c tio n a n d R e a s s e m b ly
5 .5 .2 A ir-p re s s u re T e s t
C on du ct th e a ir-pressu re te st to check fo r w a te r leaks
due to d am aged core. To check, a p p ly an a ir pressure
o f 195 kPa (2 kg f/cm 2) to the core. Replace the core if it
is leaking a ir or o th e rw is e defective.
M OTE?
M e y e r a p p ly p re s s u re o y e r s p e c ific a tio n .
15-35
15 INTAKE AND EXHAUST - TROUBLESHOOTING
6. TR O U B LES H O O TIN G
L ow o u tp u t In su fficie n t intake a ir
Loaded a ir clea n e r e le m e n t Clean
A ir su ction (w ith d u st and o th e r fo re ig n m a tte r)

fro m intake system Repair
o D efective tu rb o ch a rg e r
T u rb o ch a rg e r ro ta tio n failu re
Seized bearing Replace
o C arbon d e p o sit on tu rb in e w heel Clean
o T u rb in e w h e e l and tu rb in e back p late in te rfe rin g Check
o T u rb in e w h e e l and tu rb in e h o u sin g in te rfe rin g Check
Bent sh aft and tu rb in e w heel Replace
C om p re sso r w he e l and c o m p re s s o r c o v e r in te rfe rin g Check
o Seized th ru s t sleeve a n d /or th ru s t bearing Replace
o In co rrect slid in g betw een inside parts Clean, check

due to c lo g g e d lu b ric a tin g o il pipe
o Dam aged co m p re sso r w heel Replace
Dam aged tu rb in e w he e l Replace
L ow exhaust e fficie n cy
D eform e d fro n t pipe, m u ffle r a n d /or tail pipe Replace
(large exha u st resistance)
Q D efective tu rb o ch a rg e r
T u rb o ch a rg e r ro ta tio n fa ilu re (See above) Check
o Dam aged tu rb in e w he e l Replace
W h itish and In co rrect in je ctio n tim in g A d ju s t G roup 13

m uch exhaust
gas L ow co m p re ssio n pressure Check G ro u p 11
L o w q u a lity fuel Replace G ro u p 13
D efective tu rb o c h a rg e r
Oil leaks due to w o rn p iston rin g , a n d /or in s e rt Replace
Dam aged o il seal due to clog g e d o il re tu rn pipe Replace
Dark and m uch Loaded air cleaner e le m e n t Clean

exhaust gas
T ro u b le in e ng in e p ro p e r Check G ro u p 11
N o n u n ifo rm fuel in je c tio n a m o u n t to cylin d e rs A d ju s t G ro u p 13
A b n o rm a l noise P oor co nn e ctio n o f intake and exhaust system s C orrect

a n d /o r v ib ra
tio n fro m D efrom e d fro n t pipe, m u ffle r o r ta il p ip e (large exhaust resistance) Replace
intake and
exhaust system D efective tu rb o c h a rg e r (See above) Check
15-36
16
ENGINE ELECTRICAL.
CQ W TE1TS
1. G E N E R A L ...................................... 2 5.3 3 0 A ,4 Q A , 80A A LTER N A TO R 34

1.1 S T A R T E R ................................... 3 5.3.1 R em o val and In s ta lla tio n ... 34
1 .2 A L T E R N A T O R ............................ 5 5 .3 .2 D isassem b ly ...................... 35
1 .3 S A F E T Y (RELAY .......................... 8 5 .3 .3 In s p e c tio n ......................... 38
1 .4 R E G U L A T O R .............................. 9 5 .3 .4 R easse m b ly ....................... 44
1 .5 1NTAECE ABR (HiEATER ................. 10 5 .3 .5 In s p e c tio n asid A d ju s tm e n t
1 .6 A U T O M A T IC S T O P D E V IC E ....... 10 a fte r In s ta lla tio n ............... 46
2 . S P E C IF IC A T IO N S .......................... 13 5 .4 SOA A LTER N A TO R ................ 49
3 . S E R V IC E S T A N D A R D S .................. 14 5.4.1 R em o val and In s ta lla tio n .. 49
3.1 S E R V IO ! S T A N D A R D T A B L E ..... 14 5 .4 .2 D isassem b ly ...................... 49
3 .2 T IG H T E N IN G T O R Q U E T A B L E ... 16 5 .4 .3 In s p e c tio n ......................... 50
4 . S P E C IA L T O O L .............................. 17 5 .4 .4 R e asse m b ly ....................... 51
5 . S E R V IC E P R O C E B U R E S ................ 17 5 .4 .5 In s p e c tio n and A d ju s tm e n t
5.1 STARTER ................................... 17 a fte r R e asse m b ly ..............
5 .1 .1 R e m o v a l a n d In s ta lla tio n ....... 17 5 .5 SA FE TY RELAY
5 .1 .2 D is a s s e m b ly ........................... 18 [M od el R 8 T30171J ................ 53
5 .1 .3 In s p e c tio n .............................. 22 5 .6 REG U LATO R
5 .1 .4 R e a s s e m b ly ............................ 28 [M od el R 7 T 0 1 0 7 1 ] ................ 54
5 .1 .5 In s p e c tio n a Did A d ju s tm e n t 5.7 PR EH EA TER ......................... 54
a fte r R e a s s e m b ly ................... 32 5.7.1 In ta k e Air H e a te r ............... 54
5 .2 S T A R T E R R E L A Y ....................... 34 5 .7 .2 H e a te r R elay ..................... 55
5 .8 A U T O M A T IC STO P DEVIC E .. 55
5.8.1 E n erg ize -to -sto p Typ e ..... . 55
5 .8 .2 E n ergize-to-ru n T yp e ......... 59
6. T R O U B L E S H O O T IN G ............... 63
16-1
16 ENGINE ELECTRICAL - GENERAL
1. GENERAL
16-2
E N G IN E E L E C T R IC A L - GENERAL 16
1.1 S ta rte r (2) O verrunning C lu tch
The sta rter is a red uctio n sta rte r w ith a b u ilt-in

re d u ctio n gear. Its m o to r has been d ow nsized w ith
even h ig h e r speed c a p a b ility.
M a jo r co m p o n e n ts o f the sta rte r are: m o to r section
g en eratin g p o w e r; the o v e rru n n in g clutch section
tra n s m ittin g a rm ature to rq u e and p re ve n tin g the
e n g in e fro m o v e rru n n in g a fte r sta rtu p ; the m ag ne tic
sw itch section w hich puts the p in io n in m esh w ith the
rin g gear and feeds load c u rre n t in to the m o to r; and,
the red uctio n gear section re d ucin g a rm ature speeds
and tra n s m ittin g to rq u e to the p in io n .
(1) R eductio n deas1 S e ctio n
The o v e rru n n in g clutch is o f ro lle r type.

Each ro lle r is set in the w e d ge -sha pe d g ro o ve p ro
vide d by the o u te r and in n e r races (p in io n ) and is
pressed by a sp rin g .
The ro lle r is pressed a g a in st the n a rro w e r side o f the
g ro o ve by the s p rin g tra n s m ittin g o u te r race ro ta tio n
to the p in io n by its w e d g e action. On th e o th e r hand,
no to rq u e is tra n s m itte d fro m th e p in io n as the ro lle r
m oves to th e w id e r side releasing th e w e d g e action.
The end o f the a rm a tu re sh a ft is shaped as a gear and

is in m esh w ith the inte rn a l gear. A fte r red uctio n by
th e inte rn a l gears, the to rq u e is m u ltip lie d several
tim e s and is tra n s m itte d to the p in io n .
16-3
(3 ) O p e ra tio n
B3708B
W hen the p in io n com es in to c o m p le te m esh w ith th e
W h ile th e sta rte r sw itch is ON, cu rre n t flo w s fro m the rin g gear, th e c o n ta c t " P i" closes and the large
c u rre n t o f the b a tte ry d ire c tly flo w s to the m o to r
te rm in a l "S W " o f the sta rte r relay to the te rm in a l "L "
and closes the co n ta ct "P 2". se ction to tu rn th e p in io n p o w e rfu lly .
W hen the co n ta ct "P 2 " closes, cu rre n t fro m the In th is c o n d itio n , no c u rre n t flo w s to the p u ll-in co il.
b a tte ry flo w s fro m th e te rm in a l " S " o f the m a g n e tic The p lu n g e r is reta ine d by the h o ld in g coil alone.
sw itch to the p u ll-in coil "P " and h o ld in g co il "H ".

F urtherm ore, the c u rre n t th a t has decreased flo w s
fro m the te rm in a l " M " to th e m o to r section.
The p lu ng er, a ttracte d by the m a g n e tic flu x o f the
p u ll-in coil and h o ld in g co il, closes the co n ta ct " P / '
and s im u lta n e o u s ly pushes o u t the p in io n tu rn in g
s lo w ly on w eak cu rren t.
16-4
1 .2 ALTERNATOR
(1 )3 0 A , 40A , 8 0 A A lte rn a to r
The a lte rn a to r is a brush typ e in w h ic h a c u rre n t flo w s

fro m th e brushes th ro u g h the slip rin g to the fie ld coil
in the roto r.
M a jo r c o m p o n e n ts in c lu d e : the ro to r (field co il) th a t
generates m a g n e tic fie ld ; the sa tor th a t generates
e le c tro m o tiv e fo rce ; the re c tifie r th a t re c tifie rs elec
tro m o tiv e fo rce so g en erated ; the re g u la to r th a t
keeps g enerated vo lta g e constant.
W hen the sta rte r sw itch is set to OFF, the contact
p o in t P2 opens. Ja) Rotos-
The m o m e n t the sta rter sw itch is opened, the Pi is
still in closed p o sitio n and the b a tte ry cu rre n t flo w s
fro m the B te rm in a l to the p u ll-in coil (P) and h o ld in g
coil (FI).
Since the d ire ctio n o f c u rre n t th a t flo w s is reverse, the
m a g n e tic flu xe s cancel each o the r, and the return
sp ring pushes the p lu n g e r back to its o rig in a l p o s i
tio n . A t the sam e tim e , th e co n ta ct p o in t Pi opens, so
the cu rre n t to the m o to r section is cut off.
W hen th e ro to r is d riv e n by the p u lle y ro ta tio n , a

c u rre n t flo w s fro m the brushes, th ro u g h th e slip ring,
to the fie ld co il. The ro to r core tabs th e n becom e
m a g n e tic poles.
16-5
(Ib) Stator (d) Regulator
The re g u la to r alters the s tre n g th o f the fie ld coil fie ld

to sta bilize o u tp u t p o w e r w h ic h va ries w ith engine
T o g e th e r w ith the ro to r core, the sta to r core fo rm s the
speed flu c tu a tio n s .
m a g n e tic flu x path. The m a g n e tic flu x lines in the
The re g u la to r is in te g ra l w ith the brush holder. The
sta to r core are affected by the passage o f the ro to r
a s s e m b ly c o m b in e s the IC re g u la to r, the brushes and
core fie ld and g enerate e le ctricity.
th e brush springs.
(c) (Rectifier
(e) Charging circuit
1) S e ttin g the starter switch t M
The re c tifie r m a in ly co n sists o f 3 d io d e trio s , 6 dio de s

and 2 heat sinks. It re ctifie rs th e AC sta to r o u tp u t to
DC pow er.
Each heat sink has the ( + ) o r (-) leads fro m 3 dio de s
attached to it, p e rfo rm in g fu ll w ave re c tific a tio n fo r
3-phase AC.
On th e 80A a lte rn a to r, tw o o f re ctifie rs o f th is typ e are
p ro vid e d .
16-6
2) S tartin g th e engine (2 )6 0 A A lte rn a to r
A lte rn a to r
Starter sw itch
W hen the engine is started and the a lte rn a to r starts The 60A a lte rn a to r is an open typ e thre e-p ha se
g en eratio n so th a t the vo lta g e at the a lte rn a to r "B " a lte rn a to r. The th re e-p ha se AC g enerated in the sta to r
te rm in a l becom es h ig h e r than the b a tte ry vo lta g e , the coll is co n ve rte d into DC by the s ilic o n diodes.
cu rre n t flo w s as sh o w n below . A to ta l o f 12 dio de s (6 on the p o s itiv e side and 6 on
the n eg ative side) are housed in 6 heat sinks, tw o in
each heat sink.
The a lte rn a to r g enerated vo lta g e is c o n tro lle d by th e
re g u la to r.
In th is w ay, b a tte ry charge is sta rted and at the sam e

tim e , the charge lam p (if p ro vid e d ) goes out.
16-7
1 .3 SAFETY RELAY The a lte rn a to r rpm is detected and w h e n it exceeds

the reference level, the safety relay p re ve n ts the
sta rte r fro m o p e ra tin g even if its s w itc h is a cc id e n ta lly
tu rn e d on d u rin g eng in e re v o lu tio n .
O p e ra tio n
B1454A
(1) W hen the sta rte r sw itch is set to ON, c u rre n t flo w (3) W hen th e pulse fre q u e n c y at te rm in a l "P " e x
fro m the sta rte r relay to te rm in a l " S " and to te rm in a l ceeds th e sp e cifie d va lu e, c o n tin u ity betw een te rm in
"E " o f the safety relay, c lo sin g c o n ta ct Pi. The charge als " S " and "E " is lost. Then, the sta rter does n ot
lam p also illu m in a te s if p ro vid e d . o perate even if th e sta rte r s w itc h is set to ON w h ile
(2) As the sta rter runs and the e n g in e sta rts ru n n in g , the e n g in e is ru n n in g .
pulses o f fre q u e n cy 1/1 Oth o f the a lte rn a to r speed
appear at te rm in a l "P " o f the a lte rn a to r. The charge
lam p goes out.
16-8
1 .4 R E G U L A T O R {M o d e l R 7 T 0 1 0 7 1 ) Its fu n c tio n s in c lu d e :
(1) V oltage re g u la to r
M a in ta in s vo lta g e g enerated by the g e n e ra to r c o n
stant
(2) S afety relay

Keeps the sta rte r c irc u it in OFF state even w ith the
s ta rte r s w itc h tu rn e d on d u rin g o p e ra tio n o f engine.
(3) Field relay

M in im iz e s d isch arg e c u rre n t to the a lte rn a to r fie ld coil
even w h e n the b a tte ry s w itc h is left closed.
C on ne ction s o f the a lte rn a to r to th e re g u la to r are

sh o w n b e lo w . F o llo w in g d e s c rip tio n o f o p e ra tio n s is
keyed to th is fig u re .
This re g u la to r is c o m b in e d w ith the 60A a lte rn a to r,
peraftiora o R e g u la to r
S afety relay T ra n s is to r
B1891A
(1) The b a tte ry sw itch in ON p o s itio n causes fie ld p o w e r, causing a c u rre n t to flo w in the c o il VC i in the
cu rre n t to flo w in the c irc u it as fo llo w s : fo llo w in g sequence:
B attery * B a tte ry sw itch * R eg u lator IG te rm in a l * R esistor Ri * V oltage A lte rn a to r N te rm in a l R eg u lator N te rm in a l * Coil VC i > G round
re g u la to r K te rm in a l V o lta ge re g u la to r F te rm in a l A lte rn a to r F te rm in a l
> Field c o il G ro u n d
As the coil VC i is energized, th e c o n ta ct Pi is opened.
(2) W hen the sta rte r sw itch is set to ON, th e sta rter In th is state, se ttin g the sta rte r s w itc h to ON w ith the
relay coil is energized w ith its co n ta ct closed. W hen e n g in e in o p e ra tio n leaves th e s ta rte r ino pe rative .
th e sta rter cranks the e ngine, the a lte rn a to r generates
16-9
(3) W h ile the eng in e is in o p e ra tio n , fie ld cu rre n t 1 .5 IN T A K E AOR H E A T E R

flo w s in the fo llo w in g circu its, w ith a lte rn a to r o u tp u t
vo lta g e c o n tro lle d by the vo lta g e re g u la to r.
A lte rn a to r A te rm in a l R eg u lator A te rm in a l C ontact Pt V oltage
re g u la to r K te rm in a l -> T ra n sisto r R eg u lator F te rm in a l A lte rn a to r F
te rm in a l > Field c o il G ro u n d
If the tra n s is to r rem ain s o ff to o lo n g , the a lte rn a to r N

te rm in a l o u tp u t is decreased and the coil VC i loses its
m a g n e tic fo rce to such an e xte n t th a t the c o n ta ct P2
m ay be opened o r Pi closed. The c irc u it o f coil VC2
and re sisto r F2 keeps P2 closed and Pi open in such a
case.
The intake a ir hea ter is an e le c tric heater w h ich heats

the intake a ir to fa c ilita te e n g in e sta rtin g.
Place the sta rte r sw itch to HEAT p o s itio n to operate
the heater. If c u rre n t is s u p p lie d fo r a b o u t 40 to 60
seconds by keeping the s ta rte r sw itch at HEAT
p o s itio n , th e te m p e ra tu re o f th e intake air heater w ill
exceed 800C.
The intake air heater c irc u it has an in d ic a to r to let the
d riv e r recognize the heat c o n d itio n . For sa fety's sake,
a fuse is p ro v id e d in the heater relay.
1 .6 A P T O M A T ie S T O P BEWSCE
If th e c o o la n t te m p e ra tu re rises o r the o il pressure
fa lls w h ile the e n g in e is ru n n in g , th is device operates
the sto p leve r o f the in je c tio n p u m p g o v e rn o r to cut
fu el s u p p ly and a u to m a tic a lly stops the engine.
16-10
ENGINE ELECTRICAL - GENERAL
(1) E n ergize-to-sto p Type
So le n oid relay
VRi
S)<@
A lte rn a to r
Solenoid
T herm o sw itch
i---------------- Stop 'j -
^switch H
Pressure sw itch l"'"'
r e la y H ^
Battery sw itch
1
Oil pressure
B4926C
{a) S t a r t crcyt 4) In the c o n d itio n o f th e above ite m 3), the oil
1) W hen the b a tte ry sw itch is placed at "O N ", pressure rises as the e n g in e speed increases, and the
cu rre n t flo w s fro m the so le n o id relay (B) to the RY coil co nta ct o f the oil pre ssure sw itch is opened and no
and applies the vo lta g e to the co lle c to rs o f TR4 and vo lta g e a pp lie d fro m R4 to T R i. In th is c o n d itio n , the
TR5 but RY does n ot operate, as th ere is no in p u t to a lte rn a to r vo lta g e is a pp lie d up to th e base o f TRi
the base. w h ile the eng in e is ru n n in g .
2) C urren t also flo w s fro m the o il pressure sw itch to (b) A u t o m a t i c s t o p c i r c u i t

the so le n o id relay (W) to R4 to Rs and app lie s the W hen the th e rm o s w itc h and oil pressure sw itch
vo lta g e to th e base o f TR3. W hen the v o lta g e is detect an a b n o rm a l c o n d itio n , the c irc u it operates as
a pplied to the base o f TR3, c u rre n t flo w fro m R6 to C fo llo w s :
and E o f TR3 to the g ro u n d , and RY does n ot operate,
1) S o le n o id relay i Re Dl -r* C2 G ro u n d
as there is no in p u t to TR4 and TR b o f the sto p c ircu it.
V R 7 -* Base o f TR4 -
3) The engine starts, and a vo lta g e o f 24V or m ore is Base o f TRs Rs G round
a pp lie d fro m the te rm in a l "L " o f the a lte rn a to r R4 -r> C and E o f TRi Base o f TR 2 G round
th ro u g h VRi to ZD i (Zener vo lta g e 24V), and charge
b egins w ith the tim e co n sta n t (Oil pressure tim e r)
L ---- * C and E o f TR 2 -------- ^
d e te rm in e d by VRi and C l. (At th is p o in t the eng in e 2) S o le n o id re la y () * RY c o il * C and E o f TR 4 and TRs Rs > G round
oil pressure increases b eyond the specified va lu e and

the eng in e enters the o p e ra tin g state.) The charge
vo lta g e passes th ro u g h R2. If it becom es h ig h e r th an
the level o f th e e m itte r o f T R i, c u rre n t flo w s fro m R4
to C and E o f TR i and biases TR2. TR2 passes c u rre n t
fro m R4 to C and E o f TR2 and to the g ro u n d , and the
c irc u it fro m Rs to base o f TR3 is caused to be OFF. (Oil
pressure sw itch c irc u it opened)
16-11
3) Thus RY co nta cts close, the so le n o id operates, {c) P u s h b u tto n s to p

and the eng in e stops. W hen th e e n g in e sto ps, the To sto p the e n g in e d u rin g o p e ra tio n , o p e ra te the stop
a lte rn a to r vo lta g e goes out. A t th e sam e tim e , the s w itch , and the stop o p e ra tio n is p e rfo rm e d as at th e
sto p tim e r m ade up o f C2 and VR7 h olds the s o le n o id . tim e o f an a u to m a tic stop. (The e n g in e stops re g a rd
less o f w h e th e r the a lte rn a to r v o lta g e is available.)
(2 ) E n e rg iz e -to -ru n T y p e
S o lenoid relay
B4927B
(a ) S ta r t c ir c u it S ta rte r sw itch (c) S o le n o id relay () R esistor Ro G round

D iode D3 > RY h o ld in g co il H
* G ro u n d
1) W hen th e b a tte ry sw itch is tu rn e d ON:
D iode Di C apacitor C
S o le n o id relay () RY p u ll-in co il P -r TR i c o lle cto r

TR 2 co lle c to r W hen the ca p a c ito r C is ch arge d, v o lta g e is a pp lie d
fro m VR i to the base o f TRi a ctu a tin g TRi.
RY co nta cts do n o t o pe ra te w ith no in p u t to the base
As vo lta g e is a p p lie d to TR i c o lle c to r, TR i e m itte r, and
o f TR i and TR2.
to TR2 base, a c u rre n t flo w s fro m TR2 co lle c to r to TR2
2) W hen the sta rte r sw itch is placed in th e START
e m itte r, re s is to r R2, and g ro u n d , causing the RY
p o s itio n :
p u ll-in coil P to close the RY contacts.
16-12
E N G IN E E L E C T R IC A L - G E N E R A L , S P E C IF IC A T IO N S 16
3) W hen the RY contacts tu rn ON: This causes the c u rre n t to flo w fro m the s ta rte r (AC)
C urren t flo w s fro m so le n o id relay to RY, so le no id s w itc h to o il pressure sw itc h , th e rm o s w itch , so le n o id
relay , and the so le n o id , a ctiva tin g the so le n o id and r e la y , R Y h o ld in g co I H , and to g ro u n d , keeping the
s ta rtin g the engine. RY co nta cts in ON state.
4) As the engine starts and sta rte r sw itch is placed in (to) A u to m a tic s to p c ir c u it
the ON p o sitio n , vo lta g e to the so le n o id relay is cut
W hen th e th e rm o s w itc h and oil pressure sw itch
o ff; h ow eve r, TR i and TR2 stay ON fo r a p p ro x im a te ly
detect an a b n o rm a l c o n d itio n , each sw itch tu rn s OFF
a n o th e r 30 seconds by th e d isch arg e c u rre n t o f the
and the RY contacts open, d e a c tiv a tin g the so le n o id
ca pa citor C. D uring ca p a cito r C's d isch a rg in g , the oil
and s to p p in g the engine.
pressure b u ild s up as the eng in e speed increases,
causing the o il pressure sw itch to tu rn ON. (c ) P u s h b u tto n s to p
To s to p the eng in e d u rin g o p e ra tio n , o perate the stop
s w itch , and the stop o p e ra tio n is p e rfo rm e d ju s t as
w he n the a u to m a tic sto p is p e rfo rm e d .
2 SPECSF1CTDOWS
V o lta ge - P olarity 24V - (-) g ro u n d
S tarter Type Front nose e le c tro m a g n e tic push-in ty p e re d u c tio n sta rte r
(M itsu b ish i Electric
Corp. products) M o de l M3T95082 M 5T50276 M 5T50277 M5T50279
O u tp u t 24V-5kW 24V-6kW
R eduction S ingle stage re d u c tio n by in te rn a l s p u r gear

m e cha n ism
S ta rte r relay M o de l IS tan d a rd] |O p tio n | lO p tio n ]

U1T06074 U1T06071 U1T07076
A lte rn a to r Type A lte rn a to r w ith b u ilt-in Y -connection A lte rn a to r w ith

(M itsu b ish i Electric IC re g u la to r a lte rn a to r w ith b u ilt-in IC
C orp. product) s ilic o n dio d e re g u la to r
re c tifie r
M odel A2T A2T A2T A4T A4T A4T A4T A6T A6T
72987 72986 73387 57986 57987 65772 65773 75386 75387
O u tp u t 24V-30A 24V-40A 24V-60A 24V-80A
R egulator M odel R7T01071

(V oltage re gu la to r) - (RFT24HI -
(Safety relay) (RX-Q2)
S afety relay M o de l R8T30171 - R8T30171
Intake air Type E lectric h eating type

heater
C apacity x I6D22, 22-Tj I6D22-TC]
q u a n tity 2 kW x 1 0.3 kW x 6
H eater relay M odel U1T06671
Fuse ca pa city 91 A
16-13
16 ENGINE ELECTRICAL - SPECIFICATIONS
SERVICE STANDARDS
A u to m a tic S to p S y s te m [O p tio n ]
Item S p ecification
Stop so le n o id Type Electro m a g n e tic type

(N ip p on Denso Co.,
Ltd. p rod u ct)
S o le n o id relay M o de l [E ne rg ize -to -sto p type| [E nergize-to-run type]

(N ikko Denki p rod u ct) 0-25000-5592 0-25000-6720
Oil pressure sw itch Type D ia p h ra g m , b u ilt- n e le ctric co nta ct
T h e rm o sw itch Type W ax type, b u ilt-in ele ctric contact
3. SER V IC E STAM DATO S

3.1 SERVICE STANOARO TABLE
U n it: m m
D escrip tion N o m in a l value L im it C orrection and

IBasic d ia m e te r] rem arks
S tarter C o m m u ta to r O.D. 38.7 38.1 Replace.

(M3T95082)
C o m m u ta to r p e rip h e ry ru n o u t 0 to 0.03 0.1 Replace or
correct.
D epth o f g ro o ve betw een se gm e n ts 0.7 to 0.9 0.3 Replace o r

correct.
Brush len g th 17 11 Replace.
Brush sp rin g tension 25 to 34 N 18 N Replace.

(2.5 to 3.5 kgf) (1.8 kgf)
P inion gap 1 to 3 - A d ju s t w ashers.
Gear shaft th ru s t gap 0.1 to 0.5 - A d ju s t w ashers.
N o-load V oltage 23V - Check.

chara cteristics
C urre n t 110A o r less -
R otatin g speed 3 100 rp m o r m ore -
M a gn e t sw itch o p e ra tin g vo lta g e 16V o r less - Replace.
S ta rte r C o m m u ta to r O.D. 43.2 42.2 Replace.

(M5T50276)
(M5T50277) C o m m u ta to r p e rip h e ry ru n o u t 0 to 0.03 0.1 R eplace o r
(M5T50279) correct.
D epth o f g ro o ve betw e e n segm ents 0.7 to 0.9 0.3 R eplace o r

correct.
Brush sp rin g tension 25 to 34 N 18 N Replace.

(2.5 to 3.5 kgf) (1.8 kgf)
P inion gap M5T50279 1 to 3 A d ju s t w ashers.
M5T50276 4 to 6
M5T50277
Gear sh aft th ru s t gap 0.1 to 0.5 - A d ju s t washers.
N o-load V oltage 23.5V - Check.

chara cteristics
C urrent 110A o r less -
R otating speed 3 300 rp m o r m ore -
M agn e t sw itch o p e ra tin g vo lta g e 16V o r less - Replace.
16-14
E N G IN E E L E C T R IC A L - S E R V IC E S T A N D A R D S 16
U n it: m m
D escrip tion N o m in a l value L im it C orre ctio n and

IBasic d ia m e te rl rem arks
S ta rte r relay Coil resistance 10.4 i> - Replace.
A lte rn a to r S lip rin g O.D. 40.8 to 41.2 40.4 Replace.

(A2T72987)
(A2T72986) Brush sp rin g tension 3.1 to 4.3 N 2 N Replace.
(A2T73387) (0.32 to 0.44 kgf) (0.2 kgf)
30A
Field co il resistance (at 20 C) A p p ro x . 9 1 - Replace.
Load T e rm in a l vo ltag e 27V - Check.

chara cteristics
(W hen cold) C urrent 17A or m ore -
R otatin g speed 1 500 rpm -
Load T e rm in a l vo lta g e 27V - Check.

chara cteristics
(W hen cold) C urrent 26A o r m ore -
IC re g u la to r re gu la te d vo lta g e range 28 to 29V - Replace.

(5 000 rp m , 5A o r less)

(A4T57986)
40A (0.32 to 0.44 kgf) (0.2 kgf)
Field c o il resistance (at 20 C) A p p ro x. 9 i l - Replace.
Load T e rm in a l vo ltag e 27V - Check.

chara cteristics
(w he n cold) C urrent 26A o r m ore -
R otating speed 1 600 rpm -
Load T e rm in a l vo lta g e 27V -

chara cteristics
(w he n cold) C urre n t 37A o r m o re -
R otating speed 2 500 rpm .

IC re g u la to r re gu la te d vo lta g e 28 to 29V - Replace.
(5 000 rp m , 5A o r less)

(A6T75386I
80A (0.32 to 0.44 kgf) (0.2 kgf)
Field c o il resistance (at 20L'C) A p p ro x . 7.2 i l - Replace.
Load T e rm in a l vo ltag e 27 V - Check.

chara cteristics
(w hen cold) C urrent 39A o r m o re -
Load T e rm in a l vo ltag e 27V -

chara cteristics
(w hen cold) C urre n t 71A o r m o re -
IC re g u la to r re gu la te d vo ltag e 28 to 29V - Replace.

(5 000 rp m , 5A o r less)
16-15
16 E N G IN E E L E C T R IC A L - S E R V IC E S T A N D A R D S
U n it: m m
D escrip tion N o m in a l value L im it C orrection and

IBasic d ia m e te r| rem arks
A lte rn a to r S lip ring O.D. 46 45.4 Replace.

(A4T65772)
(A4T65773) Brush sp rin g te n sio n 3.7 N .(0.38 kgf) 2 N Replace.
60A (0.2 kgf)
Field co il resistance (at 20'C) A p p ro x . 13 1 - Replace.
Load T e rm ina l vo lta g e 28V - Check.

chara cteristics
(w he n cold) C urrent 60A o r m ore -
R eg u lator R egulated vo lta g e 28 lo 29V - Replace.

(R7T01071) (A lte rn a to r: 4 000 rpm )
Safety relay Resistance betw e e n L and R te rm in a ls A p rro x . 200 i l - Replace.

(R8T30171)
Intake T im e requ ire d fo r a ir heater in d ic a to r 40 to 60 secs. - Check.

a ir heater to b ecom e red h ot
A u to Energize S o le n o id P o in ter clearance 1.5 to 2.0 - Replace.

m a tic -to -sto p
stop type Clearance b e tw e e n s to p lever and 0.4 to 0.5 -
device e xte rn al sto p p er
H o ld in g co il c u rre n t 5A o r less -
S o le n o id relay Delay tim e at s ta rtin g 13 to 23 Replace.

(after 28.5V app lied to te rm ina l seconds
" B " and " W " and 28.5 V
to te rm in a l " A " )
D elay tim e at sto p p in g 25 to 35

(a fte r 24V a p p lie d to te rm in a l "B " seconds
and " W " and no vo lta g e to
te rm in a l " A " )
T h e rm o sw itch a ctu a ting te m p e ra tu re 93 to 97C - Replace.
Oil pressure sw itch a ctu a ting pressure 69 to 98 kPa - Replace.

(0.7 to 1.0 kg f/c m 2) o r less
O il pressure s w itch Coil resistance 190 to 280 - Replace.

relay (24 V)
M in . o p e ra tin g voltage 16V o r less -
Energize S o le n o id P o in te r clearance 1.5 to 2.0 - Replace.

-to-run
type C learance between 0.4 to 0.5
sto p lever and
e xte rn a l sto p p er
H o ld in g c o il current 1A o r less -
S o le n o id relay d ela y tim e 26 to 34 seconds - Replace.
T h e rm o sw itch a ctu a ting te m p e ra tu re 93 to 97C - Replace.
Oil pressure s w itch a ctu a tin g pressure 79 to 118 kPa - Replace.

(0.8 to 1.2 kg f/c m 2) o r less
3 .2 T IG H T E N IN G T O R Q U E T A B L E
D escrip tion Thread size T ig h te n in g to rq u e Remarks

O.D. x pitch N m (kg fm )
(m m )
A lte rn a to r p u lle y nut M 17 x 1.5 83 to 105 (8.5 to 11)
M 20 x 1.5 135 to 160 (13.5 to 16.5)
A lte rn a to r sh aft nut - 345 to 360 (35 to 37)
16-16
E N G IN E E L E C T R IC A L - S P E C IA L T O O L ,
S E R V IC E P R O C E D U R E S m
4 . S P E C IA L T O O L
U n it: m m
5 . S E R V IC E P R O C E D U R E S 5.1 STA R TER

NOTE: 5.1.1 R em o val and In s ta lla tio n
W h en e ver rem oving e le c tr ic a l p arts from
She v e h ic le , be sure So p la c e th e b a tte ry
s w itc h ira FF p o sitio n , d is c o n n e c t th e
n e g a tiv e b a tte ry c a b le , and w in d th e c a b le
end w ith vinyl in su latio n ta p e .
The sta rte r m o u n tin g b o lt on the in n e r side (crankcase

side) can be e a sily m o u n te d o r re m o v e d by use o f the
special to o l, Socket.
16-17
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5 .1 .2 D is a s s e m b ly
<M 3T>
Yoke a ssem bly O v e rru n n in g clutch

2 Rear bracket 14 Packing
3 Brush h o ld e r 15 Plate
@ Brush sp ring 16 Spacer
Brush 17 Lever
6 A rm a tu re 18 C ollar
* 7 F ro n t bea rin g * 19 Gear s h a ft bearing
* 8 Rear bearing Ring
M a g n e tic sw itc h Pinion sto pp er
10 C enter bracket 22 F ront bracket
G ear bracket *2 3 Sleeve bearing
@ G ear sh aft
Part m arked w ith * should not be rem oved unless defects are
evident.
For parts w ith an encircled num ber, refer to D isassem bly Procedure
that fo llo w s.
B1104B
16-18
E N G IN E E L E C T R IC A L - S E R V IC E P R O C E D U R E S 16
<M 5T>
Roughened co m m u ta to r surface,
Gear shaft thrust seizure, ridge wear,
gap w o rn dam aged gear
NV 0.1 to 0.5 Rotating
------------------------------ co n d itio n 6
M ounted c o n d itio n of
ball and fie ld coil
Yoke assem bly Gear bracket

2 Rear bracket (12) Gear shaft
3 Brush h o ld e r O v e rru n n in g clutch
Brush sp ring 14 Packing
Brush 15 Lever
6 A rm a tu re *16 Gear sh aft bea rin g
*7 F ro n t bearing Ring
*8 Rear bearing Pinion s to p p e r
M a g n e tic sw itch 19 Front bracket
10 C enter bracket *2 0 S le e v e bearing
* should not be rem oved unless there is anything

w ro n g w ith them .
On parts m arked o, refer to the disassem bly procedure described
below.
B9071C
16-19
Disassembly Procedure (3) Removal of Overrunning Clutch

The d isa sse m b ly p ro ced ure fo r the M3T95082 is
described.
The p ro ced ure fo r the o th e r sta rters is the same.
(1) Removal of Yoke Assembly
R em ove th e m a g n e tic sw itc h and separate the fro n t

bracket a sse m b ly and yoke assem bly.
NOTE;
O not drop the armature.
Especially when disassembling with the
armature staying in the yoke, do not tiit (a) Rem ove the gear bracket m o u n tin g b o lt and
the yoke assembly. rem ove the o v e rru n n in g clutch, to w h ic h the gear
(2) Inspection of ear Shaft Thrust Gap sh aft and gear bracket rem ain installed , fro m the fro n t
bracket.
B efore d isa sse m b ly, set the dia l in d ic a to r as sh o w n to

m easure th e th ru s t gap in th e gear shaft. If the (b) A p p ly a to o l pipe to the p in io n s to p p e r and
m e a su re m e n t is o u t o f sp e cific a tio n , use a d ju stin g h a m m e r the p in io n s to p p e r o u t to w a rd the p in io n
w ash ers to o b ta in co rrect gap. [For a d ju s tm e n t p ro ce side. Then rem ove the ring and rem ove the o v e rru n
dure, refer to S ection 5.1.3 (8).] nin g clutch.
16-20
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
M OTE:
O verrunning clutch
B2959A
(d) R em ove the o v e rru n n in g clutch and gear bracket

fro m th e gear shaft.
When the ring is removed, keep ike gear
shaft ira overhanging condition. |4) IRemoval of Brush Spring
(c) Rem ove the ring fro m the rin g g ro o ve o f the gear To rem ove the brush s p rin g , firs t release the brush
sh ^ft. Rem ove the p in io n s to p p e r fro m the gear shaft. sp ring and rem ove the brush.
16-21
Item NV L
C o m m u ta to r M3T 38.7 38.1

outside diam eter
M5T 43.2 42.2
C o m m u ta to r outside 0 to 0.03 0.1

circum ference run o u t
Depth o f groove 0.7 to 0.9 0.3

betw een segm ents
Short circu it test,

coil gro u n d test,
open circu it test
Coil open c irc u it test
M elted contacts
Loose contact
Item NV L
NV ... N om inal Value
L ... L im it Brush spring 25 to 34 N 18 N
tension (2.5 to 3.5 kgf) (1.8 kgf)
Brush length M3T 17 11
M5T 23 14
Insulation test - -
B1104E
16-22
In sp ec tio n P rocedure (c) In s p e c tio n of co m m u ta to r
The insp ectio n p rocedure fo r the M3T95082 s ta rte r is
described. On the o the r sta rters, o n ly the differen ce s
are jo in tly described.
{I ) A rm a tu re In s p e c tio n
(a) oil short c irc u it te s t
D7507A
M easure the ru n o u t o f c o m m u ta to r u s in g a d ia lg a u g e
and tu rn in g the a rm a tu re by hand.
If the ru n o u t exceeds the lim it, correct, ensu rin g th a t
the O.D. lim it is n o t exceeded.
D7505A If the c o m m u ta to r surface is rough d e v e lo p in g ridge
w ear, c o rre ct w ith sandpaper (No. 300 to 500).
Place th e a rm a tu re on a g ro w le r tester. H old a piece o f A fte r co rre c tio n , m ake sure to check the ru n o u t again.
iro n in parallel w ith the a rm a tu re and s lo w ly tu rn
{d} C o m m u ta to r O.D.
a rm a tu re by hand. If the iro n piece is attracte d or
vib ra te s, it m eans th ere is a s h o rt circu it. Replace the
arm ature.
(fe) Coil ground te s t
M easure the c o m m u ta to r O.D. If the m easurem ent

exceeds the lim it, replace the arm ature.
D7506A
Check fo r c o n tin u ity across th e c o m m u ta to r and sh aft

(or core). If th ere is a c o n tin u ity , in d ica tin g th a t the
co il is g ro u n d e d , replace the arm ature.
16-23
{ } M ie a d e p th b e t w e e n g ro o v e lead and brush ( + ).

If th ere is no c o n tin u ity , in d ic a tin g an open circu it,
replace the yoke assem bly.
(b )C o il g ro u n d te s t
M easure th e M ica d ep th o f g ro o ve b etw een seg

m ents. If it does n ot reach the lim it, correct.
Check th a t there is no c o n tin u ity betw een the yoke

and brush ( + ).
If th ere is c o n tin u ity in d ic a tin g th a t the coil is
g ro u n d e d , check fo r p o o r in s u la tio n .
If re p a ir is im p o s s ib le , replace the yoke assem bly.
(3 ) in s p e c tio n of B ru sh
If the se g m e n t indicates the fa u lty c o n d itio n as show n

' in the illu s tra tio n , replace th e arm ature.
(2 ) In s p e c tio n o f F ie ld C o il
(a ) C o il o p e n c ir c u it te s t
(a) M easure the brush length and, if the m ea sure

m e n t is less th an th e lim it, replace the brush as an
assem bly [(-) side: yoke a s se m b ly; (+) side: brush
h o ld e r assem bly],
(b) If the brush is u n e v e n ly w o rn o r d eve lo ps rough
surfaces, correct w ith s a nd pa pe r (No. 300 to 500).
N O TE :
C o rre c t th e b ru s h c o n ta c t s u rfa c e t a
D7510B c u rv e o f th e c o m m u ta to r.
Check th a t th ere is c o n tin u ity b etw een the te rm in a l
16-24
(4) In s p e c tio n off Brush Spring (6) In sp ec tio n off M a g n e tic S w itc h
(a) Cool open c irc u it te s t
M easure th e installed load o f th e brush sp rin g . U sing

a new brush read the load at the m o m e n t the spring Check th a t there is a c o n tin u ity across "S " and "M
leaves th e brush. te rm ina ls.
If the sp rin g te nsio n is b e lo w th e lim it, replace the If there isn't, replace the m a g n e tic sw itch.
sp ring .
fS) Brush [Holder In s u la tio n T e s t
Check to ensure th a t th e re is a c o n tin u ity across "S

and g ro u n d te rm in a ls.
Check to ensure th a t th e re is no c o n tin u ity betw een If th ere is n 't, replace th e m a g n e tic sw itch.
the ( + ) brush h o ld e r and (-) h o ld e r plate.
If th ere is c o n tin u ity , replace the brush holder.
16-25
ENGINE ELECTRICAL - SERVICE PROCEDURES
(b) F u s e d c o n ta c t c h e c k (7 ) in s p e c tio n o f O v e rru n n in g C iy tc h
Check th a t th ere is no c o n tin u ity across "B " and " M " Install the gear sh a ft to the o v e rru n n in g clutch and
te rm in a ls. If there is, replace the m ag ne tic sw itch. check to see if th e gear sh aft tu rn s s m o o th ly w hen
tu rn e d clockw ise (in the d rive d ire c tio n ) and locks
(c ) L o o s e c o n ta c t te s t
w he n tu rn e d co u n te rclo ckw ise .
If any unusual c o n d itio n is noted, replace the o v e rru n
ning clutch.
(8) A d ju s tm en t f G e a r S h a ft T h ru s t G ap
Close the contact o f the m a g n e tic sw itch as sh ow n.
If th e th ru s t gap is o u t o f sp e c ific a tio n , inse rt the

a d ju stin g w ash er in to th e p o s itio n sh ow n.
[For a djustin g pro ced ures, refer to S ection 5.1.2 (2).]
(A d ju stin g w a sh e r: 0.25, 0.5 m m )
In th is co n d itio n , check th a t th ere is a c o n tin u ity

across " B " and " M " te rm in a ls . If th ere isn't, replace
the m a g n e tic sw itch.
(9) R e p la c e m e n t o B earings (b) R e p la c e m e n t of fro n t and re a r b earings
(a) R e p la c e m e n t o g ea r bearing (Rem oval)
(Rem oval)
Press d o w n w ith a press.
U sing the bearing p uller, rem ove the b earings fro m
If the bearing o f the gear sh aft Is defe ctive, p u t a pin the a rm ature.
or b o lt In each o f the fo u r holes (6 m m In d ia m e te r) in (Installatio n)

the Internal gear and press d o w n the bearing o u t of
p o s itio n w ith a press.
(Installatio n)
Install the rear bearing by strikin g Its Inner race

u n ifo rm ly w ith a s o ft ham m e r.
A p p ly a to o l pipe to the bea rin g Inner race and

h a m m e r it Into p o sitio n .
Install the fro n t bearing a p p ly in g a pipe o f sam e

d ia m e te r as Its in n e r race and s trikin g it Into p osition .
16-27
5 .1 .4 R e a s s e m b ly
<M 3T>
A ssem bly sequence

(Recom m ended greases)
*1: M ystik JT-6 (Kyodo Yushi) >>23
or equivalent @>19 >(TJ
h -
*2 : MULTEMP MS-2 (Kyodo Yushi)
o r equivalent
i'
r
*3: MULTEM P HD-2 (Kyodo Yushi) 16- ^ 15- ^ 14- ^ 10^ -
o r equivalent
*4 : MOLYCOAT AS-19 (D ow Coning) 6>7>8-------
o r equivalent
3 >5>4>(i V
For parts w ith an encircled num ber, refer to Reassembly

Procedure that fo llo w s.
D7548C
16-28
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES m
<M 5T>
(Recom m ended greases)

*1 : M ystik JT-6 (Kyodo Yushi)
. or equivalent
*2 : MULTEMP MS-2 (Kyodo Yushi)
o r equivalent < A sse m b ly sequence>
*3 : MULTEMP HD-2 (Kyodo Yushi)
or equivalent . 16 (11) 3'na>(i71(1s-
*4 : MOLYCOAT AS-19 (Dow Coning) 1920
o r equivalent
14 109H
678 r
3 4 5 11)
For parts w ith an encircled num ber, refer to Reassembly Procedure

that fo llo w s.
B9073B
16-29
R e a s s e m b ly P ro c e d u re
The reassem bly pro ced ure fo r the M 3T95082 s ta rte r is
described. On the o th e r starters, o n ly the differen ce s
are described.
(1 ) R e a s s e m b ly th e G e a r S h a ft, O v e rru n
nin g C lu tc h , a n d G e a r B r a c k e t in th e
F o llo w in g W a y
(c) Fit the ring in to th e ring g ro o v e in the gear shaft.
(a) Coat the p o rtio n s in gear sh aft sh ow n w ith the

specified greases and in sta ll the gear bracket and
o ve rru n n in g clutch o ve r the gear shaft.
(d) Pull hard the p in io n gear to w a rd the rin g and

secure it by fittin g th e rin g into the ring g ro o ve in
p in io n stopper.
(2 ) In s ta lla tio n f L e v e r
(a ) C o lla r fix e d ty p e < M 3 T >
(b) Install the p in io n sto p p e r to th e gear sh a ft in the

d ire ctio n show n.
Install th e lever in the d ire c tio n s h o w n , to g e th e r w ith

the c o lla r, into the fro n t bracket.
16-30
ENGINE ELECTRICAL - SERVICE PROCEDURES 16
(b) Pin fin e d ty p e < M 5 T > (4) Installation of M agnetic S w itch
Insert the lever in th e d ire ctio n sh o w n and m o u n t It

w ith the p in 1fro m o u tsid e the fro n t bracket.
(3 ) In s ta lla tio n o f O v e rru n n in g C lu tc h and

G e a r S h a ft
Coat the p o rtio n ind icate d w ith the specified grease

and install the m a g n e tic sw itch to the lever, e n su rin g
th a t B te rm in a l faces up fo r th e M 3T s ta rte r and S
te rm in a l faces up fo r th e M 5T starter.
Before in sta llin g the o v e rru n n in g clutch and gear

sh aft to the fro n t bracket, be sure to a p p ly the
specified greases to the p o rtio n s indicated.
U pon in sta lla tio n , m ake sure th a t the lever is w ed ge d
in to the o v e rru n n in g clutch.
16-31
(5) In s ta lla tio n of Y o k e A ssem bly (a) W ire the reassem bled sta rte r as s h o w n above.
(b) T urn ON sw itche s and K2 to p ro je c t the p in io n .
(c) T urn OFF s w itc h K2 to s to p p in io n fro m ro ta tin g .
A p p ly grease to the sp lin e s o f the a rm a tu re before

m o u n tin g th e yoke assem bly to th e ce nte r bracket.
M@YEs
W hen th e yo ke ass em b ly and c e n te r brack
M odel N om inal Value
e t are m o unted, th e lo c a tin g notch should
M3T95082 1 to 3
be alig n ed w ith th e p ro je c tio n . M5T50279
M5T50276 4 to 6
5 .1 .5 In s p e c tio n and A d ju s tm e n t a fte r M5T50277
R e assem b ly
(1) In s p e c tio n of Pinion Gap B0054D
(d) M easure th e axial m o v e m e n t (p in io n gap) w he n

the p in io n is p ushed lig h tly to w a rd th e a rm a tu re side.
16-32
MOTE:
1. Use a w ire as th ic k as possible and
sec u re eac h co n n e c tio n firm ly.
2. Apply v o lta g e g rad u ally from QV up to
24V .
(b) M easure the c u rre n t and ro ta tin g speed w h e n the
specified vo lta g e is app lie d. If the m e a su re m e n t is o u t
o f sp e c ific a tio n , replace the starter.
M easure the ro ta tin g speed by illu m in a tin g the p in io n
w ith strob e light.
N o m in a l values (N o-load characte ristics)
M odel Voltage C urrent R otating speed

(e) If the m ea su re m e n t is o u t o f sp e cific a tio n , in
M3T 23 V 110A o r less 3 100 rpm or m ore
crease or decrease the n u m b e r o f w ash ers used at the
M 5T 23.5 V 110A o r less 3 300 rpm or m ore
p o rtio n to w h ich m a g n e tic sw itch is m ou nte d .
W ashers
0.25, 0.5, 1.0 m m (c) G ra d u a lly increase the vo lta g e fro m 0V and
m easure the vo lta g e w h e n the p in io n sp rin g s o u t and
{2) In sp ec tio n of Mo-load C h a ra c te ris tic s
turns.
and M a g n e tic S w itc h O p eratin g V o l
If the v o lta g e exceeds the s p e c ific a tio n , replace the
ta g e
starter.
N om in al value 16V o r less

(m a gn e tic sw itc h operat ng voltage)
(a) Set up a c irc u it as sh o w n in c lu d in g the a m m eter,

v o ltm e te r and battery.
16-33
16 E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES
5 .2 STARTER RELAY
In s p e c tio n P ro c e d u re
(1) Check fo r c o n tin u ity betw een the SW and L

te rm in a ls and check to ensure th a t the coil resistance
is up to sp e c ific a tio n .
(2) Check to ensure th a t w h e n the b a tte ry v o lta g e
(24V) is a p p lie d across the SW and L te rm in a ls , th ere
is c o n tin u ity b etw een the B and S te rm in a ls .
5 .3 30A , 40A , 80A ALTERNATO R

5 .3 .1 R e m o v a l arad In s ta lla tio n
16-34
5 .3 .2 D isassem bly
(T; Rear bracket assem bly 11 Spacer

2) S tator 12 R otor a ssem bly
(3> R ectifier 13 S pring
(3f\) R ectifier < 8 0 A o n ly > *1 4 Rear bea rin g
@ R eg ula tor a ssem bly R otor
Brush F ront bracket a ssem bly
Brush sp ring 17 C over
7 Rear bracket 18 C over
8 P ully and fan *19 F ront bearing
@ Pulley (20) F ro n t bracket
(To) Fan
Parts m arked w ith * should not be rem oved unless defects are
evident.
For parts w ith an encircled num ber, refer to Disassem bly Procedure
that follow s. B3907E
16-35
D isassem bly P ro c ed u re
(1 9 S e p a ra tio n of Front B ra c k e t A ssem bly
from P e a r B ra c k e t A ssem bly
2. A t tim e off s e p a ra tio n , use c a re not to

lose th e spring fitte d to th e o u tsid e of
819490
th e re a r b earin g .
Rem ove the th ro u g h b o lt and, using a s c re w d riv e r, {2) Removal of Pulley

pry o ff th e fro n t bracket assem bly fro m the rear
bracket assem bly.
MOTE:
H old the ro to r in a vice, etc. and rem ove the p ulley,

fan and fro n t bracket.
MOTE:
1. The re a r bearin g is tig h tly fitte d . B efore
se p a ra tio n , th e re fo re , p re h e a t th e b e a r
ing box of th e re a r b ra c k e t by an air
dryer to fa c ilita te s e p a ra tio n .
W hen holding th e ro to r in a v ic e , be sure to

hold a t illu s tra te d p o rtio n.
16-36
{3} R em oval of Station* Coil (4) S e p a ra tio n of R e c tifie r < 8 0 A >
B3909A
Separate the re c tifie r by u n s o ld e rin g th e area sh ow n.
MOTES
W hen unso ld erin g , finish 54 in a sh o rt tim e
(less th an 5 seco n d s) w ith a so ldering iron.
To rem ove the sta to r co il, u n s o ld e r the sta to r coil

leads soldered to the rectifie r.
MOTEs
W hen unsoldering, finish iti in a short tim e
(less than 5 seconds) w ith a soldering iron.
16-37
D escription NV L
Field coil 30A, 40A A p p ro x. 9 ! -

resistance
80A A p p ro x. 7.2 Si -
Slip ring O.D. 40.8 to 41.2 40.4
G round test - -

L ... L im it
B3907F
16-38
In sp ec tio n (Procedure (2) In s p e c tio n of IRotor
f 11) In s p e c tio n of S ta to r (a) C o n tin u ity b e tw e e n slip ring and c o re
(a) C o n tin u ity across leads
Check th a t th ere is no c o n tin u ity b etw een th e s lip ring
Check th a t there is c o n tin u ity across s ta to r leads. If and core.
there is no c o n tin u ity in d ic a tin g a broken w ire , If th ere is, replace the ro to r as it is g ro u n d e d .
replace the stator. (b) Field co il re s is ta n c e

(b) C o n tin u ity across s ta to r lead s and co re
M easure th e resistance across slip rings. Replace the
Check th a t th ere is c o n tin u ity across the s ta to r leads ro to r If the resistance is n o t w ith in the sp ecificatio n.
and core.
If there is, replace the sta to r as it is g ro u n d e d .
16-39
(c)Slip ping 0 .0 . (b) Inspection of brush spring
M easure the slip rin g O.D. If the slip rin g has rou gh
surface o r is u n e v e n ly w o rn , c o rre c t w ith sand pa pe r
o r lathe.
C orrectio n m u st be m ade w ith in the lim it o f slip ring
O.D.
(3) Inspection of Brush and Brush Spring

(a) Inspection of brush
If th e s p rin g pressure is lo w e r than th e lim it, replace,
(c) Replacement of brush and brush spring
Wear lim it line
D8062A
Replace the brush if it is w o rn b eyo n d the lim it.
1) U n s o ld e r the p o s itio n s h o w n in the illu s tra tio n

and rem ove the brush and brush sp ring .
16-40
(a) Measurement of diode mounted to heat
sink (6 places)
2) W hen so ld e rin g the b rush, in se rt a pin in to the

brush hole and fix to the re g u la to r assem bly.
M OTE:
When soldering or unsoldering, work
quickly (within about 5 seconds} with a
soldering iron.
(4) Inspection of Rectifier
M easure resistance o f each d iode. M easure both
w h e n w ith the c irc u it te ste r (+) p ro be a pp lie d to
the d io d e and w he n w ith the (-) probe a p p lie d to
th e diode.
a If resistance is in fin ite in b oth cases, the d io de M easure b etw een the heat sink and s ta to r coil lead
is open. co nn ectio ns.
e If resistance is close to zero in b oth cases, the (b) Measurement of diode trio (3 places)
d io d e is shorted.
In the case o f open or sh orted d io de , replace the

rectifier.
M easure according to th e fo llo w in g procedures.
M easure b etw een th e plate co n n e ctin g to the reg ula

to r and the s ta to r coil lead co nn ectio ns.
16-41
{Si Inspection ff Bearings (In s ta lla tio n )
Replace the bea rin g if d efect is evident,
{a) Replacement f front bearing

(R em oval)
1) Rem ove the b e a rin g cover.
1) A p p ly a lig h t coat o f engine o il to th e o u tsid e o f

th e bea rin g and install to the in sid e o f the fro n t
bracket u sing a press.
Install flu sh w ith th e co ver m o u n tin g p o rtio n .
2) A p p ly a rod to the spacer on th e fro n t side o f the

fro n t bracket and strike o u t the bearing.
2) Install the co ve r and strike th e spacer w ith a s o ft

h a m m e r, etc. to m ake sure th a t th e bearing and co ver
are in c o n ta ct w ith each o the r. If not, strike the spacer
to b rin g th em in to contact.
16-42
|b) ^placement of rear bearings (Insta lla tio n )
(Rem oval)
Rear bearing
A p p ly a lig h t coat o f e n g in e o il to the insid e o f the
MOTis bea rin g and using a press, install w ith th e s p ring
Use care not to cause damage to the slip fittin g g ro o v e o f th e bea rin g fa cing th e ro to r fie ld coil
ring by the bearing puller. side.
16-43
16 ENQBiXJE E L E C T R IC A L - S E R V IC E PROCEDURES
5.3=4 R e asse m b ly
<30A, 40A alternator>
<80A alternator>
Components
1: 3, 3A <80A only>, 4, 5, 6, 7
12: 13, 14, 15
16: 17, 18, 19, 20
<Assem bly sequence>
16 (20 -> 19 18 -> 17) -> @ (15 -> 14 -> @) -> 8
(11 -> 10 -> 9) -> 2 -> 1 ( 7 > 6 > 5 > (3)A<80A only>)
On components marked o, refer to the follow ing reassembly
procedure.
B2990M
16-44
Reassembly Procedure Installation of Front Bracket Assembly and
(1) Installation off Rectifier {SQA Alterna Rear Bracket Assembly
tor)
(a) Push in the brush by hand and in se rt the pin into
W hen the re ctifie rs are to be co nn ecte d to g e th e r by the bru sh hole fro m the rear o f the rear bracket to fix
so ld e rin g , do the so ld e rin g w ith the re g u la to r as w ell the brush.
as the re ctifie rs m o u n te d to the rear bracket. (b) N o tin g the s p rin g p o s itio n o f the ro to r bearing
m o u n te d to the fr o n t bracket side, install the rear
MOTE:
bracket assem bly.
When soldering, finish it in a short time
{ess than 5 seconds). M OTE;
After completion of reassembly, be sure to
(2) Installation of Spring
remove the pin and close the hole.
Install the sp ring w ith its h ig h e s t p o in t seated in the

deepest o f the sp rin g fittin g g ro o ve o f the bearing.
16-45
E N G IN E E L E C T R iC A L - S E R V IC E PROCEDURES
c tio n and A d ju s tm e n t a fte r Dra-

tion
P re c a u tio n s
th e a lte rn a to r, o b se rve the fo llo w in g
D8074A
(c) Do not use a m e g g e r o r o th e r h ig h -v o lta g e

m u lti-m e te r, or d am aged d io d e and re g u la to r w ill
result.
act the b a tte ry reversely,

o f the b a tte ry is reversed w he n
m ade, a large c u rre n t flo w s fro m the
n ato r, d a m a g in g the d io d e and 1C
D8075B
(d) Do n o t expose th e a lte rn a to r to the w ater. If the

a lte rn a to r is exposed to w ater, s h o rt-c irc u it m ay
resu lt, causing d am aged a lterna to r.
annect the b a tte ry te rm in a l connec-

in g in e is ru n n in g , o r a su rg e vo lta g e
arating th e d io d e and re g u la to r.
(e) O p e ra tin g th e a lte rn a to r w ith its " B " and " L "
te rm in a ls sh o rte d results in the d am aged d io d e trio .
2) W h ile g ra d u a lly increa sing the a lte rn a to r speed
and red ucin g the load resistance, m easure the c u rre n t
value w ith the specified te rm in a l vo lta g e and speed.
If the m ea su re m e n t is b e lo w the sp e c ific a tio n , check
a lte rn a to r parts.
N o m in a l v a lu e (w hen a lte rn a to r is cold)
< 3 0 A a lte rn a to r>
T e rm in a l vo ltag e 27V 27V
C urrent 17A o r m ore 26A or m o re
R otating speed 1 500 rpm 2 500 rpm
< 4 0 A a lte rn a to r>

(f) W hen q u ick-ch a rg in g the b a tte ry w ith a quick
charger, be sure to d isco n n e ct te rm in a l co n n e ctio n s T e rm in a l vo ltag e 27 V 27V
in advance. O th e rw ise , a dam ag ed d io d e and re g u la C urrent 26A o r m o re 37A o r m ore
to r w ill result. R otating speed 1 600 rpm 2 500 rpm
(2) Performance Test

(aiTest bench inspection < 8 0 A a lte rn a to r>
T e rm ina l vo lta g e 27V 27V
C urrent 39A o r m ore 71A or m ore
R otating speed 1 500 rpm 2 500 rpm
(b) On-vehicle inspection
Voltmeter
83623B
R terminal 1) P rovide a sw itch b etw een the b a tte ry and a lte rn a

to r " B " te rm in a l. W ith the sw itch tu rn e d o ff, connect
B3622C an a m m e te r (w ith 60A fu ll-s c a le to the 30A o r 40A
a lte rn a to r and 100A fu ll-sca le to th e 80A a lterna to r)
P erform th e te st using the c irc u it sh o w n above. and v o ltm e te r.
1) W ith the load resistance set at m a x im u m (m e a n 2) T urn on the sw itch and m ake sure th a t the
ing th a t th ere is a lm o s t no load c u rre n t flo w in g ), close v o ltm e te r indicates the b a tte ry vo ltag e.
sw itche s K t and K2. 3) S tart up the eng in e and im m e d ia te ly tu rn on all

lam p sw itche s. Then, increase th e engine speed and
read the m a x im u m c u rre n t va lu e w h e n th e a lte rn a to r
speed reaches 5 000 rpm .
16-47
4) If th e cu rre n t rea din g is 70% o r m ore o f the (b) n-vebicle inspection

n o m in a l o u tp u t, the a lte rn a to r m ay be regarded as in
g o o d c o n d itio n .
Kl@T:
The omvehicie test: is an easier way of
inspection; the test bench inspection is
necessary for more accurate results.
{3} Inspection of Regulator
(a) Test bench inspection
Am m eter Voltmeter Battery
1) C onnect a v o ltm e te r and a m m e te r and p ro v id e a

sw itch as show n.
2) The re g u la to r is in goo d c o n d itio n if th e v o ltm e te r
registers 0 w h e n the sw itch tu rn s ON. If th e v o ltm e te r
p o in te r deflects, the a lte rn a to r or w irin g is defective.
3) W ith the a m m e te r te rm in a l sh orted to p re ven t
flo w o f the s ta rte r c u rre n t th ro u g h it, sta rt the engine.
4) Increase the eng in e speed to a ro u n d 2 000 rpm
and read the reg ula ted v o lta g e value if the charge
c u rre n t is 5A or less.
If the charge cu rre n t is 5A or m ore, c o n tin u e c h argin g
fo r a w h ile o r replace the b a tte ry w ith a fu lly -c h a rg e d
one.
Or, a 1/4 i (25W) re sisto r m ay be connected in series
to th e b a tte ry to lim it th e charge current.
5) If the m e a su re m e n t is o u t o f s p e cifica tio n , replace
the re g u la to r assem bly.
B3624C
Inspect the re g u la to r reg ula ted vo lta g e as fo llo w s

using th e c irc u it sh o w n above.
1) Use a fu lly -c h a rg e d b attery. T urn on th e sw itch.

2) G ra d u a lly increase the a lte rn a to r speed up to
5 000 rpm . Check th a t th e c u rre n t va lu e at th is speed
is 5A o r less.
3) The re g u la to r is in g o o d c o n d itio n if th e reg ula ted
vo lta g e u nd er th is c o n d itio n is w ith in s p e c ifica tio n .
If not, replace the re g u la to r assem bly.
N o m in a l value 28 to 29V
16-48
5.4 6QA ALTERNATOR
5.4.1 Removal and Installation
[R efer to 5.3.1.]
5.4.2 Disassembly
1 C over 10 S tato r *19 Pulley

2 Brush h o ld e r a ssem bly 11 Plate *20 Fan
3 Brush h o ld e r 12 Lead w ire assem bly 21 R otor a ssem bly
4 Brush 13 T e rm in a l set @ R otor
5 Brush sp ring 14 C on ne cto r *23 Rear bearing
6 End co ver 15 C ondenser Front bracket assem bly
7 C over 16 Heat sink set 25 C over
8 B o lt set 17 Rear bracket *26 F ront bearing
9 Rear bracket P ulley a ssem bly @ F ront bracket
Parts marked * should not be removed unless anything wrong is

evident.
On parts marked o, refer to the disassembly procedure in 5.3.2.
B4539A
16-49
5.4.3 finspectioira

L ... L im it
For the inspection procedure, refer to 5.3.3.

To check the heat sink fo r a sh o rt circuit, no disassem bly is
required.
The sh o rt-circuit can be id e n tifie d by checking fo r co n tin u ity
between the in d ivid u a l co n n ecto r te rm in a ls. [Refer to 5.4.5.)
B4539B
16-50
5 -4 .4 R e a s s e m b ly
18
C o m p o n e n ts
2: 3, 4, 5
9: 11, 12, 13, 15, 16, 17
21: 22, 23
24: 25, 26, 27
< A s s e m b ly s e q u e n c e >
24 (27 > 26 > 25) >21 (23 22) 18 (20 19) 10 9 (17 16
> 1 5 > 1 3 1 2 1 1 ) 1 4 > 8 > 7 6 2 ( 5 > 4 * 3) > 1
B4543A
16-51
5 = 4 .5 In s p e c tio n a ra d A d ju s tm e n t a fte r
R e a s s e m b ly
(1 ) S im p le P r o c e d u r e s f o r C h e c k in g A lt e r
n a to r fro m O u ts id e I n s p e c tio n b y C o n
tin u ity T e s te r
M e asu rin g Good Defective

p oin ts
F - E Tester sh ow s co n tin u ity . No c o n tin u ity (Brush in p o o r co n ta ct o r fie ld co il o p e n -circuite d )

Resistance 0 (Field co il s h o rt-c irc u ite d )
N - A Tester s h o w s c o n tin u ity w he n If te ste r sh ow s no c o n tin u ity w h e n (black) is co nnected to N and

(black) is co nnected to N and (red) co nnected to A, all o f three ( + ) d iodes are o pe n -circu ite d
(red) co nnected to A. or s ta to r co il open -circuite d .
If tester sh ow s c o n tin u ity w hen (black) is connected to A and
(red) co nnected to N, ( + ) d io d e s are s h o rt-circu ite d .
N - E Tester sh ow s c o n tin u ity w h e n If te ste r sh ow s no c o n tin u ity w he n (black) is co nnected to E and

(black) is connected to E and (red) co nnected to N, all three (-) d io d e s are o p e n -circuite d .
(red) co nn e cte d to N. If tester s h ow s c o n tin u ity w he n (black) is co nnected to N and
(red) connected to E, ( -) dio d e s are sh ort-circu ite d .
NOTE: L o a d te s t
T h e c o l o r s in p a r e n t h e s e s s h o w t h e c o l o r s Increase the load resistance R to a m a x im u m and
o f t e s t e r le a d r o d s . A ll th r e e d io d e s a re close the sw itche s K i and 2 . M easure the c u rre n t
r a r e ly o p e n - c ir c u it e d . value w h e n the a lte rn a to r reaches the specified
E a c h d io d e s h o u ld b e t e s t e d t o d e t e r m in e speed.
w h e t h e r i t is g o o d o r d e fe c tiv e .
N o m in a l value
(w hen a lte rn a to r is cold)
T e rm ina l vo ltag e 28 V
C urrent 60 A o r m ore
R otating speed 2 200 rpm
(2 ) P e r fo r m a n c e T e s t
16-52
5 .5 SAFETY R E L A Y [M o d e l R 8 T 3 Q 1 7 1 ]
In s p e c tio n
M easure vo lta g e at each te rm in a l in the sequence

sh o w n b e lo w to id e n tify fa u lty parts.
( t ) O im - v e liic le T e s t
Sequence E ngine V oltage at V o lta ge at V oltage at te rm in a l

o pe ra tio n te rm in a l "P " te rm in a l " S " "R " o r " L "
1 S ta rte r sw itch ON o 1 V or less T e rm ina l "R "

( + ) d io d e sh orte d if close o A p p ro x. 24 V
to batte ry vo ltag e o If 0 V, w irin g is fa u lty
T e rm in a l " L " (w ith charge lam p)
A p p ro x . 24 V
T e rm ina l " L " (w ith o u t charge lam p)
A p p ro x . 3 V or less
o If close to batte ry vo ltag e , w irin g
or a lte rn a to r is fa u lty
2 D u rin g cra nkin g o A p p ro x . 1 V o r less

o If close to b a tte ry voltage,
safety relay is fa u lty
(cranking im p o s s ib le )
3 Id lin g (600 rp m or o A p p ro x. 13 to 16 V o A b ulb co nn e cte d betw een

h igher) batte ry and te rm in a l "S "
does n ot co m e on
o If b u lb co m es on despite
n o rm a l te rm in a l "P " vo ltag e
(sh ow n to left), replace
safety relay and test again
( 2 ) O f f f - v e h ic le T e s t
The resistance valve b etw een te rm in a ls "R " and " L "
shall be w ith in sp ecified range.
16-53
5 .6 REG ULATO R |M d e l R 7 Y O 1 0 7 1 ] 5 .7 PREHEATER
In s p e c tio n 5 .7 .1 In ta k e A ir H e a te r
(1 ) R e m o v a l a n d In s t a lla t io n
[Refer to G roup 15 Intake and Exhaust]
(2 ) In s p e c tio n
A ir heater
f t ) R e g u la te d V o lt a g e o f V o lt a g e R e g u la to r
N o m in a l va lu e (betw een A and E te rm in a ls ) ... 28 to

29V w ith a lte rn a to r at 4 000 rpm
B attery o ve rcha rg ed ... V o ltag e to o high

B attery d isch arg ed ... V o ltag e to o lo w
M OTE:
T h is r e g u la t o r u s e s a t r a n s is t o r t y p e v o lt
age r e g u la to r , so th e r e g u la te d v o lt a g e
c a n n o t b e c h a n g e d . Df t h e r e g u l a t e d v o l t
Battery
a g e is o u t o f t h e n o m in a l v a lu e , r e p la c e t h e
r e g u la to r .
D8803C
(2 ) V o lta g e R e g u la to r R e g u la te d V o lta g e
M e a s u r in g P ro c e d u re P erform the fo llo w in g in sp e ctio n and check the
fu n c tio n o f each part o r the w irin g if necessary.
(a) Increase the e n g in e speed u n til the a lte rn a to r
(a) T im e req uired before in d ic a to r becom es red -h o t:
reaches the sp ecified speed.
(b) C on tinu e ch a rg in g u n til the ch a rg in g c u rre n t to S tandard tim e
th e b a tte ry fa lls to less th an 10 A (the b a tte ry fu lly 40 to 60 seconds
charged). (b) Check each te rm in a l o f the air heater fo r lo o se
(c) M easure th e vo lta g e across th e A and E te rm in a ls. ness and the heater e le m e n t fo r d am age and c o n ta ct
(d) M easure th e vo lta g e across the A te rm in a l and the w ith o th e r parts.
n eg ative te rm in a l o f the b a tte ry and check to ensure
th a t th ere is no d iffe re n ce b etw een the va lu e and the
va lu e m easured u n d e r Item (c).
16-54
5 .7 .2 IH IeaeF R e la y 5 .8 A U T O M A T IC S T O P DEVDC1
In s p e c tio n 5 .8 .1 E n e r g iz e - to - s to p T y p e
(1 ) S to p S o le n o id
(1) Check to ensure th a t th ere is c o n tin u ity betw een

th e te rm in a ls "B " and "S " w he n 2.3 A e xcitin g c u rre n t
is a pp lie d betw een te rm in a l SW in th e fig u re and
b od y earth.
(2) Check also the heater relay fu se and replace w ith
new one if it has been b u rn t out.
W hen rep la cing fuses, be sure to use a fuse o f
specified capacity.
(a) C onnect the stop lever and so le no id using the rod

and rem ove th e so le n o id cover.
(b) Push m a n u a lly th e sto p lever to the sto p p osition
and a d ju st the rod so th a t the so le n o id p o in te r gap
becom es as specified.
(c) Check th a t the sto p lever to e xterna l sto pp er
clearance is as specified w h e n the stop leve r is on the
o pe ra tion side.
(d) In the state o f (c) above, a p p ly specified vo ltag e to
so le n o id "B " te rm in a l and check th a t th e p o in te r gap
and a m m e te r reading are as sp ecified. (Stop lever
stop side)
(e) T igh ten the lock n ut o f the rod.
(f) Check th a t the so le n o id p o in te r c o lo r has not
changed and then install the cover.
16-55
(2) Solenoid Relay A fte r the tests o f the above ite m s 1) and 2), a llo w 5
m in u te s before m aking retests. It takes 5 m in u te s
(a) Unit test
befo re the ca p a c ito r Ci w h ic h is an e le m e n t o f the
tim e co n sta n t o f the o il pressure tim e r fin ish e s
d isch arg in g.
M ake co nn ectio ns as sh o w n above and p e rfo rm the

fo llo w in g checks.
1) Oil pressure tim er

Set the snap sw itch A to ON. O perate a sto p w atch as
,soon as th e snap sw itch B is set to ON, and m easure
th e tim e req uired before the so le n o id is operated.
2) Stop timer
Set the snap sw itch B to OFF 5 seconds a fte r the
s o le n o id has been operated. A t th e sam e tim e, using
a sto p w atch, m easure the tim e req uired befo re the
so le n o id is reset.
The snap sw itch B is set to OFF 5 seconds after
o p e ra tio n o f the so le n o id because if the so le n o id is
ope ra te d, it takes 5 seconds before th e a lte rn a to r
vo lta g e disappears.
3 ) M anuaS s to p tim e r
W hen the push sw itch C (stop sw itch ) is set to ON, the

so le n o id w ill be operated. O perate a stop w atch as
soon as the sto p sw itch C is set to OFF, and m easure
the tim e req uired before the so le n o id is reset.
16-56
(b) O n -v e h ic le smspecSiora
Check th e so le n o id relay accordin g to the fo llo w in g
flo w c h a rts and d e te rm in e w h e th e r it is good or n ot on
the basis o f the te rm in a l vo lta g e , etc, m easured in the
in d iv id u a l states.
The te rm in a l sy m b o ls d en ote those o f the s o le

noid relay.
o The vo lta g e 24V m eans the b a tte ry voltage.
P erform m e asu re m e nts w ith e ngine ru nn in g.
P erform m e asu re m e nts w ith e ngine ru nn in g.

1
16-57
(3 ) T h e rm o S w itc h C onnect the pipes as sh o w n above, close th e cocks A

and B, and sta rt the engine. A fte r the o il pressure has
risen, fu lly open the cock A to lead the oil pressure to
the oil pressure sw itch. Then close th e cock A to sh ut
Item NV
o ff the o il passage to the eng in e and h o ld th e oil
O perating 93 to 97"C
tem perature
pressure d ire c tly in the oil reservoir.
S lo w ly open th e cock B to lo w e r th e o il pre ssure and
ON-OFF 7C
difference check the o il pressure s w itc h o p e ra tin g o il pressure
w ith the test o il pressure gauge.
(5 @51 P re s s u re S w itc h IRelay

D9559A
W hen vo lta g e is 24V

The th e rm o sw itch w o n 't o pe ra te if the te m p e ra tu re
Item NV
sensing p o rtio n is n ot in co n ta ct w ith co olan t. If the
Coil resistance 190 to 280 i t
co o la n t level is lo w or if th ere is o n ly steam , the
M in im u m ope ra tin g 16 V
th e rm o sw itch w o n 't o pe ra te c o m p le te ly . vo lta g e
Im m erse the te m p e ra tu re -se n sin g p o rtio n in w ater,
heat the w a te r, and check th e th e rm o sw itch o p e ra t
ing te m p e ra tu re w ith a m e rcu ry th e rm o m e te r.
Heat the w a te r g ra d u a lly w he n the te m p e ra tu re NV ... N o m in a l Value
approaches near the o p e ra tin g te m p era ture .
H I @51 P re s s u re S w itc h
D9562A
(a) Check to ensure th a t th ere is c o n tin u ity betw een

the te rm in a ls @ and (5).
(b) Check to ensure th a t th ere is no c o n tin u ity
betw een the te rm in a ls and @.
(c) Check to ensure th a t there is c o n tin u ity betw een
the te rm in a ls and and th a t the coil resistance has
a n o m in a l value.
(d) Check to ensure th a t w h e n the b a tte ry v o lta g e is
a p p lie d across the te rm in a ls and , th ere is
c o n tin u ity b etw een the te rm in a ls and and no
c o n tin u ity betw een the te rm in a ls @ and .
16-58
5 .8 .2 E n e rg iz e -to -ru n T y p e (2 ) S o le n o id K e la y
(1 ) S to p S o le n o id {a) UraiS to s t
E
B C H s
; r
SW1 SW3 ^ ^SW 2
T erm inal voltage

24V
Solenoid or coil load
30A 3A
I Delay tim e
NV 26 to 34 sec. 7 t NV... N om inal Value
D9564A
W ire as sh o w n and check the fo llo w in g .
1) Relay o p e ra tio n and d elay tim e
a) Check if the so le n o id is energized w h e n sw itche s

S W 1 and S W 2 are tu rn e d ON.
b) U sing a stop w atch, m easure the tim e req uired fo r
the so le no id to retu rn a fte r s w itc h S W 2 is tu rn e d OFF.
2) Relay h o ld in g
a) T urn ON sw itch S W i and S W 2 and, after the

so le no id is a ctivated, tu rn ON the sw itch SW3.
(a) C onnect the stop lever and so le n o id using the rod b) Turn OFF the sw itch S W 2 and m ake sure th a t the
and rem ove the so le n o id cover. so le no id rem ain s a ctivated fo r m ore th an 34 seconds.
(b) Push m a n u a lly the sto p lever to the o p e ra tio n c) A fte r v e rify in g 2) above, tu rn OFF the sw itch SW3
p o s itio n and a d ju st th e rod so th a t th e so le no id to ensure th a t the so le n o id returns.
p o in te r gap becom es as sp ecified. In th is state, also
chpck th a t the stop lever to e xternal sto p p e r clearance
is as specified.
(c) In the state o f (b) above, a p p ly sp ecified vo lta g e to
so le n o id "B " te rm in a l and check th a t th e p o in te r gap
and a m m e te r reading are as sp ecified . (S top lever
o p e ra tio n side).
(d) T ig h te n the lock n u t o f the rod.
(e) Check th a t the so le n o id p o in te r c o lo r has not
changed and then in sta ll the cover.
16-59
16 E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES
(Ib) O n -v e h ie le in s p e c tio n
Check th e so le n o id relay a ccordin g to the fo llo w in g
flo w c h a rt and d e te rm in e w h e th e r it is g oo d o r n o t on
the basis o f the te rm in a l vo lta g e , etc. m easured in the
in d iv id u a l states.
T e rm in a l s ym b o ls d enote th ose o f the so le n o id
relay.
a V oltage 24V m eans th e b a tte ry vo lta g e .
16-60
P erform m e asu re m e nts w ith e ngine runn in g.
I
P erform m e asu re m e nts w ith e ng in e ru nn in g.

I
16-61
(3) Thermo Switch {4} @51 Pressure Switch
Item NV
O perating 93 to 97C
te m p e ra tu re
ON-OFF 7C
difference
D9559B
The th e rm o sw itch w o n 't o pe ra te if th e te m p e ra tu re

sensing p o rtio n is n ot in co n ta ct w ith co olan t. If the
co o la n t level is lo w o r if th ere is o n ly steam , the
th e rm o sw itch w o n 't o perate c o m p le te ly .
Im m erse th e te m p e ra tu re -se n sin g p o rtio n in w ater,
heat th e w ater, and check th e th e rm o s w itc h o p e ra t
ing te m p e ra tu re w ith a m e rcu ry th e rm o m e te r.
Heat the w a te r g ra d u a lly w h e n th e te m p e ra tu re
approaches near th e o p e ra tin g te m p e ra tu re .
C onnect the pipes as sh o w n above, close the cocks

"A " and " B " , and sta rt the e ngine. A fte r the o il
pressure has risen, fu lly open the cock " A " to lead the
o il pressure to th e o il pre ssure s w itc h . Then close the
cock " A " to sh ut o ff the o il passage to the engine and
h old th e o il pressure d ire c tly in th e o il reservoir.
S lo w ly open th e cock "B " to lo w e r th e oil pressure
and check the o il pressure s w itc h o p e ra tin g o il
pressure w ith th e te st oil pressure gauge.
16-62
ENGINE ELECTRICAL - TROUBLESHOOTING 16
6 . T R O U B L E S H O O T IN G
S ym p to m Probable cause Rem edy Ref. g ro u p
S ta rte r w ill D efective b a tte ry or lo w capacity Replace o r charge

not start.
D efective w irin g
0 D efective sta rte r w irin g C orrect
0 D efective sta rte r relay w irin g
D efective m a g n e tic sw itch w irin g
D efective heater relay w irin g
0 D efective sta rte r sw itch w irin g
0 D efective b a tte ry or b a tte ry sw itc h w irin g
D efective m a gn e tic sw itch Replace
D efective sta rte r relay
W o rn , d am aged, b in d in g brush
D efective m o to r Replace a rm a tu re o r yoke
D efective o ve rru n n in g clutch Replace
D efective h eater relay
D efective sta rte r sw itch
S tarter starts but Pinion n ot m e shin g w ith ring gear

engine does not.
In co rrect vo lta g e at m a g n e tic sw itch S te rm in a l Replace s ta rte r relay
o r s ta rte r sw itc h
0 In co rrect vo lta g e at sta rte r relay SW te rm ina l
0 W orn o r d am aged p in io n Replace
0 W orn or d am a g e d ring gear Replace G ro u p 11
Pinion m eshes w ith ring gear but does n ot rotate

0 D efective b a tte ry o r lo w capacity Charge or replace
0 Poor brush contact Replace brush or

brush sp rin g
0 D efective o ve rru n n in g clutch Replace
A lte rn a to r is Low V -belt tension A d ju s t G ro u p 14

fu n ctio n in g
n o rm a lly but Dam aged V-belt Replace
b a tte ry is
overd isch arg e d. Defective w irin g
0 D efective a lte rn a to r w irin g C orrect
D efective batte ry Replace
B attery is norm a l Defective a lte rn a to r

b ut is o v e r
0 Open c irc u it in sta to r co il Replace
discharged.
0 S ta to r co il and core g ro u n d e d
0 S lip ring and ro to r core g ro u n d e d
0 D efective fie ld co il
0 W o rn s lip ring
0 W o rn brush
0 Defective brush sp rin g
0 D efective re c tifie r
0 Defective re g u la to r
16-63
16 ENGINE ELECTRICAL - TROUBLESHOOTING
C harger lam p does D efective re g u la to r Replace

not com e on w hen
e ngine is stopped
(sta rte r sw itch ON).
Prem ature loss of D efective a lte rn a to r (see "B a tte ry is n o rm a l b u t is Replace

b a tte ry electroyte. o v e rd isch a rg e d ".)
H igh b a tte ry e le ctro
lyte te m p e ra ture . D efective re g u la to r
Engine is hard to D efective w irin g

start.
D efective a ir h eater w irin g C orrect
D efective h eater relay w irin g
D efective w a te r te m p e ra tu re sensor w irin g
D efective h ea ter relay o r b lo w n fuse R eplace
16-64
21
etT H
CONTENTS
1. G E N E R A L .................................................. 2 5.2 C L U TC H PROPER ................ 7

2. SPECIFICATIONS .............................. 3 5.2.1 D isassem b ly and In s p e c
3. SERVICE STANDARDS ..................... 3 tio n ................................ 7
3.1 SERVICE STANDARD TABLE ..... 3 5 .2 .2 R e as s e m b ly and A d ju s t
3.2 TIG HTENING TOROUE TABLE ... 3 m e n t .................. 11
4. SPECDAL TOOL ............................. . 4 5.3 BEAR IN G CASE .......................... 12
5. SERVICE PROCEDURES ................... 5 5.3.1 D isassem b ly and In s p e c
5.1 REMOVAL AND INSTALLA tion .................................. 12
TION ........................................... 5 5 .3 .2 R e asse m b ly ............................ 13
6. TR O U B L E S H O O T IN G ........ 14
C A U T IO N ;
W h e n s e r v ic in g c lu t c h a s s e m b lie s o r c o m p o n e n t s , d o N O T c r e a t e d u s t b y
s a n d in g o r b y c le a n in g c lu t c h p a r ts w it h a d r y b r u s h o r w it h c o m p r e s s e d
a ir . (A w a t e r d a m p e n e d c lo t h s h o u ld b e u s e d ).
T h e c lu t c h d is c c o n t a in s A s b e s to s F ib e r s w h ic h c a n b e c o m e a ir b o r n e if
d u s t is c r e a te d d u r in g s e r v ic e o p e r a t io n s . B r e a t h in g d u s t c o n t a in in g
A s b e s to s F ib e r s m a y c a u s e s e r io u s b o d ily harn.
21-1
21 CLUTCH - GENERAL
1. GEiMEKiAL
E0754A
The clutch is a d ry sin g le disc typ e w h ic h tra n s m its is p e rfo rm e d , th e pressure s p rin g fo rc e causes th e
and disco nn ects e n g in e p o w e r th ro u g h th e clutch pre ssure plate to press th e clutch d isc a g a in st th e
s h ift shaft. e n g in e fly w h e e l to tra n s m it pow er.
W hen the o p e ra tio n fo r clutch d ise n g a g e m e n t is The clutch co nsists o f a clu tch disc, pressure plate and
p e rfo rm e d , the clutch release leve r is pushed. Since release lever assem bly. The clu tch d isc has a w o v e n
th e clutch release leve r p ivo ts ro u n d th e release lever fa cing .
pin in the release lever s u p p o rt p ro v id e d in th e clutch The d riv e system is th e strap d riv e typ e w h ic h uses a
.cover, the pressure sp rin g is co m p re sse d , ca using the s tra p plate b etw e en the clu tch c o v e r and pressure
clutch disc clam pe d betw een the e n g in e fly w h e e l and plate to co u p le th e m . T his system insures sm o o th
pressure plate to becom e free and cuts tra n s m is s io n e n g a g e m e n t and d is e n g a g e m e n t o f the clutch.
o f pow er. W hen the o p e ra tio n fo r clutch e n g a g e m e n t
21-2
CLUTCH - SPECIFICATIONS, SERVICE STANDARDS 21
2. S P E C O F IC A T IO M S
C lutch (O ption]
Clutch 16 0 2 2 1 I6D22-T, TC|

Type Dry sing le d isc co il s p rin g type D ry single disc c o il s p rin g typ e
M o de l C10W41 or C12W43 C12W43
Facing M a te ria l W oven W oven
O.D. x I.D. m m 410 x 250 o r 430 x 250 430 x 250
Bearing case Type D ire ct-co u p le d type
M o de l PC12
3. SEKVDCE S T A N D A R D S
3.1 SERVBCE STANDARD TABLE
D escription N o m in a l value L im it C orre ctio n and
(Basic d ia m e te r] rem arks
Clutch D epth fro m facing surface to rive t head 2.2 to 2.8 0.2 Replace.
disc
Flatness 0.6 o r less - Replace.
Lateral ru no u t 1.2 o r less - Replace.
Vertical ru n o u t C10W41 1.0 o r less

1.5
C12W43 1.2 or less
Play in tu rn in g d ire ctio n 0.06 to 0.195 0.42 Replace.
Pressure Free C10W41 99.5 - Replace.

sp rin g length
C12W43 92.1 -
Installed load C10W41 1 205 to 1 325 N 1 070 N Replace.

(Installed le n g th : 63) (122.6 to 135.4 kgf) (109 kgf)
C12W43 1 425 to 1 570 N 1 270 N

(145 to 160.2 kgf) (129 kgf)
S pring squareness C10W41 3.5 o r less 5.2 Replace.

(In free len g th state)
C12W43 3.2 o r less 4.8
Pressure Flatness o f fric tio n surface 0.05 or less 0.2 C orre ct o r replace.
piafe
Thickness 59.7 to 59.9 56.8 Replace.
S trap b olt fittin g hole 12.21 to 12.22 12.5 Replace.
C learance betw een release lever p in and b u sh in g (12.7] 0.3 Replace.

0.06 to 0.15
C learance betw een strap plate and stra p b o lt |12.2| 0.3 Replace.
0.01 to 0.11
Release lever height 36.5 to 37.5 - A d ju st.

(D im ension fro m clutch co ve r to p surface) (D ifference a m o n g fo u r levers:
0.7 o r less)
C learance betw een release fo rk sh aft and (301 0.2 Replace.

needle ro lle r bearing 0.03 to 0.08
3.2 TIGHTENING TORQUE TABLE

D e scrip tion Thread size T ig h te n in g torque
S trap b o lt M 12 x 1.5 39 to 49 (4 to 5)
Lock p late m o u n tin g bolt M 8 x 1.25 9.8 to 15 (1 to 1.5)
Pressure p late and lever assem bly m o u n tin g b o lt M 10 x 1.5 32 to 49 (3.3 to 5.0)
Bearing case m o u n tin g b o lt M 16 x 2.0 140 (14.2)
21-3
m CLUTCH - S P E C IA L T O O L
4. SPECDAL @[L
U n it: m m
21-4
CLUTCH - SERVICE PROCEDURES 21
5. SERVBCE P R O C E D U R E S NOTE:
5.1 R E M O V A L AMD HIMS T A LL A YOON 1. B e fo re re m o v in g th e c lu tc h , b e s u re to
in s ta ll th e s to p p e r b o lt a n d p la in
(1 ) R e m o v a l
w a s h e r to p re v e n t th e s tra p p la te fro m
b e in g d a m a g e d .
2. U s e th e s to p p e r b o lt (MHO x 1 .2 5 8 5
w ith e ffe c tiv e le n g th 3 0 m m o r m o re )
a n d p la in w a s h e r (fo r M 1 2 th re a d s )
c o m m e r c ia lly a v a ila b le .
(2 ) In s ta lla tio n
(a) Install the clutch disc u sin g the special to o l, C lutch

A lig n m e n t A rb or.
NOTE:
W h e n in s ta llin g th e c lu tc h d is c , m a k e sure
th a t it is in s ta lle d in th e c o r r e c t d ire c tio n :
in s ta ll it so th a t its s id e w ith th e p a rt
n u m b e r s ta m p e d is v is ib le .
W hen re m o vin g the pressure plate and leve r a ssem

b ly, secure the pressure plate w ith th e special to ols,
S to p p e r B olt and Plain W asher.
Before re m o vin g the pressure plate and leve r a ssem
bly, install the special to o l, C lutch A lig n m e n t A rb o r, to (b) Secure the pressure plate o f the pressure plate
p re ven t the clutch disc fro m d ro p p in g . and lever assem bly w ith th e s to p p e r b olts, th en install
the c lu tch , a lig n in g it w ith the knock p ins in the
fly w h e e l.
215
21 CLUTCH - S E R V IC E P R O C E D U R E S
NOTE: id} A d ju s tm e n t a fte r in s ta lla tio n of c lu tc h

. B e fo re installiing She c lu tc h , c h e c k and and b e a rin g ca s e
cleaiii She Sly w h e e l and re p a ir r re p la c e
as n e c e s s a ry .
2. T ig h te n bolts e v e n ly , in She d iagonal
order.
3. A fte r in s ta lla tio n , he sure to re m o v e She
s e t holt.
(e) In s p e c tio n of re le a s e Sever h eig h t
The clutch s h o u ld be set in th e m o st w o rn p o s itio n as

w e a r o f the clutch disc d u rin g service causes th e
clutch to slip.
1) M ove th e leve r in the d ire c tio n th a t the clutch
engages. A t a p o s itio n w h e re a click is heard in th e
clutch, tu rn th e a d ju s tin g b o lt A u n til it is blocked by
the sto p p e r, and lock it by tu rn in g d o w n the b o lt
a n o th e r tw o or th re e threads.
2) From th e p o s itio n w h e re the release b e a rin g has
to u ch e d th e release lever, tu rn the a d ju s tin g b o lt B in
the d ire c tio n th a t th e clutch d isengages, check to see
th a t the clu tch is in d ise ng ag e d p o s itio n , and then
lock the bolt.
U sing C lutch Lever A lig n e r (special to o l), check the

h eigh ts o f the clutch co ve r and release lever.
Use the s u p p o rt n u t fo r a d ju s tm e n t.
21-6
CLUTCH - S E R V IC E P R O C E D U R E S 21
5.2 CLU TC H PROPER
5.2.1 D isassem bly and In s p e c tio n
D epth to rive t head C learance o f hub spline

NV 2.2 to 2.8 tu rn in g d ire ctio n
L 0.2 NV 0.06 to 0.195
L 0 42
Flatness 0.6 or less
Lateral ru n o u t 1.2 or less
V ertical ru no u t
NV 1.0 o r less (C10W41) S tia p b o lt fittin g hole Flatness
1.2 o r less (C12W43) NV 12.21 to 12.22 NV 0.05 o r less
L 1.5 L 12 5 L 0.2
Thickness
NV 59.7 to 59.9
L 56.8 (C10W41) (C12W43)
Installed load Installed load
(Installed le n g th 63) (Installed len g th 63)
NV 1 205 to 1 325 N NV 1 425 to 1 570 N
(122.6 to 135.4 kgf) (145 to 160.2 kgf)
L 1 070 N (109 kgf) L 1 270 N (129 kgf)
Free le n g th 99.5 Free le n g th 92.1
S quareness Squareness
NV 3.5 o r less NV 3.2 o r less
L 5.2 L 4.8
C learance fro m strap p late

BD 12.2
VN 0.01 to 0.11
C learance betw een L 0.3
and bushing
BD 12.7
NV 0.06 to 0.15
L 0.3
BD ... Basic D ia m e te r
L ... L im it
(ij Clutch disc assembly 9 Release lever pin
(2 ) Strap bolt 10 Return spring
3) Lock bolt 11 Release lever support
(4) Lock plate 12 Release lever pin
( 5) Support nut 13 Release lever subassembly
(6) Clutch cover (with strap plate) 14 Bushing
(7) Pressure spring (15) Pressure plate
8 Spring seat
For parts w ith an e ncircled n u m b e r, refer to D isassem bly and Insp e ction
Procedure th a t fo llo w s .
MOTE:
1. S in c e th e c lu tc h c o v e r a n d p re s s u re p la te a re b a
la n c e d , m a k e a lig n m e n t m a rk s b e fo re d is a s s e m b ly .
2. Do n o t re m o v e th e s tra p p la te .
E0757A
21-7
D isassem b ly and In s p e c tio n P ro ced u re (2) In s p e c tio n of C lu tch Disc

(1) R em o val off C lu tc h C o ver {a} Facing w e a r
(a) C om press the pressure s p rin g w ith the s to p p e r M easure the a sse m b ly th ickne ss o f fa cing and the
b olts and, at the sam e tim e , re m o ve th e strap bolts, d epth fro m fa cing surface to riv e t head o r cup head. If
s u p p o rt nuts, and o th e r parts. th e m e a s u re m e n t is b e lo w th e lim it, replace th e clutch
disc assem bly.
{lb} F la tn e s s of c lu tc h disc
(b) Put a lig n m e n t m arks on the clutch co ve r and

pressure plate. C om press th e pressure s p rin g using
the special to o l, C lutch In sta lle r, and at th e sam e tim e M easure th e fla tn e s s o f fa cin g surface. If it is beyond
rem ove the s to p p e r bolt. th e lim it, c o rre ct or replace.
(c) G ra d u a lly loosen the han dle o f C lutch In sta lle r to
rem ove the clutch cover.
21-8
CLUTCH - S E R V IC E P R O C E D U R E S 21
(c) C lu tch disc runout (3) In s p e c tio n of P ressure P la te
(a) M e a s u re m e n t of th ic k n e s s
U sing the ru n o u t tester, m easure the clutch disc

ru n o u t. If the m e a su re m e n t exceeds s p e c ific a tio n , M easure the pressure plate th ickne ss and, if it is
co rre ct o r replace th e clutch disc. b e lo w the lim it, replace.
(d) Spline play in tu rn in g d ire c tio n (b) M e a s u re m e n t off fla tn e s s
E0697B
U sing a piano w ire , m easure th e play in the tu rn in g M easure the fla tn e ss o f the pressure plate fric tio n
d ire c tio n o f the clutch disc h ub sp lin es and bearing surface. R egrind o r replace if th e lim it is exceeded.
case clutch shaft. If th e lim it is exceeded, replace the
clutch disc.
21-9
f) S tra p feBS fitt in g h o le LB . {5} In s p e c tio n f P re s s u re S p rin g
M easure the I.D. o r stra p b o lt fittin g h ole in the M easure the free le n g th , squareness, and installed
pressure plate and, if th e lim it is exceeded, replace. load o f the pressure s p rin g . If th e m ea su re m e n t is
b e lo w the lim it, replace the sp ring .
In s p e c tio n f IReOease Lewes'
M easure the release leve r pin O.D. and b u sh in g I.D..

Replace if clearance exceeds sp e cifica tio n .
21-10
CLUTCH - SERVICE PROCEDURES 21
5 .2 .2 [R eassem b ly a n d A d ju s tm e n t
32 to 49 Nm
(3.3 to 5.0 kgfm)
2
it CiT Tfc.
; .Sv ' 7
' =f.3. 8
9.8 to 15 Nm
icq ||i 2
ja -j (1 to 1.5 kgfm)
'> 13
^ m \ 7 10
5
-is ii ]fy& /y fc y " Strap plate
11
39 to 49 Nm
9 2 (4 to 5 kgfm)
IIIC -fJ p \ .. Strap support washer
12 Strap -S S T
Apply Molybdenum plate Strap plate
disulfide grease.
1 15 6 washer 1 1
<Assembly sequence;
- 12-,
~ 1 19 10 b 765 4 3 2 1
For parts w ith an encircled number, refer to Reassembly Procedure

that follows. E0754B
(2) To install the clutch cover, a lign th e a lig n m e n t
(1) W h e n e ve r the pressure plate fric tio n surface is m arks and, using th e special to o l, C lutch Installer,
co rrected , in se rt a d ju stin g w ash ers of thickness te m p o ra rily tig h te n th e s to p p e r bolts.
e q u iva le n t to co rre ctio n a m o u n t.
Friction surface A d ju s tin g w a sh e r

co rre ctio n a m o u n t thickness
Less than 1 N one re qu ire d
1 o r m ore and less than 2 One 1.2
2 o r m ore and less than 3 T w o 1.2 o r one 2.3
21-11
21 CLUTCH - SERVICE PROCEDURES
(3) W ith th e pressure s p rin g co m p re ssed by the (4) A fte r in s ta llin g the clutch, check th e clutch cover
s to p p e r b olts, in sta ll th e strap b o lt, s u p p o rt n ut, and and release leve r fo r h e ig h t using the special to o l,
o th e r parts. C lutch Lever A lig n e r.
5 .3 B E A R IN G A S E
5 .3 .1 D is a s s e m b ly a n d In s p e c tio n
Cracks, dam age
BD... Basic Diam eter

L ... Lim it
1 Clutch shifter
*2 Clutch release
bearing 7 Clutch release 11 Snap ring bearing
3 Return spring fork 12 Ball bearing 16 Clutch housing
4 Stopper plate 8 Drive shaft front 13 Bearing case
5 Stopper cover
NOTE:
P a rts m a rk e d * s h o u ld n o t b e re m o v e d u n le s s th e y a re to
b e re p la c e d .
E0760A
21-12
CLUTCH - S E R V IC E PROCEDURES 21
5 .3 .2 R easse m b ly
In s ta lla tio n of M eedle R o ller B earing U sing special to o l, the N eedle R oller Bearing Installer,
install the needle ro lle r b e a rin g in the housing.
The needle ro lle r bea rin g sh o u ld be pressed in up to
the sp ecified d im e n s io n w ith the o il seal side in w a rd
and the inscribe d side o u tw a rd .
MOTE:
W hen in s ta llin g th e n e e d le ro lle r b earing,
d ire c t th e lip in th e c o rre c t d irectio n .
21-13
21 CLUTCH - TROUBLESHOOTING
6a TROUBLESHOOTINGS
S y m p to m Probable cause Rem edy Ref. grou p
C lutch drags D efective clutch p ro p e r

w he n (D isassem ble and check clutch assem bly)
d isengaged Replace o r lub ricate
D am aged o r p o o rly lub ricate d p ilo t bearing
D am aged release bea rin g Replace
U neven h e ig h t o f release lever or its dam age A d ju s t h e ig h t or

replace
D efective clutch disc Replace
Dam aged o r d e fo rm e d clutch disc
W o rn or ru sty sp lin e s and clutch disc hub Replace o r re pa ir

defe ctive parts
0 D istorted o r d am aged p ressure plate G rin d o r replace
D istorted o r d am a g e d flyw h e e l G roup 11
C lutch slips D efective clu tch p rop e r

(D isassem ble and check clutch assem bly.)
U neven h e ig h t o f release lever A d ju s t
Pressure sp rin g lo sin g p ro p e r tension Replace
D efective clutch disc Replace
W o rn facing
D e form e d clutch disc
H ardened fa cing R em ove hardened

surface o r replace
Oil on facing R em ove o il or replace
D istorted o r d am aged pressure plate G rin d o r replace
D istorted or dam a g e d flyw h e e l G roup 11
C lutch is not D efective clutch p ro p e r

s m o o th ly engaged (D isassem ble and check clu tch assem bly)
D efective clutch disc Replce
D istorted fa cing Replce
H ardened facing R em ove hardened

surface o r replace
Loose rivet Replace
Oil on fa cing R em ove o il or replace
B ind in g clutch d isc splines C orrect o r lub ricate

splines
C lutch d isc to rs io n sp rin g lo sin g p ro p e r Replace

te n sio n o r broken
U neven h e ig h t o f release lever A d ju s t
Pressure sp rin g losin g p ro p e r tension Replace
D istorted o r dam a g e d pressure plate G rin d o r replace
D istorted or dam a g e d flyw h e e l G roup 11
21-14
CLUTCH - T R O U B L E S H O O T IN G 21
S ym p to m P robable cause R em edy Ref. g rou p
Clutch is W orn, d am a g e d, o r p o o rly lub ricate d p ilo t bearing Replace or lub ricate
n oisy w hen
disengaged W orn, d am a g e d, o r p o o rly lub ricate d release bea rin g
D efective clutch disc

W o rn clutch disc splines Replace
C lutch d isc to rs io n sp rin g losin g prop e r

te n sio n or broken
Bent strap plate Replace clutch cover
C lutch is D efective clu tch disc

n oisy w hen Replace
C lutch disc to rs io n sp rin g lo sin g proper
e ngaging
te n sio n o r broken
W o rn clutch d isc hub splines
W orn sp lin e s o f clutch shaft Replace
Pressure sp rin g lo sin g p ro p e r te n sio n Replace
L ow idle speed A d ju s t G ro u p 11
21-15
61
SPECIAL EQUIPMENT
COW TENTS
1. EMERAL ...................................... 2 5. S E R V IC E PROCEDURES ................ 8

2 S P E C IF IC A T IO N S .......................... 4 5.1 AIR CO M PRESSO R ..................... 8
3. S E R V IC E STA N D A R D S .................. S 5.1.1 R em o val and In s ta lla tio n ....... 8
3.1 SE R V IC E STA N D A R D TA BLE ..... 5 5 .1 .2 D isassem b ly ........................... 11
3 .2 T IC H T E W IN TO R Q U E YAiSLE ... 6 5 .1 .3 In s p e c tio n and C o rrec tio n ..... 14
4. SPEC IA L TOOL .............................. 7 5 .1 .4 R e asse m b ly ............................ 19
5.2 PRESSURE G OVERNOR ............. 22
5.2.1 D isassem b ly and In s p e c
tion ......................................... 22
5 .2 .2 R easse m b ly and Adjust-
m en t ....................................... 23
61-1
61 S P E C IA L E Q U IP M E N T - GENERAL
1. G E N E R A L
fill Air C o m p ressor
[1 -cylin d e r A ir C om pre ssor] [2 -c y lin d e r A ir C om pressor]
B4809A B4810A
The air co m p re sso r, in sta lle d at the fly w h e e l housing

on the left side o f e ngine, is d rive n at o n e -h a lf the
eng in e speed by the tim in g gear tra in (in je ctio n p um p
gears) o f the engine. A c o u p lin g is m o u n te d at the
rear end o f the air c o m p re sso r cran ksha ft to d rive the
in je ctio n pum p.
L u b rica tio n is a cco m p lish e d by the eng in e o il led
th ro u g h the o il pipe fro m the eng in e oil cooler. The
eng in e o il passes th ro u g h th e o il hole in the cran k
s h a ft to lu b rica te bearings. The c y lin d e r lin e r and
co n n e ctio n rod sm all end are s p la sh -lu b ric a te d using
crank ro ta tio n . Excess o il re tu rn s to the oil pan fro m
the hole at the b o tto m o f crankcase th ro u g h tim in g
gear train . The c y lin d e r head is w ate r-co o le d to p re ven t o v e r
h eating by the co m p re s s io n heat o f the air c o m p re s
sor. C oolant led fro m the oil c o o le r cools each va lve o f
the c y lin d e r head, then returns to the w a te r o u tle t
pipe.
61-2
S P E C IA L E Q U IP M E N T - GENERAL 61
Snap ring
U nlo a de r valve
C ylin de r head nlo a d er valve
uide
D elivery valve U nlo a de r valve To a ir tank
h old e r sp rin g
0 -n n g
S u ctio n valve
S p rin g holde seat
D e livery valve Suction valve
sp rin g S uctio n valve
D e livery valve sp rin g
D elivery valve
seat
B4812A
A su ction valve, d e liv e ry valve, and u n lo a d e r valve

are p ro vid e d in the c y lin d e r head o f the a ir c o m p re s
sor.
B4814A
The co m p re ssed a ir o ve rco m e s the force a pp lie d by

the d e liv e ry valve s p rin g to open the d e liv e ry valve,
being sent u n d e r pressure to the a ir tank.
Valves o perate as fo llo w s :
The su ction valve is ope ne d by the n eg ative pressure

generated d u rin g d o w n w a rd stroke o f the piston ,
w h ic h in tro d u ce s a ir in to th e cylin d e r. W hen the
p isto n goes u p w a rd , the va lve is closed by the su ction
valve sp rin g to co m p re ss air.
61-3
61 S P E C IA L E Q U IP M E N T - G E N E R A L , S P E C IF IC A T IO N S
(2 ) P re s s u re G o v e rn o r
The pressure g o v e rn o r c o n tro ls c o m p re s s o r o pe ra

tio n to keep the air tank pressure w ith in sp ecified
lim its .
To th e high pressure valve o f th e d ia p h ra g m , the
sam e air pressure as in the air tank acts alw ays
th ro u g h the filte r, th e re b y b alancing w ith th e a d ju s t
ing s p rin g force. W hen the pressure in the a ir tank
increases to exceed th a t o pe ning pressure o f the high
pressure valve, th e a ir forces up th e hig h pressure
The u n lo a d e r valve, o p e ra tin g w ith the pressure
va lve seat o f the d ia p h ra g m . This causes increase o f
g o v e rn o r, co n tro ls pressure in th e air tank. W hen the
acting area so th a t the d ia p h ra g m m oves up q u ic k ly
a ir pressure in the a ir ta nk exceeds the specified
to close the seat o f the lo w pressure valve.
pressure (pressure g o v e rn o r o p e ra tin g pressure), the
W hen the lo w pressure valve is closed, a ir n o w flo w s
pressure g o v e rn o r opens to send the com pressed air
th ro u g h the valve b o d y to force d o w n th e u n lo a d e r
to the u n lo a d e r valve. The com pressed air n ot o n ly
va lve o f the a ir co m p re ssor, th e re b y s to p p in g air
depresses the u n lo a d e r va lve , b ut keeps the suction
s u p p ly to the a ir tank.
va lve open, causing th e a ir c o m p re sso r to operate
As the a ir pressure in the air tank g ra d u a lly d rops, the
u n d e r no load.
d ia p h ra g m is fo rce d d o w n by the a d ju s tin g spring
W hen the a ir pressure in the air tank fa lls b e lo w
and the lo w pressure va lve o pens and the high
sp e cifica tio n , th e pressure g o v e rn o r resum es o pe ra
pressure one closes. As a result, the air on the
tio n , d isch a rg in g com pressed air pre sen t at to p o f the
u n lo a d e r side is exhausted th ro u g h the e xhaust hole
u nloa de r. Then the u n lo a d e r va lve sp rin g puts the
and a ir s u p p ly to the air tank is resum ed.
u n lo a d e r va lve back to its o rig in a l p o s itio n , causing
the su ction va lve to beg in o p e ra tio n .
2a SPiCIFieATIO M S
A ir C om pressor
Type W a ter-cooled 1-c y lin d e r typ e W ater-cooled 2 -cylin d e r type
C ylin d e r d ia m e te r x stroke mm 85 x 50 80 x 50
C ylin de r ca pa city cc 284 502
T u rn in g d ire ctio n C lockw ise C lockw ise

(as vie w e d fro m d riv e side)
Pressure g o v e rn o r
Type D iaphragm typ e
61-4
S P E C IA L E Q U IP M E N T - S E R V IC E S T A N D A R S 61
3. S E R V IC E STAWOAKOS
3U SERVflGE STAMDAIRD TABLE
(1) 1 -cylin d er Aar C o m p ressor
U n it: m m
D escription N om in al value Lim it C orrection and

IBasic d ia m e te rl rem arks
S u ctio n valve sp rin g Installed loa d / 4.4 N (0.45 kgf 1/5 3.5 N (0.36 kgfl/5 Replace.
in sta lle d len g th
D e livery valve sp rin g 4.5 N (0.46 kg 0/9.5 3.6 N (0.37 kgfl/9.5
C ylin de r lin e r to p iston Top p o rtio n 185] 0.27 Replace p iston or

clearance c y lin d e r liner.
S kirt p o rtio n (85| 0.18
Piston rin g g ro o ve to co m p re ssio n ring clearance - 0.08 Replace. (Replace p iston

ring s as a set.)
Piston ring o pen end clearance - 1.0 Replace. (Replace piston

ring s as a set.)
Fit betw een p isto n p in hole and p iston pin [181 0.08 Replace.
Piston p in to co rin e ctin g rod sm all end clearance 118] 0.07 Replace p iston pin or
co nn e ctin g rod.
End play o f cra nksh a ft - 1.0 Replace.
C rankshaft jo u rn a l to bea rin g clearance |42| 0.1 Replace crankshaft or

crankcase.
C rankshaft to co nn e ctin g rod bearing clearance 1341 0.1 Replace. (Replace bearing
fo r w o rn p la tin g .)
End pla y o f co nn e ctin g rod - 0.5 Replace crankshaft or

co n n e ctin g rod.
C on n e cting rod bearing W hen in te rn a l p la tin g Replace bearing.

is w o rn to expose
co p p e r color.
|2} 2-c y lin d e r Air C o m p ressor

U n it: m m
D escription N om in al va lue L im it C orre ctio n and

(Basic d ia m e te rl rem arks
S u ctio n valve sp rin g Installed load/ 4.4 N (0.45 kgf)/5 3.5 N (0.36 kgf)/ Replace.
in stalle d le n g th
D e livery valve sp rin g 4.5 N (0.46 kgf)/9.5 3.6 N (0.37 kgfl/9.5
C y lin d e r lin e r to p iston Top p o rtio n |80| 0.29 Replace p iston or

clearance c y lin d e r liner.
S kirt p o rtio n [80] 0.17
Piston rin g g roo ve to p iston ring clearance - 0.08 Replace. (Replace p iston
rin g s as a set.)
Piston rin g o pen end clearance - 1.0 Replace. (Replace p iston

ring s as a set.)
Fit betw e e n p isto n p in hole and p iston pin 1161 0.08 Replace.
Piston p in to co nn e ctin g rod sm all end clearance [16| 0.07 Replace p iston pin or
c o nn e ctin g rod.
End pla y o f cra nksh a ft - 1.0 Replace.
C rankshaft jo u rn a l to bearing clearance [42| 0.1 Replace crankshaft or

crankcase.
C rankshaft to co nn e ctin g rod bea rin g clearance 1341 0.1 Replace. (Replace bearing
fo r w o rn plating.)
End pla y o f co nn e ctin g rod - 0.5 Replace crankshaft o r

c o nn e ctin g rod.
C onnecting rod bearing _ W hen in te rn a l pla tin g Replace bearing.

is w o rn to expose
co p p e r color.
61-5
61 SPECIAL EQUIPMENT - SERVICE STANDARDS
U n it: kPa (kg f/cm 2)
D escription N o m in a l value L im it C orre ctio n and

IBasic dia m e te r) rem arks
H igh pressure va lve o pe n in g pressure MC802148 - A d ju s t o r replace

72
/2 (7
l/ . J31I +
_3 '4
q_ l +0.05)
5 ( 0'351
MC802150 78 (8 0) + 3 4 ( + 0 35) -
78 ,8 '0) - 0 .5 (-0.05)
L o w pressure va lve o p e n in g pressure MC802148 p .'i (R d) ( + 0.05) -

63 (6-4) -3 .4 (-0.35)
M C802150 -
70 (7 1) + - 5 ( + ' 51
70 l7 -1' -3 .4 (-0.35)
3 .2 T IG H T E N IN G T O R Q U E T A B L E
( I j A i r C o m p re s s o r
Loca tio n tig hte ne d Thread size T ig h te n in g to rq u e Remarks

C y lin d e r head n ut 1 c y lin d e r M 10 x 1.25 23 to 27

(2.3 to 2.8)
C y lin d e r head b o lt 2 c y lin d e rs M 10 x 1.5 39 to 49

(4 to 5)
C ylin de r lin e r m o u n tin g b o lt 2 c y lin d e rs M 10 x 1.5 25 to 29

(2.5 to 3)
Bearing h o ld e r b o lt 1 c y lin d e r M 8 x 1.25 14 to 18

(1.4 to 1.8)
Bearing h o ld e r n ut 2 c y lin d e rs M 8 x 1.25 14 to 18

(1.4 to 1.8)
C onnecting rod cap nut M 8 x 1.25 23 to 25

(2.3 to 2.6)
U n lo a d e r va lve guid e M 28 x 1.5 98 to 115

(10 to 12)
D e livery valve h o ld e r M 36 x 1.5 98 to 115 A p p ly 0.2 to

(10 to 12) 0.3 cc o f
THREEBOND NEJI
LOCK 1323B to
three threads
S uctio n va lve h o ld e r M 45 x 1.5 98 to 115

(10 to 12)
In jectio n p u m p gear m o u n tin g nut M 24 x 1.5 215 (22)
J o in t PT 1/8 15 to 20
(1.5 to 2.0)
T a ch o m e ter se nso r M 16 x 1.5 24 to 35

(2.4 to 3.6)
L oca tio n tig h te n e d Thread size T ig h te n in g to rq u e Remarks

Sleeve lock n ut - 15 to 20 (1.5 to 2)
A d ju s tin g scre w lock nut - 9.8 to 15 <1 to 1.5)
61-6
SPECIAL EQUIPMENT - SPECIAL TOOL 61
4. SPEC0AL TOOL
A ir C o m p re s s o r
U nit: m rn
61-7
61 SPECIAL EQUIPMENT - SERVICE PROCEDURES
5 . S E R V IC E P R O C E D U R E S
5.1 A IR C O M P R E S S O R
5 .1 .1 R e m o v a l arid In s ta lla tio n
[ 1 -c y lin d e r type] [2 -c y lin d e r type]
1 W ater o u tle t pipe

2 A ir o u tle t pipe
3 U n lo a d e r pipe A
4 U n lo a d e r pipe B (2 -cylin de r typ e only)
5 W ater in le t pipe
6 A ir su ction hose (1 -cylin d e r type)
A ir su ctio n pip e (2-cylin de r type)
7 Oil pipe
8 A ir co m p re sso r 89Q50B
B9051B
NOTE:
1. T o re m o v e th e a ir c o m p re s s o r, re m o v e
th e in je c tio n p u m p b e fo re h a n d .
2 . A t in s ta lla tio n , th e in je c tio n p u m p g e a r
in s ta lle d on th e a ir c o m p re s s o r s h o u ld
b e in m e s lt a s s p e c ifie d .
61-8
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES 61
In s ta lla tio n of Air C om pressor (2) Insert the b o lt (M10 x 1.5 a bo ut 100 m m long)
fro m the rear end o f the fly w h e e l h ou sin g to s u p p o rt
the air co m p re ssor. U sing the b o lt as a g uide , in se rt
the air co m p re s s o r into the m o u n tin g hole o f the
fly w h e e l h ou sin g. A t the p o s itio n w h e re b o th ends o f
the In jectio n p um p gear and Id ler gear C have
to u ch e d each o the r, alig n th e inscribed line on the
rear plate w ith th a t on the in je c tio n p u m p gear to o th
surface, and then push the air co m p re s s o r in.
(1) Crank the eng in e to a lign the sta m p ed m ark " 1 , 6 "
on th e p e rip h e ry o f the fly w h e e l w ith the p o in te r o f
the in sp e ctio n w in d o w in the fly w h e e l h ou sin g and
p u t the p isto n in the No. 1 c y lin d e r o f the eng in e a tto p
dead center on the co m p re ssio n stroke.
If the p iston in the No. 1 c y lin d e r is at to p dead center
on the co m p re ssio n stroke, the No. 1 c y lin d e r w ill
have a va lve clearance. If both in le t and e xhaust
valves have no va lve clearance, the p iston in the No. 6
c y lin d e r w ill be at to p dead center on the co m p re ssio n
stroke. So let the eng in e rotate 360.
M OTE;
W hen th e en g in e is to be c ra n k e d , m ake
sure th a t it is c ra n k e d m an u a lly m ore than
1180 in th e norm al d ire c tio n .
(3) Rem ove the ta c h o m e te r sensor or p lu g . Look

th ro u g h the th re ad e d hole to c o n firm th a t the p ro je c
tio n on the sensor plate is p o s itio n e d at th e center o f
the th re ad e d hole, and th e n secure the a ir co m p re s s
or. If the p ro je c tio n on the sensor plate is n ot
p o s itio n e d at the center o f th e threaded hole, rem ove
the air c o m p re sso r and p e rfo rm Item (3) again.
A fte r the a ir co m p re s s o r has been in sta lle d , in sta ll the
plug.
M O TE;
Of th e in je c tio n pum p g e a r arad id le r g e a r
a re m isalig n ed a to o th , ab o u t h a lf of th e
p ro je c tio n on th e sen sor p la te w ill be
hidden from th e plug hole.
61-9
(4 ) InstalBaSoir off T a c h o m e te r S e n s o r (b) A d ju s tin g ty p e

(a ) N o n -a d ju s ta b le ty p e
Sealant to be applied
to threaded portion
(THREEBOND 1211) Hexagonal po rtio n
--------------------------------------24 to 35 Nm
To m o u n t the ta c h o m e te r sensor, a p p ly sealant to th e

th re ad e d p o rtio n o f the sensor and screw it in u n til it
To in sta ll the ta c h o m e te r sensor, a p p ly sealant to the
seats on the s e nso r plate. T h e rea fte r, back it o ff
threaded p o rtio n o f the se nso r and screw the sensor
tw o -th ird s o f a tu rn (240) (to m ake 1.0 m m clearance).
in u n til th e hexagonal p o rtio n o f th e sensor seats.
T ig h te n the lock n u t to the sp ecified to rq u e .
61-10
SPECIAL EQUIPMENT - SERVICE PROCEDURES 61
5 .1 .2 D is a s s e m b ly
[ 1 -cylin d e r Type)
1 Sensor plate 11 Spring holder .211 Oil ring
2 Injection pump gear 12 Delivery valve spring 22 Snap ring
3 Collar 13 Delivery valve 23 Piston pin
4 Cylinder head 14 Delivery valve seat 24 Piston
5 Stud bolt '15 Suction valve holder 25 Bearing holder
6 Snap ring 16 Suction valve spring 26 Oil seal
7 Unloader valve 17 Suction valve 27 Connecting rod
8 Valve spring 18 Suction valve seat 28 Connecting rod cap
9 Valve guide 19 Cylinder liner 29 Connecting rod bearing
10 Delivery valve holder 20 Compression ring 30 Crankshaft
31 Crankcase
For parts w ith an encircled n um b e r, refer to D isassem bly P rocedure th a t

fo llo w s.
D9252A
M OTE:
O n o t re m o v e th e s tu d b o lt u n le s s tro u b le is e v id e n t.
61-11
[2 -cylin d e r Type]
1 Sensor plate 11 Delivery valve spring 21 Snap ring
2 Injection pump gear 12 Delivery valve 22 Piston pin
3 Collar 13 Delivery valve seat 23 Piston
4 Cylinder head (14) Suction valve holder 24 Bearing holder
5 Snap ring 15 Suction valve spring 25 Oil seal
6 Unloader valve 16 Suction valve 26 Connecting rod
7 Valve spring 17 Suction valve seat 27 Connecting rod cap
8 Valve guide 18 Cylinder liner 28 Connection rod bearing
9 Valve holder (19) Compression ring 29 Crankshaft
10 Spring holder o; Oil ring 30 Crankcase
For parts w ith an encircled n um b e r, refer to D isa sse m bly P rocedure that
fo llo w s.
D9253A
The p rocedures fo r d isa sse m b ly o f the 1- and 2- p ro ced ures fo r d is a s s e m b ly o f th e 1 -c y lin d e r typ e are
c y lin d e r typ es are m uch the sam e. So o n ly the d escrib e d b elow .
61-12
D is a s s e m b ly P ro c e d u re
(2) U sing Piston Ring T ool (special to o l), rem ove the
(1) U sing S u ction Valve T ool (special to ol), rem ove co m p re s s io n ring and oil ring fro m the piston.
the su ction va lve h o ld e r fro m the b o tto m surface o f M O TE:

the c y lin d e r head and rem ove the su ction va lve W h e n a p is to n rin g is re m o v e d , do n o t
sp rin g , su ction va lve and su ction valve seat. w id e n th e o p e n e n d s o f th e p is to n rin g
IMTE: m o re th a n 2 8 m m fo r 1 -c y lin d e r ty p e an d
S in c e th e s u c tio n v a lv e h o ld e r is s ta k e d by m o re th a n 2 6 m m fo r 2 -c y lin d e r ty p e .
p u n c h in g , do n o t a tte m p t d is a s s e m b ly u n
le s s tro u b le is e v id e n t.
61-13
61 S PEC 8A L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
5 .1 .3 In s p e c tio n a end C o rrec tio n

Tension
Loa d /in sta lle d len g th
NV 4.5 N (0.46 kgf)/9.5
L 3.6 N (0.37 kgf)/9.5
Piston rin g g ro o v e to i
co m p re ssio n ring clearance =
L 0.08
Piston rin g open

end clearance
L 1.0
Basic D iam eter

N om in al Value
L im it
D9252B
61-14
S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S 61
[2 -cylind e r Type]
L ... L im it
D9253B
61-15
61 S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
fH} Poston and Cylinder Liner (a) M easure the clearance betw een th e p iston ring
g ro o v e and co m p re s s io n ring. If the clearance is over
the lim it, replace the co m p re s s io n rin g o r p iston.
NOTE:
Measure the clearance a00 around the pis
ton-
(b) Fit th e p iston rin g o ve r a sta nd ard gauge or new

c y lin d e r lin e r and m easure the open end clearance. If
th e clearance is o v e r th e lim it, replace the p iston ring.
IMOYEs
Push the piston in and measure the clear
M easure the c y lin d e r lin e r in sid e d ia m e te r and p iston
ance with the piston ring in horizontal
to p and skirt o u tsid e d ia m e te r and calculate the
position.
clearance.
If the clearance is o ve r the lim it, replace the p iston o r
(3) Connecting Rod and Crankshaft
c ylin d e r liner.
(2) Piston Ring
(a) C alculate the clearance fro m the p iston pin o u t

side d ia m e te r and co n n e c tin g rod sm all end inside
d ia m e te r. If th e clearance is o ve r the lim it, replace the
p isto n pin o r c o n n e c tin g rod.
61-16
S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S 61
(c) M easure th e cra n ksh a ft jo u rn a l o u ts id e d ia m e te r
[Crankshaft]
M e asu rin g
and bearing insid e d ia m e te r and calculate the clea r
M e asu rin g p o s itio n d ire c tio n
ance. If the clearance is o ve r th e lim it, replace parts.
l~
~T\ V End play
C JV
[C onnecting rod bearing] D9268A

M e asu rin g
M easuring d ire ctio n p o s itio n
(d) M easure the end p lay in the co n n e c tin g rod and

cran ksha ft and, if the p la y exceeds the lim it, replace
the co n n e c tin g rod.
(4) Piston Pirn)

B4134A
(b) M easure the d ia m e te r o f co n n e ctin g rod bearing

slid in g section. If the d ia m e te r is sm a lle r th an the
lim it, replace the crankshaft.
Replace the co nn ectin g rod bearing if the p la tin g layer
on its Inner surface is w o rn o u t and co p p e r c o lo r
m etal appears.
D9271A
M easure th e p isto n pin o u ts id e d ia m e te r and the pin

fittin g hole in sid e d ia m e te r o f th e p is to n and calculate
the clearance. If the lim it is exceeded, replace the
p iston pin o r piston .
61-17
( 5 ) U n llo a d le r W a ly A s s e m b l y If the u n lo a d e r va lve in u n lo a d e r va lve assem bly is

b a d ly w o rn , replace th e u n lo a d e r valve assem bly.
61-18
5 .1 .4 R eassem b ly
[ 1 -cylin d e r Type]
98 to 115 Nm
(10 to 12 kgfm )
98 to 115 Nm
23 to 25 Nm

31>30>29>(|^>@>25>26>24>23>22>@>@>19>5>4>
3. -> --------------- -------------- ^
14- ^ 13- > 12- . 11 - > 10^ 18- > 17^ 1& ()
8>7>6>9------------------------------------
For reassem bly o f parts w ith an encircled num ber, see procedure
give n in the fo llo w in g .
B3256C
61-19
61 S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
< A sse m b ly se quence>

30>29-24->25>28-*(S>>&e^-*23>22*21>ao) >18>4>3(i>.'i)
13>12>11>10>9>17>16*15>t4>
8>7>6*5-----------1
For reassem bly o f parts w ith an e ncircled n u m b e r, see p roce d u re g iven In the
fo llo w in g .
N2753B
61-20
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES 61
(1 ) A s s e m b ly of C o n n e c tin g Rod
Make sure th a t the a lig n m e n t m ark on the co n n e ctin g

rod is a lig ne d w ith th a t on the co n n e ctin g rod cap.
(2 ) In s ta lla tio n of P is to n R in g s
M ake sure th a t th e rig h t p is to n rin gs are installed at

the rig h t p o s itio n s and th e ir sides w ith letters
sta m p ed face up. Keep th e co m p re s s io n ring ends
120 a pa rt fro m one a n o th e r; place the oil rin g ends at
the ce n te r b etw een the ends o f co m p re s s io n rin gs;
place th e side ring ends 45 fu rth e r aw a y to th e rig h t
and le ft fro m the o il rin g ends.
(3 ) In s ta lla tio n o f S u c tio n V a lv e IHIeldes1
61-21
61 S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES
{4} Installation of Injection Pomp ear
Punch at three places,

except the head gasket
surface
B3251A
Stake th e c y lin d e r head at th re e places sh ow n o ve r

the su ction valve holder. Install th e in je c tio n p u m p gear, sensor plate, and n u t
as in s tru c te d in th e fig u re .
5.2 P^ESSTOIE GOVERNOR

Dam age, corrosion
S ettlin g , dam age
Dam age, corrosion < D is a s s e m b ly se q u e n c e >

1 C over 6 Filter
Dam age, d e terio ra tion
2 A d ju s tin g screw 7 Screen
3 S pring 8 Cap
4 Sleeve 9 D iap hrag m
7 5 Snap ring 10 Body

Repair Kit:
6 Pressure G overnor Kit
5
B4081A
61-22
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES m
5 .2 .2 R e a s s e m b ly a n d A d ju s t m e n t
U n it: kPa (kgf/cm 2)
Part no. N om inal value
High pressure valve Low pressure valve

opening pressure ope ning pressure
M C 802148 to / 7 o ^ 3 .4 (-f 0 .3 5 ) co laa \ + 0 - 5 ( + 0 .0 5 )

63 (6 .4 ) _ 3 4 (_ 0 35)
11 [ 1 -3 ' - 0 . 5 ( - 0 .0 5 )
M C 802150 7 H
7 la n))
8 (8 .0 f 30 .45 (( + Q
0 .3
0 55)) ~in l i t \ * 0-5 (4 0 .0 5 )
70 {7A ) - 3 . 4 ( - 0 .3 5 )

1 0
9 *8 7 6 *5>4 3>2 * 1
B4080B
T e s tin g (3) S lo w ly decrease the a ir ta nk pressure and check

th a t the a ir gauge rea din g starts to increase w hen the
Pressure g o ve rn o r A ir gauge n o m in a l pressure (lo w pressure valve o p e n in g pre s
sure) is reached.
For a d ju s tm e n t, use th e a d ju s tin g screw . A fte r a d ju s t
m ent, tig h te n firm ly w ith the lock nut.
(4) A fte r tig h te n in g th e lock nut, check again the high
and lo w pressure va lve o p e n in g pressures. If th e y are
o u t o f s p e c ific a tio n , a d ju s t again.
(5) Install and seal the cover.
B4082A
(1) C onnect an a ir gauge b etw een the pressure

g o v e rn o r and air tank.
(2) S tart the eng in e and increase air pre ssure s lo w ly
w h ile o b se rvin g th e a ir gauge. Check th a t th e reading
o f the gauge w he n it has sta bilized is as specified
(high pressure valve o p e n in g pressure).
If not, a djust by a d ju stin g tig h te n in g a m o u n t o f the
sleeve. A fte r a d ju stm e n t, tig h te n fir m ly w ith the lock
nut.
61-23
A MITSUBISHI
MOTORS CORPORATION
ENGINE
Shop Manual
364 MAR. 1989
2 0 0 (H)

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A

6 D 2 (for industrial use)

Pub. No. 97841-02003

Stop Manual GROUP INDEX

This shop m anual contains the specification, co n LUBRBCATI0IM .............................. IE 1

No. G roup nam e D escrip tion

00 General E xternal v ie w , m a jo r s p e cifica tio ns, e n g in e o u tp u ts classifie d by a p p lic a tio n , e ng in e n um b e rs,

2. TERM S AMO U N ITS

(1) Front and Rear

(2) Right and Left

(3) Service Standard Term s

(4) T igh ten ing T orque

3. TABLE F OMVERSBQM RATE FOR FO O T-PO UND MAYS OMTQ SO MOTS

U n it S ign o f SI u n it Sign o f fo o t-p o u n d u n it C onversion rate

Mass q u a n tity o f m a tte r kg lb 1 kg = 2.2046 lb

D im ension m ft. 1 m = 3.2808 ft.

Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)

Force N (N ew ton) Ibf 1 N = 0.2248 Ibf

Pressure kPa (kilopascal) lb f/in .2 1 kPa = 0.145 Ib f/in .2

Stress N /cm 2 Ib f/in .2 1 N /cm 2 = 1.45 Ib f/in .2

M o m e n t o f force N m Ibf. ft 1 N m = 0.7375 Ibf. ft

O u tp u t kW (kilo w a tt) HP 1 kW = 1.34 HP

Tem perature C F tC = d .8 tC + 32)F

Inner or o u te r p e rip h e ry dam aged,

N um b e rs assigned ind ica te a typ ica l d is a s s e m b ly sequence.

1 Connecting rod cap Oil ring

1. EXTER N A L VIE W ....................... . 2 3. E N G IN E N U M B ER S AND

< T u rb och a rg e d e n g in e >

Engine m odel 6D22-TC (Tu rb och a rg ed , w ith

Type Diesel, 4-cycle, Diesel, 4-cycle, Diesel, 4-cycle,

C om b u stio n m e th o d D irect in je c tio n D irect in je c tio n D irect in je c tio n

No. and a rra n g e m e n t o f cylin d e r 6 in-line 6 in -lin e 6 in-line

C ylin de r bore x stroke mm 130 x 140 130 x 140 130 x 140

T o ta l d isp la cem e n t cc 11 149 11 149 11 149

E m p ty w e ig h t kg* 980 1 010 1 015

* E m pty w e ig h t as m easured a ccording to M its u b is h i M o to rs C o rp o ra tio n sta n d ard .

The e ngine n u m b e r is s ta m p e d on the p osition as

The engine n u m b e r is im p o r ta n t in k n o w in g the

The caution plate is located as illustrated. The caution

4 . GEMEFAL PRECAUTIONS FOR SER

(7) The oil seals, packings, O-rings, and o th e r rub be r

(1) Before p e rfo rm in g the service p rocedures given

special tools) in the rig h t place to prevent d a m a g e s to sw itches and levers.

correct reassembly. by sharp edges o r corners o f the parts.

position that w o u ld n ot m a r the appearance and or w e ld in g m achine. W e a r g loves as required to

5. GEMEI3AL BOLTS AM MUYS T IG H T - MTEs

Dia. m m Pitch m m 4T (Head m ark 4 o r O) 7T (Head m ark 7 o r 0 ) 8T (Head m a rk 8 o r )

Flange bolts and nuts

Dia. m m Pitch m m 4T (Head m ark 4 o r O) 7T (Head m ark 7 o r ) 8T (Head m ark 8 o r 0 )

1. G ENERAL ........ 2 5 .3 FLY W H EE L, T IM IN G GEAR AND

For m o re effective co o lin g o f the co m b u s tio n c h a m

The c o m b u s tio n ch a m b e r is m ad e up o f the cylin d e r

The valve m ech an ism is o f overhead valve type and is

and exhaust valves, and the end sliding p ortion is

The co nn ectin g rod is a die fo rg in g o f I cross section

(a) The crankshaft is a h ig h -rig id ity die fo rg in g in te g

Flyw heel h o u sin g O -ring

The fro n t p o rtio n o f the crankshaft is a fla ng e type to

(b) The crankshaft gear d rivin g tim in g gear is fitte d

U pper m ain Low e r m a in T h ru st plate

{7} Tim ing G ears

The tim in g gears are a cc o m m o d a te d in the flyw h e e l sh o w n above,

The fly w h e e l is m ade o f cast iron. The p ilo t bearing o f