Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II

Shop Manual
MITSUBISHI
MOIORS
diesel engine
Pub. No. 97841-02003

602
ENGINE
Shop Manual
m
GROUP INDEX
GENERAL
m
ID
FOREWORD ENGINE
This shop manual contains the specification, con LUBRICATION ..............................

struction, operation, adjustment and service proce
dures of the Model 6022, diesel engine for service
mechanics engaged in servicing of the Mitsubishi
FUEL AND ENGINE CONTROL
ID
m
ID
diesel engines.
COOLING ......................................
Please make the most of this shop manual to perform
correct servicing and wasteless operations.
Note that some of the contents of this shop manual
INTAKE AND EXHAUST
m
Ill
are subject to change owing to improvements, etc.
that may be introduced after publication of this shop ENGINE ELECTRICAL
manual.
CLUTCH
Applicable Engine Models

MAR. 1989
SPECIAL EQUIPMENT ..................
Bl
6022
6022-T } Fo, indust,ial use
6022-TC
EngineParts2@gmail.com Parts phone: 269 673 1638

ORGANIZATION GROUP CLASSIFICATION
1. GROUP CLASSIFICATION
This manual is organized into several groups classified according to the engine basic elements.
No. Group name Description
00 General External view. major specifications. engine outputs classified by application, engine numbers.
caution plate. general precautions for servicing. general bolts and nuts tightening torque table
11 Engine Engine proper !cylinder head. valve mechanism. camshaft. piston. crankshaft, timing gear. flywheell.
specifications. service standards, special tool, troubleshooting
12 Lubrication Lubrication system (oil pump, oil filter, oil coolerl, specifications, service standards, special tool,
troubleshooting
13 Fuel and engine Fuel system (injection pump. injection nozzle, fuel filter, pump drive case, water separator!. specifications.
control service standards, special tool. troubleshooting
14 Cooling Cooling system (water pump. thermostat. radiator, cooling system cleaning procedures, fanl. specifications,
service standards. special tool, troubleshooting
15 Intake and exhaust Air cleaner, turbocharger, after cooler, specifications, service standards. special tool, troubleshooting
16 Engine electrical Starter, alternator, preheating system. relays, aut6matic stop device, specifications. service standards.
special tool, troubleshooting
21 Clutch Clutch proper, bearing case, specifications. service standards, special tool, troubleshooting
61 Special equipment Air compressor, air pressure governor, specification, service standards, special tool
NOTE:
Each group starts with page 1 .
2
ORGANIZATION - TERMS AND UNITS, TABLE OF
CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
2. TERMS AND UNITS

The following terms and units are used throughout the entire texts of this manual.
(1) Front and Rear
The terms "front" is the fan side and "rear" the flywheel side of the engine.
(2) Right and Left
The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine.
(3) Service Standard Terms
• Nominal value
Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an
assembly, or the standard performance of an assembly.
• Limit
Shows the value of a part at which the part is no longer serviceable from the performance as well as strength
viewpoints, requiring replacement or repair.
(4) Tightening Torque
Over- or undertightening of bolts and nuts has critical effects on performance and functions.
Tightening torque is therefore specified for some tightening points.
All tightening torque specifications may be considered as "dry" unless "wet" is specified.
Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening
Torque Table.
(5) Units
For length, weight, area, and volume, the SI unit (International System of Units) is used with the metric notation
jointly shown in parentheses.
°
Temperature is shown in centigrade ( C).
3. TABLE OF CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
Unit Sign of SI unit Sign of foot-pound unit Conversion rate
Mass quantity of matter kg lb 1 kg = 2.2046 lb

g oz 1 g = 0.035274 oz
Dimension m ft. 1 m = 3.2808 ft.

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

1 lit. = 0.220 gal. (Imp.)
cc oz 1 cc = 0.033814 oz (U.S.)
1 cc = 0.035195 oz !Imp.)
Force N (Newton) lbf 1 N = 0.2248 lbf
Pressure kPa (kilopascal) lbf/in. 2

1 kPa = 0.145 lbf/in.2
1 kPa = 0.2953 in.Hg
Stress N/cm2 lbf/in.2 1 N/cm2 = 1.45 lbf/in.2
Moment of force N m lbf. ft 1 N m = 0.7375 lbf. ft
Output kW (kilowatt) HP 1 kW= 1.34 HP
Te mperature "C "F t° C = ( 1.8t°C + 32) ° F
3
ORGANIZATION - READING THE ILLUSTRATION
4. READING THE ILLUSTRATION

(Ex. 1: Disassembly and Inspection)
NV ... Nominal Value

L Limit C)----4
o---s Damage. abnormal wear
0--6 Indicates the

service standards.
Damage. discoloration
:��-3
--<) '-.·�
�Piston pro1ect1on
J NV 0.87 to 1.33 mm
Scratches on outer periphery,

cracks on top, melted or
discolored
•connecting rod end play
NV 0.2 to 0.5 mm
L 1.0 mm
Inner or outer periphery damaged,

corroded or peeled
\
indicates inspection to
be made before disassembly.
Indicates visual checks.

corroded or peeled
Numbers assigned indicate a typical disassembly sequence.
'., 2
co·nnecting rod cap
Connecting rod bearing
® Oil ring
7 Snap ring
@ Piston 8 Piston pin
© 1st compression ring 9 Connecting rod
® 2nd compression ring
\
Indicates that the disassembly
procedure is explained in the text.
C2337C
4
ORGANIZATION - READING THE ILLUSTRATION
(Ex. 2: Reassembly)

L Limit
Expander spring
1st compression ring
bull portion
end gap direction
Piston proJecl1on
1Flange projection
i _________,
._
NV O 87 lo 1 33
1 NV O lo 0.08 mm I
2nd compression
ring end gap ring end gap direction
direction
Replace 0-ring
/
Replace rubber ring Gives instruction for jobs to
be done at assembly
34 Nm
(3.5 kgfml
7 0-r ;"'
/�- ___J
I
Replace lock Install with
washer J r-------� arrow upward
Bend lock
2 -""=::IL--'--'-'.J.J.\ \\
1 --=i-w::\.'.-.L�+ -�..L.._/-+�
Lug
direction
175 Nm
(18 kgfm)
10 15
14
Face oil groove
370 Nm 115 Nm
toward sliding surface.
(38 kgfm) (12 kgfml Connecting rod
I
Wet Wet Apply engine oil end play
or lithium grease NV 0.2 to 0.5 mm Crankshaft end play
to lips L 1.0 mm I NV 0.09 to 0.23 mm
L 0.4 mm
Specifies the lightening torque;

!wet) means the part must be tightened in wet state.
Indicates a typical assembly sequence - <Assembling sequence>
J
Indicates that the assembly
procedure is explained in the text.
C5835C
identical among various types of available systems

(1) Illustrations (exploded views and assembly draw
and units.
ings) show a typical service procedures if it is
5
m·
GENERAL
CONTENTS
1. EXTERNAL VIEW •..••••••••••••.•.•••••.••.•. 2 3. ENGINE NUMBERS AND

2. MAJOR SPECIFICATIONS . •••..•...•••••• 3 CAUTION PLATE .••.••••••••••••••••••.•••••• 4
2.1 MAJOR SPECIFICATIONS ••.•.•.••.•. 3 4. GENERAL PRECAUTIONS
2.2 ENGINE OUTPUTS CLASSIFIED FOR SERVICING •••..•••..•..••••••••••••..••. 5
BY APPLICATION ••...•.••.......•...•.•.. 3 5. GENERAL BOLTS AND NUTS
TIGHTENING TORQUE TABLE ..•..••• 6
00-1
GENERAL - EXTERNAL VIEW
1. EXTERNAL VIEW
.. -· . -- - - - ------
- ---- ----
-
<Natural-aspirated engine>
A0243A
<Turbocharged engine>
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS
2. MAJOR SPECIFICATIONS
2.1 MAJOR SPECIFICATIONS
Engine model 6022-TC (Turbocharged, with

6022 6022-T (Turbocharged)
Item after coolerl
Type Diesel. 4-cycle. Diesel, 4-cycle, Diesel, 4-cycle,

water-cooled water-cooled water-cooled
Combustion method Direct injection Direct injection Direct injection
No. and arrangement of cylinder 6 in-line 6 in-line 6 in-line
Cylinder bore x stroke mm 130 X 140 130 X 140 130 X 140
Total displacement cc 11 149 11 149 11 149
Engine dimension
(without fan)
Overall length mm 1 390 1 390 1 401
Overall width mm 898 872 882
Overall height mm 1 023 1 162 1 209
,,
Empty weight k g' 980 1 010 1 015
• Empty weight as measured according to Mitsubishi Motors Corporation standard.
2.2 ENGINE OUTPUTS CLASSIFIED BY APPLICATION
del 6022-TC
6022-T
6022 (Turbocharged, with
(Turbocharged)
App after coolerl
Intermittent rated output kW(HPl/rpm 109 ( 1461/1 500 161 (216)/1 500 179 (2401/1 500
129 (173)/1 800 186 (2491/1 800 207 (277)/1 800
141 (1891/2 000 195 (261)/2 000 219 (2341/2 000
149 (200112 200 201 (2691/2 200 227 (3041/2 200
Continuous rated output kW (HP)/rpm 99 (1321/1 500 146 (196)/1 500 163 (218)/1 500
117 (157)/1 800 169 (2261/1 800 188 (2521/1 800
128 (1711/2 000 178 (2381/2 000 199 (2671/2 000
135 (181)/2 200 183 (2451/2· 200 206 (2761/2 200
NQTE:
1. The output (SAE, gross) is corrected to
standard ambient conditions based on
SAE J1349.
2. The continuous rated output allows
10% (one hour) overload operation.
00-3
•
3. ENGINE
GENERAL - ENGINE NUMBERS AND CAUTION PLATE
NUMBERS AND CAUTION

PLATE
( 1 ) Engine Number
VALVE CLEARANCE(COLDlj
L
INLET 0.4rnrn(0.016in).:--U.--- 1
EXHAUST0.6rnrnW.024in)
Fl RING ORDER 1-5-3-6-2-4 2
FUELINJECTION 11MINGdBTDC II
1 Valve clearance
2 Firing order
3 Fuel injection timing
89012A
E0143
The engine number is stamped on the position as
I �-----
illustrated.
Ex: 6022 -012345

Engine number
�--- Engine model
The engine number is important in knowing the

history of the engine.
(2) Caution Plate
E0175
The caution plate is located as illustrated. The caution

plate bears the valve clearance, fuel injection sequ
ence and timing.
00-4
GENERAL - GROUP PRECAUTIONS FOR SERVICING
4. GENERAL PRECAUTIONS FOR SER·

VICING
Before starting the service procedures, check the
vehicle for total time driven, use conditions. and
user's complaints and requests to know exactly the MITSUBISHI MOTORS
engine conditions. Record information where neces
sary.
To ensure you are doing correct and efficient service
�
GENUINE PARTS �
jobs, observe the following precautions:
Ao o oG A
_ _ _ _,
L_
_ _ _ _ _ _ _ _
_______
_ _ _ _ _
(7) The oil seals, packings, 0-rings, and other rubber

parts, gaskets, and split pins must be replaced with a
new one whenever they are removed. For replace
ment, use Mitsubishi Genuine parts.
A0012A
(1) Before performing the service procedures given

in this manual, know the trouble spots and isolate the
possible cause to determine whether the removal or
disassembly procedure is required.
(2) Select a flat surface for the service job.
(3) When servicing the electrical system, be sure to
disconnect the negative cable from the battery. A0007A
(4) Carefully check parts for oil leaks before cleaning.

After cleaning, it may become difficult to spot defec (8) Apply the specified grease to U-packings, oil
tive areas. seals, dust seals, and bearings before installation.
(5) Ready and make the most of the special tools (9) When work requires an assistant or two, always
required for servicing. Use the right tools (specified make sure of the safety each other. Never play with
special tools) in the right place to prevent damages to switches and levers.
parts and personal injury. (10)Make sure that your shoes are free from grease
(6) Make alignment marks and keep disassembled and oil especially when working on a heavy item.
parts neatly arranged to ensure that they are reas (11)When checking or changing lubricants, wipe off
sembled into the right positions. grease and oil from parts immediately with a waste.
• Special care must be taken for assemblies involv (12)Special care must be taken in handling sensors
ing a number of parts, similar parts, or parts and relays which are suspectible to shocks and heat.
identical at right- and left-hand sides to ensure (13)Use care so that hands and fingers are not injured
correct reassembly. by sharp edges or corners of the parts.
• For alignment and punching markings, select a (14)Wear safety goggles whenever handling a grinder
position that would not mar the appearance and or welding machine. Wear gloves as required to
function. ensure utmost safety.
• Clearly distinguish parts to be replaced from
those reused.
00-5
• GENERAL - GENERAL BOLTS AND NUTS
5. GENERAL BOLTS AND NUTS TIGHT·

TIGHTENING TORQUE TABLE
NOTE:
ENING TORQUE TABLE 1 . Threads and seat surfaces must be in
Unless otherwise specified, the parts and equipment dry state.
of vehicle must be tightened by the following stan 2. When there is a difference between the
dard bolts and nuts. Tightening torques for these nut and bolt (stud) identification marks,
bolts and nuts are shown below. tighten to the torque corresponding to
the bolt (stud) identification mark.
Standard bolts and nuts
Unit: Nm (kgfm)
Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or 8) BT (Head mark 8 or <Bl
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

Unit: Nm (kgfml
Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or 8) BT (Head mark 8 or <Bl
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 (B.O 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)
Identification mark of nut

Identification mark of stud
6T
4T
®
�I
8T
@
4T 7T
Numerical Notched
mark
0 8 @
<+
mark
®
ldented
mark
(2)
Embossed
mark
� �
A0067A
A0066A
00-6
m-
ENGINE
CONTENTS
1. GENER·AL ...................................... 2 5.3 FLYWHEEL, TIMING GEAR AND

2. SPECIFICATIONS •••••••••••.•.•••••••••••• 8 CAMSHAFT ................................ 30
3. SERVICE STANDARDS .................. 9 5.3.1 Disassembly ........................... 30
3.1 SERVICE STANDARD TABLE ..... 9 5.3.2 Inspection .............................. 34
3.2 TIGHTENING TORQUE TABLE ... 12 5.3.3 Disassembly ...................._....... 38
4. SPECIAL TOOL .............................. 13 5.4 CRANKCASE AND MAIN MOVING
5. SERVICE PROCEDURES ................ 17 PARTS ..........................·.............. 42
5.1 MEASUREMENT OF COMPRES· 5.4.1 Disassembly ........................... 42
SION PRESSURE ........................ 17 5.4.2 Inspection .............................. 46
5.2 CYLINDER HEAD AND VALVE 5.4.3 Reassembly ............................ 56
MECHANISM .............................. 18 5.5 INSPECTION AND ADJUSTMENT
5.2.1 Disassembly ........................... 18 OF VALVE CLEARANCE ............. 62
5.2.2 Inspection .............................. 21 6. TROUBLESHOOTING .................... 64
5.2.3 Reassembly ............................ 27
11-1
•
1. GENERAL
ENGINE - GENERAL
(1) Combustion Chamber
Injection
nozzle
B0376A
Piston
For more effective cooling of the combustion cham
ber, water directors which direct coolant flow are
pressed into the bottom of the cylinder head.
(2) Valve Mechanism
Valve ca·p
Adjusting screw
Rocker shaft Valve cotter
bracket _,__--'!..-�//
B0375A Valve spr_ing
Valve spring
inner
The combustion chamber is made up of the cylinder Lower retainer
head and piston top. The injection nozzle as well as Valve stem
seal
the nozzle tube is mounted to the cylinder head. The
nozzle tube holds the nozzle in position and protects Valve guide
the nozzle sheathed by it from coolant. Since the

outside of the nozzle tube is exposed to the water
jacket, the top end of the tube is sealed off with an
Tappet
0-ring and the bottom end staked to prevent entrance
of water.
Combustion is accomplished by compressing the fuel
directly injected into the combustion chamber.
B0377A
The valve mechanism is of overhead valve type and is

constructed as shown above.
11-2
ENGINE - GENERAL
(a) Both inlet and exhaust valves are made of

m
surface-treated heat-resistant steel. The valve seat
angle is 45.
A valve stem seal is provided on the stem of valve to
control the quantity of lubricant of the valve and valve
guide sliding portions.
(b) The valve springs are unevenly-pitched springs.
Two inner and outer springs different in coiled
direction are installed.
· · Rubber rin�1
(c) The rocker and rocker shaft are supported on the '- 0-ring
rocker shaft bracket and are independently installed
for each cylinder. Some rockers are used for both inlet 80378A
and exhaust valves, and the end sliding portion is
quenched. (b) The coolant fed in from the water pump at the left
The rocker shaft is a hollow round rod sealed off by front end of the crankcase cools the oil cooler, then
thrust plates at both ends. The inside of the shaft flows through the water jacket holes and around all
constitutes an engine oil passage. the cylinders to cool them before reaching the
(d) A steel ball and concave piece are respectively cylinder head.
welded to the bottom and top ends of the push rod (c) The cylinder liner is of removable wet type and its
and both ends are case-hardened. top and bottom are press-fitted at the top of the
(e) The tappet is of cylindrical shape and its mating crankcase and the water jacket in crankcase, respec
surfaces with the camshaft are spherical. The tappet tively.
is removable through the side of the crankcase. Rubber rings and 0-rings are installed at the top and
(f) The cam profile of the camshaft has a special bottom of cylinder liner to prevent entry of coolant.
curve. The surface is induction-hardened to improve The water jacket has a coolant throttling shelf for
the performance of the valve mechanism at high higher cooling performance.
speed operation and improve wear resistance. (4) Piston and Piston Ring
(3) Crankcase and Cylinder Liner (a) Piston
<6022, 6022-TC>
Weight
<6022 _T;·· - Size mark
(A, B, C) 1 _ Part number
_
•
7":;;�, - · --..)
�da�� I ''�
Weight.rna<k Piston ring

/��
�L\e,
,-::.
If]-'� __ --,,)// insert
, . -y\_./ l'-0--,-;:.,
1
Srrn mark Part !

__(A��·- CJ._. -��-�� /
"F" with an arrow
for the front mark
84205A
B0319E
(a) Seven camshaft bushings are installed to the The piston, made of aluminum alloy casting, has a
camshaft bearing portion of the crankcase. To facili toroidal type combustion chamber at its top.
tate insertion and removal of the camshaft from the
rear end of the case, the bearing I.D. is narrower
toward the front.
11-3
Ill ENGINE - GENERAL
A Niresist piston ring insert is cast into the 1st piston (5) Connecting Rod and Connecting Rod
ring groove to increase durability. Bearing
Stamped on the top surface of the piston are a size
mark (or oversize dimension on oversize pistons) for <6022-T C> I
selection fit with the cylinder liner, a piston weight
mark, part number, identification mark, and the "F" ,
with an arrow for the front mark showing the piston
installing direction. -··-- -·�-----· I
Piston pin for connecting piston to connecting rod is
of full-floating type and is prevented from moving out
by means of a snap ring installed on each end of the
pin ends.
On the piston for the 6022-TC, a cooling cavity is
provided.
(b) Piston ring
� 1st compression ring

� [full keystone type)
2nd compression ring

-,' ) [taper faced inner
=---l�--�cut type!
(oX Oil ring

[dual type with
<6022. 6022-TC> an expander spring I B0379E
The connecting rod is a die forging of I cross section

<6022-T only> providing high rigidity. A lead bronze bushing is
B0374C
press-fitted onto the small end. The connecting rod
bearing of the big end is a split type plain bearing.
There are three piston rings installed: two compres
Through the stem of connecting rod, an oil passage is
sion rings and one oil ring. The sliding surface of each
provided obliquely to lubricate the small end bushing.
ring is hard chrome plated to improve durability.
On the top of connecting rod for the 6022-TC, an oil
The piston rings are shaped as shown in the figure.
hole is provided for cooling the piston.
The connecting rod and connecting rod cap are
coupled with four bolts.
11-4
(6) Crankshaft and Main Bearing
ENGINE - GENERAL
·-- ··-·-·--- ---·-··----- ---------

m �
-
·· Rubber type (single mass;;>/ Torsional damper
·-, //
I
I
hole
Journal sectin11
� Torsional damper
Balance weight Crankshaft

pulley
84206A
(a) The crankshaft is a high-rigidity die forging integ · Crankshaft

<Viscous type>
ral with the· balance weight.
An oil hole in each journal is through to that in pin, - · Torsional damper
feeding some of the main bearing lubricating oil to _}]

_ - Crankshaft
pulley
the pin for lubrication of the connecting rod bearing. �
�------- -
- ------- - - - ----�
Flywheel housing 9-ring 1rr1i Crankshaft B4489A
The front portion of the crankshaft is a flange type to

\ which the crankshaft pulley is mounted with bolts. A
\ torsional damper mounted to the pulley absorbs the
torsional vibration of the crankshaft.
80351A
(b) The crankshaft gear driving timing gear is fitted

onto the rear end of the crankshaft.
Note that the crankshaft has an axial lip type oil seal
fitted to each of its front and rear ends.
11-5
m
(a) Main bearing
ENGINE - GENERAL
The main bearing is a split type plain bearing made of

special alloy plated kelmet metal with backing metal.
The upper main bearing has an internal oil groove
and oil hole which coincides with the oil hole in the
crankshaft.
Seven pairs of main bearings are provided. Split type
thrust plates are mounted to the rear-most bearing to
bear the thrust of the crankshaft.
Upper main Lower main Thrust plate

bearing bearing
B0382A
(7) Timing Gears
Camshaft gear
2�63
Injection pump gear
2=63
Idler gear "A"

2=33
Crankshaft gear
Z=63
Idler gear "C"

2=68
Idler gear
2z47
Oil pump gear

2=53 B0383B
The timing gears are accommodated in the flywheel shown above.

housing at the rear of the engine. The gear train is as
11-6
ENGINE - GENERAL
Each gear is a carbon steel helical gear having a (8) Flywheel

m
high-prescision tooth surface machined by the shav
ing machine and given surface treatment to improve
durability.
A timing mark is stamped on each timing gear.
Correct meshing can be achieved by aligning the
timing marks at reassembly.
Pilot bearing
The crankshaft gear, press-fitted onto the crankshaft Cylinder No.
and held in position by a dowel pin, drives all gears. II11)]III I
Cylinder No.
''
1111111111
80386A
Idler gear "A"
Collar The flywheel is made of cast iron. The pilot bearing of

Crankshaft the clutch shaft is installed at the center of the
flywheel. The ring gear which meshes with the starter
pinion is shrinkage-fitted on the outside periphery of
the flywheel.
The ring gear teeth crests are induction-hardened to
Thrust plate 80384A assure high durability. One side of the teeth is
chamfered to make sure that the starter pinion fits
The idler gear is, at one end, mounted to the easily.
crankcase with the idler shaft bolt, and supported, at The cylinder numbers and angle scale are stamped on
the other end, on the flywheel housing. the outside periphery of the flywheel as shown in the
A bushing is pressed into the idler gear which turns figure.
on the idler shaft.
The bushing is lubricated by the engine oil flowing
through the inside of the idler shaft from the crank
case oil hole.
11-7
•
2. SPECIFICATIONS
ENGINE - SPECIFICATIONS
Item Specifications
Engine model 6022 6022-T 6D22-TC

Type Water cooled, Water cooled, Water cooled,
4- cycle diesel 4-cycle diesel 4-cycle diesel
Number of cylinders- arrangement 6-in-line 6-in-line 6-in-line
Valve mechanism Overhead valve Overhead valve Overhead valve
Combustion chamber Direct Direct Direct
injection type injection type injection type
Cylinder bore x stroke mm 130 X 140 130 X 140 130 X 140
Total displacement cc 11 149 11 149 11 149
Compression ratio 17 16 15.5
Firing order 1-5-3-6-2- 4 1-5-3-6-2 -4 1-5-3-6-2-4
Cylinder liner Type Wet type Wet type Wet type
Piston Type Trunk. slipper Trunk, slipper Trunk, ·slipper
skirt type skirt type skirt type
(Cooling cavity provided)
Piston ring O'ty Compression ring: 2 Compression ring: 2 Compression ring:
Oil ring: 1 Oil ring: 1 Oil ring: 1
11-8
3. SERVICE STANDARDS
ENGINE - SERVICE STANDARDS
m
3.1 SERVICE STANDARD TABLE
Unit:mm
Description Nominal v;tlue Limit Correction and remarks

!Basic diamete, I
Compression pressure 2.75 MPa 1.96 MPa Difference between cylinder within
lat 200 rpm) (28 kgt/cm 2 l 20 kgf/cm2 0.39 MPa (4 kgf/cm 2)
Rocker to rocker shaft clearance 1281 0.2 Replace bushing.

0.03 to 0.08
Outer valve spring Free length 89.38 85 Replace.
Load (Installed length: 450 N 146.1 kgrl 380 N

58.35) (39 kgfl
Inner valve spring Free length 65.04 62.0 Replace.
Load (Installed length: 115 N (12 kgfi 100 N

50.35) (10.2 kgfl
Squareness - 2.5
Crankcase tappet hole to tappet clearance 1351 0.2 Replace tappet.

0.06 to 0.10
Push rod runout - 0.5 Replace.
Cylinder head bottom surface distortion 0.07 or less 0.08 Correct or replace.
Height from top to bottom surface of cylinder head 130 129.8 Replace.
Valve stem O.D. Inlet 11.95 to 11.96 11.85 Replace.
Exhaust 11.91 to 11.93
Valve stem to valve Inlet 1121 0.05 to 0.09 0.2 Replace valve guide.
guide clearance
Exhaust 1121 0.09 to 0.12
Depth of valve from cylinder head Inlet 0.25 to 0.75 1.0 Replace valve seat insert.
bottom surface Service limit: value when a
new valve is installed.
Exhaust -0.05 to 0.45 0.7 (- indicates projection amount.)
Valve seat angle 45" -

Valve margin Inlet 2.2 1.7 Replace.
Exhaust 2.5 2.0
Seat width of valve seat insert 2.69 to 2.96 3.5 Correct or replace.
Eccentricity of flywheel housing - 0.2 Correct installed condition.
11-9
• ENGINE - SERVICE STANDARDS
Unit:mm
Description Nominal value Limit Correction and remarks

[Basic diameter[
Flywheel Eccentricity - 0.2 Correct installed condition.

(Flywheel housing)
Friction surface distortion 0.1 or less 0.2 Correct.
Depth from clutch cover mounting 48 49.5 Replace.

surface to friction surface
Backlash Between crankshaft gear and 0.12 to 0.26 0.4 Replace.

of timing idler gear "B"
gears
Between idler gear "A" and 0.13 to 0.26 0.4
camshaft gear
Between idler gear "A" and 0.13 to 0.26 0.4

idler gear "C"
Between injection pump gear and 0.12 to 0.26 0.4

idler gear "C"
End play of idler gear 0.1 to 0.28 0.4 Replace thrust plate.
·'
Idler shaft "A" to idler gear "A" bushing clearance [401 0.2 Replace bushing.
0.03 to 0.06
Idler shaft "C" to idler gear "C" bushing clearance [461 0.2 Replace bushing.
0.03 to 0.06
End play of camshaft gear 0.05 to 0.22 0.4 Replace thrust plate.
Camshaft No. 1 journal [651 0.25 Replace bushing.

journal to 0.03 to 0.08
camshaft
bushing No. 2 journal 165.251
clearance 0.03 to 0.08
No. 3 journal 165.501

0.03 to 0.08

0.03 to 0.08
No. 5 journal [65.751

0.03 to 0.08

0.03 to 0.08
No. 7 journal 1661

0.03 to 0.08
Cam profile Inlet [8.831 8.3 Inlet: lobe height, 56.167;

(Ditterence between lobe height and base circle diameter, 47.334
base circle diameter!
Exhaust [8.821 8.3 Exhaust: lobe height, 56.036;
base circle diameter, 47.216
Camshaft bend 0.05 or less 0.08 Replace.
Crankcase top surface distortion 0.07 or less 0.2 Correct.
11-10
m Unit:mm
Oesc.r1pt1on Nom111al value Limit Correction and remarks

[Basic d1amclcr[
Cylinder 1.0. 130.014 10 130.054 130.25 Replace o� correct to oversize.

liner ·-
Cylindricity 0.02 or less
(diameter basel
Projection from crankcase top O to 0.08 -

surface
Piston to 6022 1130[ - Repair or replace cylinder liner,

cylinder 0.178 to 0.204 or replace piston.
liner clear-
ance (selec- 6022-T 11301 -
lion fit) 0.173 to 0.199
6022-TC 11301 -
0.188 to 0.214
Piston 1st ring 0.06 to 0.11 0.25 Replace piston ring or piston.
ring
groove 2nd ring 6022 0.05 to 0.08 0.15
to ring
clearance 6022-T, 6022· TC 0.07 to 0.10
Oil ring 0.03 to 0.06 0.15
Piston ring open end clearance 0.4 to 0.6 1.5 Replace.
Projection of piston from top surface of crankcase 0.87 to 1.33 - Check each part.
Piston pin hole to piston pin clearance 1501 0.1 Replace piston or piston pin.
0.01 to 0.02
Flatness of cylinder liner flange supporting surface - More than Replace crankcase.
on crankcase 0.1
Connecling Bushing to piston pin clearance 1501 01 Replace bushing.

rod 0.02 to 0.05
Bend and torsion - 0.05 or less Correct or replace.
End play 0.2 to 0.5 1.0 Replace.
Connecting Oil clearance 1841 0.25 Replace bearing.

rod bearing 0.07 to 0.13
Tension when free - Less than Replace.

90.5
Crankshaft End play 0.09 to 0.23 0.4 Adjust with oversize thrust plate.
Bend 0.04 or less 0.1 Correct or replace.
Out-of-roundness of journal and pin 0.01 or less 0.08 Grind and correct to undersize.
Cylindricity of journal and pin 0.006 or less -
Main Oil clearance 11001 0.25 Replace bearing.

bearing 0.08 to 0.15
Tension when free - Less than Replace.

106.5
Valve clearance Inlet 0.4 - Adjust.
Exhaust 0.6 - Adjust.
11-11
•
3.2 TIGHTENING TORQUE TABLE
Description Thread size Tightening torque Remarks

0.0. x Pitch mm Nm (kgfm)
Engine Cylinder M14 x 2 - Wet

proper head bolt For tightening
procedure refer lo
5.2.3 (6).
Rocker shaft bracket bolt MlO x 1.5 34 (3.5)
Rocker cover bolt MlO x 1.25 9.8 (1)
Rocker adjusting screw lock nut MlO x 1.25 59 (6)
Oil jet check valve M12 x 1.75 34 (3.5)
Connecting rod nut M13 x 1.25 115 (12) Wet
Main bearing cap bolt M18 x 2.5 370 (38) Wet
Crankshaft pulley bolt M14 x 1.5 175 (18)
Camshaft gear nut M27 X 1.5 265 (27) Wet
Idler shaft bolt "A" M16 x 2 155 (16)
Idler shaft bolt "C" M16 x 2 155 (16)
Idler shaft nut (for mounting collar! M16 x 1.5 98 (10)
Flywheel bolt M16 X 1.5 315 (32) Wet
Flywheel housing bolt M12 x 1.75 69 (7)
11-12
4. SPECIAL TOOL
ENGINE - SPECIAL TOOL
m
Tool name Part No Sh;,pe Use
Compression gauge adapter MH0614GI Measurement or c01npression pressure

::�me<e,s
Distance
between
centers 46
85001A
Thickness gauge MH061359 Adjustment of valve clearance
85011A
Valve lifter Valve liher MH061668 Removal and installation of valve cotter
Valve lifter
Hook MH061679
I.D. 42 Hook
85042A
Nozzle tube remover MH061232 Removal of nozzle tube
Diameter 12.5
�
�-+
Diameter 8.7
85051A
Gear puller MH061061 Removal of gear and pulley
Maximum pulling
0.0. 200 85071A
Piston ring tool 31191-02900 Removal and installation of piston· ring
85091A
11-13
• Tool name
Part No. Shape Use
Rocker bushing puller MH061236 Removal and installation of rocker

bushing
B5311A
Valve guide puller 30091-08100 Removal and installation of valve guide
B5111A
Valve seat insert Caulking tool body Installation and caulking of valve seat
caulking tool MH061360 insert
Caulking tool
Caulking ring inlet ,.,.--< body

MH061650
Caulking ring exhaust

MH061651 0.0.
Inlet 59
Exhaust54
Diameter 12
B5202A
Valve lapper 30091-07500 Lapping of valve
B5261A
fdler gear bushing puller MH061228 Removal and installation of idler gear
bushing (Idler gear "A")
MH062046 Removal and installation of idler gear

bushing (Idler gear "C")
Crankcase table MH061889 Measurement of flatness of cylinder

liner flange supporting surface on
crankcase
B1480A
11-14
m
Tool name P,irl No. Shape Use
Cylinder liner extractor MH061490 Removal of cylinder liner
B5131A
Cylinder liner installer MH061759 Press-fitting of cylinder liner
Connecting rod bushing puller MH061238 Removal and installation of connecting

rod bushing
B5321A
Rear oil seal slinger installer MH061652 Press-fitting of rear oil seal slinger
Froni oil seal slinger installer MH061817 Press-fitting of front oil seal slinger
Diameter '-
95 \/
B0585A
Piston Piston guide clamp MH061666 Piston guide 1.0. 130 Insertion of piston
guide clamp
Piston guide lever MH061658
Piston guide lever B51718
11-15
• Tool name
Part No. Shape Use
Nozzle tube stamp MH061229 Installation of nozzle tube
Nozzle tube installer flange MH061416
Nozzle tube installer bolt MH061231
between
centers 46
Diameter 8
85181A
Valve stem seal installer ME067431 Press-fitting of valve

stem seal
Diameter 12
Diameter 24
85191A
11-16
5. SERVICE PROCEDURES
ENGINE - SERVICE PROCEDURES
NOTE:
•
5.1 MEASUREMENT OF COMPRESSION Cover the mounting holes and injection
PRESSURE pipes to prevent entry of dust and dirt.
Compression pressure must be measured prior to

disassembly of the engine.
Measure the compression pressure at regular inter NV..
L
Nominal Value
Limit
vals and keep track of its changes. During the break-in
period or after parts have been replaced with new
ones, there is a slight increase in the pressure as the
piston rings and valve seats fit snugly in position. As
rough edges and friction between parts are gradually NV 2.75 MPa 128 kgf/cm')
reduced, the pressure comes down. L 1.96 MP a 120 kgf/cm 1 )
Difference between cylinders
Measurement Procedure 0.39 MPa 14 kgf/cm') maximum
Compression Gauge Adaptor

,, MH061461
85561A
85554A
(3) Install Compression Gauge Adaptor (special tool)

(1) Retighten the cylinder head bolts to specified on the injection nozzle mounting hole together with a
torque and let the engine warm up until the coolant gasket and connect the compression gauge (measur
temperature reaches 75°C to 85° C. ing instrument).
NQTE: (4) To make sure that the fuel is not fed under
In retightening the cylinder head bolts, pressure from the injection pump, pull the stop lever
observe the tightening sequence in (6) in of the injection pump all the way in the stop direction
5.2.3. beforehand.
(5) In this condition, let the starter run the engine and
measure the compression pressure at a rotating
speed of 200 rpm.
NOTE:
-· 1. Make sure that the engine speed is also
v\ �
.,� .
- "' measured as compression pressure
., ,<.,
.
'·
varies with the engine speed.
' 2. Make measurement for all cylinders, as
wear and other conditions vary from
one cylinder to another.
85560A
(2) Remove all injection nozzles from the cylinder

head.
11-17
m
5.2
CYLINDER HEAD AND VALVE MECHANISM

5.2.1 Disassembly
Oil hole
ing
�
,V
Wear. damaged
-!ear
threads
Water leaks.
9 19 gas leaks
Wear. damage
23
Carbon deposition,
cracks, scale
deposition, damage
18
Carbon deposition,
burn. cranks.
damage, ridge wear
Water leaks,
oil leaks,
gas leaks
<Disassembly sequence>
1 Rocker cover 13 Outer valve spring
2 Rocker bracket mounting bolt 14 Inner valve spring
3 Cylinder head bolt @ Valve stem seal
4 Thrust plate 16 Lower retainer
5 Rocker 17 Inlet valve
'6 Set screw 18 Exhaust valve
7 Rocker shaft {[9) Nozzle tube
® Rocker shaft bracket 20 Water director
9 Push rod 21 Sealing cap
10 Valve cap @ Cylinder head
@ Valve cotter 23 Crankcase side cover
12 Upper retainer 24 Tappet
For disassembly of parts with an encircled number, see following items.
C1542A
11-18
Disassembly Procedure
(2) Removal of Cylinder Head Assembly

•
(1) Removal of the Rocker Shaft Bracket
Assembly
Rocker cover
Cylinder head
Rocker shah bracket

Cylinder head
mount1n� bolt
gasket
Cylinder head bolt Knock pin
Adjusting
screw B9014B
nut
C1543B
The cylinder head is held in position by the dowel
pins on the top surface of the crankcase. To remove
(a) Where the push rod is forcing the rocker up, the the cylinder head, lift it directly upward.
rocker adjusting screws should be loosened before all NOTE:
bolts are removed. 1. To remove the cylinder head, make
sure that the injection nozzle is re,
moved beforehand. (Refer to Group 13
Fuel and Engine Control.) If the cylinder
head is placed on a workbench with the
nozzle still installed, the end of the
nozzle extending from the bottom sur,
face of the cylinder head will be dam,
aged.
2. When the cylinder head gasket is re,
moved, use care to prevent damage to
the cylinder head and crankcase.
C1544B (3) Removal of Valve Cotter
(b) The rocker shaft bracket assembly is held in

position on the cylinder head by spring pins. Lift it
directly upward to remove it.
Valve Lifter
, Hook
Valve Lifter MH061679
MH061668
Valve cotter
/
� I
852828
To remove the valve cotter, use special tools (Valve

Lifter and Hook) and compress evenly the valve
spring.
11-19
m ENGINE - SERVICE PROCEDURES
(4) Removal of Nozzle Tube
Nozzle Tube Remover

MH061232
Nozzle tube
C1527A
NOTE:
The nozzle tube need not be removed
unless water leaks, gas leaks, etc. are
evident.
11-20
5.2.2 Inspection
•
�---- - - - - - -
---- - --- - -
- ------ -- ·-··-- -------------------- - ----
BO ... Basic Diameter

Clearance Free length NV. Nominal Value
BO 28 NV 89.38 L Limit
NV 0.03 to 0.08 L 85
L 0.2
Load/installed length
NV 450N (46.1 kgfl/58.35
L 380 N (39 kgfl/58.35
Free length
NV 65.04
L 62.0
Load/ installed length

NV 115 N 112 kgfl/50.35
L 100 N (10.2 kgrl/50.35
Runout
L 0.5 S q uareness Crankcase tappet hole to
L 2.5 tappet clearance
BO 35
NV 0.06 to 0.10
L 0.2
Valve stem O.D. Valve margin

Inlet valve Exhaust valve Inlet Exhaust
NV 11.95 to 11.96 NV 11.91 to 11.93 NV 2.2 NV 2.5
L 11.85 L 11.85 L 1.7 L 2.0
Valve guide to valve stem clearance Valve seat insert seat width
Inlet valve Exhaust valve NV 2.69 to 2.96
BO 12 BO 12 L 3.5
NV 0.05 to 0.09 NV 0.09 to 0.12
L 0.2 L �2 Distortion of cylinder head bottom surface
NV 0.07 or less
Depth of valve from bottom surface of L 0.08
cylinder head
Inlet valve Exhaust valve Height from top to bottom surface of cylinder head
NV 0.25 to 0.75 NV -0.05 to 0.45 NV 130
L 1.0 L 0.7 L 129.8
Valve seal angle

NV 45'

C2757A
11-21
m
Inspection Procedure
(3) Inspection of Valve Spring

( 1) Rocker to Rocker Shaft Clearance
Squareness
!inner spring only)
�
Measuring
C2701A
position
C2734A
Mesure the free length and installed load of the spring
If the limit is exceeded, replace the bushing in the and replace if the measurement exceeds the limit. For
rocker. the inner spring, check also for squareness.
(2) Replacement of Rocker Bushing (4) Tappet to Crankcase Clearance
Measuring
<Measurement on tappet side>
position
To remove To install
C2745A
Adjusting <Measurement on crankcase side>

screw side C2762B
NOTE:
1. Align the bushing and rocker oil holes.
2. Face the bushing joint toward the ad·
justing screw.
C2763A
If the limit is exceeded, replace the tappet.
11-22
DI
(5) Runout of Push Rod (7) Valve Stem O.D.
Measuring position
C2747A C3102A
Check for runout and replace if the reading on the dial Replace the valve if the measurement is below the
indicator exceeds the limit. limit.
(6) Cylinder Head Bottom Surface Distor (8) Valve Guide to Valve Stem Clearance
tion
Measuring position
C3126B
C3125A
Calculate the clearance from the valve guide I.D. and

If the limit is exceeded, correct the distortion with a valve stem O.D. If the limit is exceeded, replace the
surface grinder. valve guide.
NOTE: EngineParts2@gmail.com Parts phone: 269 673 1638
Grind the cylinder head only to the extent
that the height from the top to bottom
surfaces is within the limit.
11-23
•
· (9) Replacement of Valve Guide
Valve Guide Puller

30091-08100
Valve guide 000
Good Bad Bad
C2707A
To install C3113A
If any unusual contact pattern is noted, correct as
Using Va!.ve Guide Puller (special tool), replace the follows.
valve guide. Minor fault: Lapping
NOTE: Serious fault: Correct valve and valve seat.
When the valve guide is installed, make (11) Correction of Valve Face
sure that the valve guide flange is securely
seated on the cylinder head.
Valve seat
(10) Valve Contact with Valve Seat Insert angle
Valve .margin ,,,_
--+---�,,-r·- .. J-
Valve
C2708A C27108
Grind the valve face with a valve refacer to obtain the

820248
specified valve seat angle.
NOTE:
(a) Apply an even coat of minium to the valve seat 1. Keep grinding margin to a m1mmum.
insert surface in contact with the valve. 2. If the valve margin is below the limit
(bl Using Valve Lapper (special tool), let the valve hit after the grinding correction, replace
against the valve seat insert once. the valve.
NOTE: 3. After the grinding correction, be sure to
1. When letting the valve hit against the lap the valve and valve seat insert.
valve seat insert, do not turn the valve. [Refer to Item (14) that follows.]
2. Contact pattern should be checked
when the valve guide is inspected or EngineParts2@gmail.com Parts phone: 269 673 1638
replaced.
11-24
(12) Correction of Valve Seat Insert (13) Replacement of Valve Seat Insert
m
Since the valve seat insert is installed by expansion
fit, replace it by the following procedures.
C3127A
Valve
Valve Valve seat
sinkage
margin angle 0.5 to 1.0
Cut off.
C2711A
(a) Grind inside surface of the valve seat insert to

reduce the thickness and then remove it at room
temperature.
Valve seat i11sert
Valve
C2710A
(a) Using a valve seat cutter, cut the insert to obtain

the specified valve seat angle and seat width. Use 15°
or 75° cutter first, then 45 ° one. Head 1.0. Head 1.0.
57 +0.03 52 +0.03
NOTE: 0 0
1. Keep the amount of cut to a minimum. (Inlet side) (Exhaust side)
2. If the valve sinkage after cutting ex· C3128A
ceeds the limit, replace the valve seat
Install Caulking
insert.
(b) After correction, lightly grind by holding about D D Caulking
Tool Body
MH061360
#400 sandpaper between the cutter and valve seat
insert.
>----<J Caulking Ring
Inlet
NOTE: MH061650
After the correction procedure, be sure to Exhaust
MH061651
lap the valve and valve seat insert. [Refer
to Item (14) that follows.]
811118
(b) Make sure that the cylinder head and valve seat
insert are provided with sufficient interference.
(c) Immerse the valve seat insert in liquid nitrogen
for cooling it, and fully heat the cylinder head.
11-25
• ENGINE - SERVICE PROCEDURES
(d) Install the valve seat insert using the Caulking NOTE:
Tool Body, Caulking Ring and Caulking Tool (special 1. Make sure that no compound sticks to
tools) and caulk the periphery of the valve sert insert. the valve stem.
NOTE: 2. Use intermediate-mesh compound ( 120
When the valve seat insert is installed, to 1 50 meshes) first, then fine-mesh
direct the chamfered side of the caulking compound (200 meshes or more) for
ring toward the valve seat insert. finishing.
3. Addition of a small amount of engine oil
(e) Reface the valve seat insert so that the seat width
to the compound helps make it easier
and valve sinkage are up to specifications.
to apply it evenly.
(14) Lapping the Valve and Valve Seat
Insert
The valve and valve seat insert contact must be even
throughout their contacting surfaces.
They must be lapped whenever either the valve or
valve seat insert has been corrected or replaced.
C3130A
(b) Using Valve Lapper (special tool), seat the valve

Compound
and valve seat insert.
While turning the valve slightly at a time, strike it
against the valve seat insert.
C2715A (c) Wash away the compound in gas oil, etc.
(d) Apply engine oil to the contacting surface to seat
(a) Apply a thin, even coat of lapping compound to them with oil.
,the seating surface of the valve. (e) Check to ensure that they are properly seated.
11-26
5.2.3 Reassembly
m
� - - - -
� �---
- ·- - - - - - - -- - -· ---· -·----------- - - - - --- --
-- - -
Close-coiled end on the

cylinder head side
1 14 10 11 12
3
4 5 6 8 7
59 Nm
(6 kgfm) Close-coiled end of on the
cylinder head side
Leak test:
No leaks are allowed
9 with a 196 kPa (2 kgf/cm')
hydraulic pressure.
Apply sealant to nozzle tube.

(THREEBOND 1211 or equivalent)
21
34 Nm
9.8 Nm (3.5 kgfm)
(1 kgfm) 22
3 2
23
24
Refer to item (6), section 5.2.3.
17 18 EngineParts2@gmail.com Parts phone: 269 673 1638
<Assembly sequence>
L
('l2,+:2o·�{;i1L+,i9,.-,18-17--,,1 s�1�14-,13-12�r, ,-,___,1 O
T'
,z4,�23_J
�B->7__,�5-,4->(3)-..,2--,1
For assembly of parts with an encircled number, see following
items.
C6641C
11-27
•
Reassembly Procedure
(3) Installation of Valve Stem Seal

(1) Installation of Water Director
Water director
aling cap
Align notch with this line.
Cylinder head
6 mm 2 mm
�
® g 0 O
Valve stem seal
Cylinder head
� 0 ®�o C6G38A
C6642A
The valve stem seal should be installed by applying
Install the water director with its notch directed as engine oil to the lip and striking down Valve Stem
shown. Seal Installer (special tool) until it touches the cylinder
head.
(2) Installation of Nozzle Tube
NOTE:
1. Before the valve is installed, apply a
Nozzle Tube
Installer Bolt small amount of engine oil to the stem.
MH061231
2. After installation, check to ensure that
the valve stem seal spring has not been
deformed or damaged.
(4) Installation of Valve Cotter
Apply engine oil.
Apply sealant
(THREEBOND 1211
or equivalent).
Valve hook
MH061679
(a) Apply sealant to the end of the nozzle tube and

insert into the cylinder head. Valve cotter
(bl Using Nozzle Tube Flange (special tooll, press the

nozzle tube against the cylinder.
(c) Apply engine oil to Nozzle Tube Stamp (special
tool) and insert into the nozzle tube. B5282B
(d) Thread Nozzle Tube Installer Bolt (special tool) to
push the stamp until it can be removed from the Install the valve cotte r, while compressing the valve
bottom of the cylinder head. spring, using Valve Lifte r (spe cial tooll.
(el After installation, perform leak test to verify NOTE:
water-tightness. Install the valve spring with the closely
coile d portion toward the cylinde r head.
EngineParts2@gmail.com
Parts phone: 269 673 1638
11-28
(5) Installation of Rocket Shaft Bracket (6) Tightening of the Cylinder Head Bolts
m
and Cylinder Head
C6649A
A Tighten the cylinder head bolts in the sequence

Cylinder head -----��;;rc=-j, \ shown above to 175 Nm (18 kgfm).
gasket After tightening, verify the correct torque, then re
?°
tighten 90° j. .
Locating
pin Parts phone: 269 673 1638
B9014C
Seat the cylinder head on the crankcase, while lining

it up with the locating pin.
11-29
•
5.3
FLYWHEEL, TIMING GEAR AND CAMSHAFT

5.3.1 Disassembly
<With mechanical tachometer drive> <With electrical speed sensor>
10A�
oSJ
�'
Damage,
unusual wear
in gear
\
5
. 7
4 Oil leaks
Wear,
1 3 deterioration
Streaks on worn surface,
cracks, taper wear
1 Flywheel mounting bolt (ri) Collar
2 Pilot bearing 7 Flywheel housing
@Flywheel 8 Rear oil seal slinger
© Oil seal retainer ® Ring gear
5 Oil seal 10 Tachometer drive
1 OA Speed sensor
For disassembly of parts with an encircled number, see following
items.
C1926F
11-30
��- •
NV .. Nominal Valu e
L Limit
-�·Timing gciir b·acklash
.
Crankshaft ge ar -,c11er gear .. B ..
NV O 12 to 0.26 ··
L 0
· 20 Oil le aks
lrller g�:r "A"�c am shaft gear
NV 0.13 to .26
L 0.4
lc11er gear "A"�-, er gear "C "
�� Oil hole
NV 0. 13 to
clogging
L 0.4
- 9 ear "C"
Inj e ction pum P gear -idler
NV o 12 t o 0.26
19
:
L 04
17
-�-Idler ge ar end play 16
NV O 1 to 0.28
:
L 04
We ar, damage
13
We ar
12
14 Wear
-:.:-Camshaft gear end play

NV OD"
. o to 0.22
L 0.4
*/
<Disassembl y sequence>
/11· Camshaft
F) Camshaft gear
13 Thrust plate
1 4 Idler shaft b o I t
15 Thrust plate
16 Idler gear "C"
17 Idler gear "A"
18 Idler gear "B"
19 Idler shaft "A"
19Aldler shaft "C"
20 Rear plate
For disassem blY of parts with . an encircled n m see fo llowing item s.
�::·
The par t m arked .;;:. must b , pec ted befor� d ssem bly
� � �
Part mar kec1 w,t h ' shou ld o ,-n �o: ed unless de fects are evident.
e remov
__ _ _ _
- _ � � � : � � � � � : �: C1927C
_
_ _ _ ---
11-31
•
(3) Measurement of Gear Backlash

(1) Removal of Flywheel
Threaded hole
for removal
C1930A
C1928B
If the backlash exceeds the limit, check idler gear
Thread the mounting bolt into the removing threaded bushing and gears and replace parts as necessary.
hole to remove the flywheel. NOTE:
(2) Removal of Oil Seal Retainer and Coller For a pair of gears, the backlash should be
measured at more than three points to
determine whether it is acceptable.
(4) Measurement of End Play in Idler Gear
and Camshaft Gear
Threaded holes
for removal il:"
Oil seal retainer C1929D
• To remove the oil seal retainer, turn down the

attaching bolts into the removing threaded holes
evenly, while making sure that the oil seal retainer C1931B
does not have eccentricity, remove the retainer with

the oil seal attached. If the end play exceeds the limit, replace the thrust
• Remove the collar by screwing M4 x 0.7 bolts into plate.
the removing threaded holes. EngineParts2@gmail.com
11-32
(5) Removal of Camshaft Gear
NOTE:
m
Do not strike the gears with a hammer.
Thrust plate Make sure that the gears are removed by
use of a gear puller.
Camshaft gear
(7) Removal of Ring Gear
Camshaft ._r
r .
Remove thrust plate
mounting bolt through ---1
this hole. /
Thrust plate mounting ___ .J,-1(]
bolt E::=1
C1932B
Accessing through the holes in camshaft gear, loosen

the thrust plate attaching bolts. Then, remove the
Ring gear
gear together with the camshaft.
B2356C
(6) Removal of Camshaft Gear
Using an acetylene torch, heat evenly the ring gear
and apply a rod to the ring gear to tap it throughout its
periphery.
Lock nut Lock washer

C1933B
Remove the lock nut and lock washer from the

camshaft gear and, using Gear Puller (special tool),
remove the camshaft gear.
11-33
•
5.3.2 Inspection
NV... Nominal Value

Depth from clutch cover L Limit
mounting surface to
friction surface
NV 48
L 49.5
Distortion of friction surface

NV 0.1 or less
L 0.2
C2758C
11-34
�- - - --- -----
-
----
- --------�----
· - ----
-- - · ---
- - -------�
-
m-
BO .. Basic Diameter
NV.. Nominal Value
L Limit
Clearance
BO 40
NV 0.03 lo O 06
L 0.2
Clearance
BO 46
NV 0.03 to 0.06
L 0.2
Cam profile Camshaft journal to

(difference between bushing clearance
lobe height and base BO No. 1 ... 65.00
circle diameter) No. 2 .. 65.25
BO No. 3, 4 ... 65.50
(intake valve caml No. 5, 6 ... 65.75
8.83 No. 7 ... 66.00
!exhaust valve cam) NV 0.03 10 0.08
8.82 L 0.25
L
(difference between
lobe heigh! and base
circle diameterl
8.3
Bend
NV 0.05 or less
L 0.08
C2759C
11-35
•
(2) Correction of Flywheel Friction Surface

( 1 ) Distortion of Friction Surface
Clutch cover
mounting surface
Friction surface
C35098
Correct the friction surface with a surface grinder.

Place the flywheel on a surface plate and move a dial Make sure that the friction surface is parallel to
indicator in the diametral direction of the flywheel to surface A within 0.1 mm.
measure distortion. If the dimension of portion B exceeds the service
Use of a portable jack will make it possible to take a limit, replace.
more accurate reading. (3) Idler Gear to Idler Shaft Clearance
If the distortion is in excess of the repair limit, grind
the friction surface.
NOTE: Measuring position
If the ring gear shows and abnormal condi

tion, replace the ring gear before measure EB
ment. [Refer to 5.3.1 (7))
+
Measuring position
C38078
If the limit is exceeded, the bushing in the gear should

be replaced.
11-36
(4) Replacement of Idler Gear Bushing
(6) Camshaft Jour.nal to Crankcase Cam•

m
shaft Bushing Clearance
Pressure Pressure
Idler Gear
Bushing Puller
MH061228
(for idler gear "A")
MH062046
(for idler gear "C")
� Bushing
Idler gear
To remove To install C3808A C4102A
Replace the bushing by the procedures shown in

illustration, using Idler Gear Bushing Puller (spe_cial
tool).
NOTE:
1. Install the bushing with chamfered side
of gear I.D. inward.
2. After installation, check to ensure that
the bushing to idler shaft clearance is
within the nominal dimension. If it is
below the nominal dimension, ream the C4114A
bushing.
If the limits are exceeded, the bushing in the crank
(5) Cam Profile
case should be· replaced.
(7) Bend of Camshaft
Measuring
position
Forward
9.5 9.5 Base

circle
diameter
C4101A
C4118A
Measure the lobe height and base circle diameter and
replace the camshaft if the difference between the
two is below the limit. Measure the bend of the camshaft. If the limit is
exceeded, replace.
NOTE:
The cam must be measured at locations NOTE:
shown as it is tapered. Turn the camshaft a turn and read the
deflection of the pointer, using a dial in·
dicator.
One half of the reading is the bend.
EngineParts2@gmail.com Parts phone: 269 673 1638 11-37
m
5.3.3 Disassembly
Mounting condition
Eccentricity
20 7 L 0.2
Bend lock washer Idler gear end play

NV 0.1 to 0.28
L 0.4
265 Nm
(27 kgfm) (wet)
10
Camshaft gear end play
NV 0.05 to 0.22
L 0.4 16
12
/19A
15 155 Nm
315 Nm --(16 kgfml
14
(32 kgfmHwet) 98 Nm
(10 kgfm)
Apply engine oil or

5 lithium grease to
the oil seal lips.
8 98 Nm (10 kgfml
14
5 ---.....__155 Nm
(16 kgfm)
9 19 15
3 Mounting condition
Runout Backlash Backlash
L 0.2 NV 0.13 to NV 0.13 to
0.26 0.26
L 0.4 L 0.4
Backlash
NV 0.12 to
0.26
L 0.4
Backlash
NV 0.12 to 0.26
L 0.4
69 Nm (7 kgfm) �--------'
<Assembly sequence>
Qi}-+ 19-->19A-->(!�@---•@--> 15---+ 14 10A

l
� a (ij--> 6--+ 5---+ 4---, 3__, 2....... 1
13-->12-->(11 1oJ l@
For assembly of parts with an encircled number, see following
items.
For assembly of part marked *, refer to Group 61 Special
Equipment. B1902E
11-38
(3) Installation of Camshaft Gear

m
( 1) Installation of Rear Plate
I fo_fel_
L�
264 Nm
' (27 kgfm) (Wet)
Lock washer
(to be bent)
84227A
C6230C I
Install the camshaft gear so that the side having
The bottom of gasket installed between the rear plate stamped numbers "4" faces front.
and crankcase will protrude. After the flywheel hous (4) Installation of Camshaft
ing has been installed, cut away the protruding
portion.
(2) Installation of Idler Gears
Crankshaft gear
\
Idler gear B
C6231C
Install the camshaft so that the alignment mark "4" on

155 Nm
(16 kgfm) C6231D
the camshaft gear is aligned with the alignment mark
"4" on idler gear A.
Then, install the idler gear B so that its alignment NOTE:
mark "1" is aligned with the alignment mark "1" on When the camshaft is inserted, take care
the crankshaft gear. not to damage the camshaft bushing.
Next, install idler gears A and C so that their
(5) Check camshaft gear and idler gear for
alignment marks "2" are aligned.
correct end play.
Tighten the idler shaft bolt to specification.
[Refer to Section 5.3.1 (4)]
(6) Check backlash in gears.
[Refer to Section 5.3.1 (3)1
11-39
(7) Installation of Rear Oil Seal Slinger (9) Installation of Flywheel Housing
Rear oil seal slinger Locating pin
Threaded groove
C5529B C6230D
(8) lnst�llation of Ring Gear Install the flywheel housing and gasket so that they
are aligned with the locating pins in the crankcase.
Cut the bottom portions of the gasket aher installatioh
Ring gear
as they are excess.
Cut at the same time the excess portions of the gasket
between the rear plate and crankcase.
(10) Flywheel Housing Eccentricity Check
Flywheel
B2357C
(a) Heat the ring gear for 3 minutes with piston heater
(approx. 100 °c).
· (b) Fit the ring gear onto the flywheel with the
nonchamfered side of the teeth end toward the
Flywheel housing
flywheel. C6233B
Install the flywheel housing to the crankcase by

tightening to the specified torque.
Measure the mounting condition (eccentricity) at the
flywheel housing joint. If the pointer of a dial indicator
deflects beyond the limit, loosen the bolts and lightly
strike the housing to correct the mounting condition.
11-40
ENGINE - SERVICE PROCEDURES ID
(11) Installation of Oil Seal (1 2) Flywheel Runout Check
Oil seal
Seat oil seal end on
the retiliner positively
all around.
315 Nm
(32 kgfm)
(Wet)
/ /// / //, Flywheel

C6209A C6236B
When press-fitting an oil seal to the retainer, apply Install the flywheel to the crankshaft by tightening to
force uniformly to the entire periphery. the specified torque.
Measure the flywheel mounting condition (runout). If
the pointer of the dial indicator deflects beyond the
limit, check the bolt tightness or mounting surface.
11-41
•
5.4
CRANKCASE AND MAIN MOVING PARTS

5.4.1 Disassembly
Damage. abnormal wear

0-------
�5
��,
0---- 6
Damage. discoloration 7
·>:<· Piston projection
8 NV 0.87 to 1.33
C) Scratches on outer periphery,

{) �
op, melt•• °'
�,� <
�::;:fo
:0
racks
9
- C � k
- - - -- _ _ _ _�
�-
·>:<· Connecting rod end play ·::::'__..... 10
NV 0.2 to 0.5
L 1.0 3 Inner or outer periphery damaged,
corroded or peeled
�
NV Nominal Value
L Limit
corroded or peeled
Disassembly sequence
Connecting rod cap ® -Oil ring
2 Lower connecting rod bearing 7 Piston pin
3 Upper connecting rod bearing ® Piston
© 1st compression ring ® Connecting rod
® 2nd compression ring *10 Connecting rod bolt

items.
Part marked with * should not be removed unless defects are
evident.
Service items marked with·>:<· should be inspected before disassem
bly.
C2337D
11-42
--- -
- ---·�---------
-
--·- ---··· ------------- - - - -----�

m
Oil hole clogging
26
5.4.)
Main bearing
18, 20
15
NV Nominal Value
L Limit
19
Scratches, cracks, indentation,
seizure, plugged oil hole, I
corrosion
-�· End play
12 NV 0.09 to 0.23
L 0.4
11
11 Torsional damper 17 Thrust plate '1 22 Cylinder liner
.,
(i 2) Crankshaft pulley 18 Lower main bearing '2 23 Check valve
13 Front oil seal 19 Crankshaft 24 Oil jet
14 Front cover 20 Upper main bearing 25 Oil spray plug
'1 15 Front oil seal slinger 'l ii) Crankshaft gear 26 Crankcase
16 Main bearing cap

items.
The part marked -�· must be inspected before disassembly.
Parts marked with •1 should not be removed unless defects are
evident.
For inspection of the part marked with •2. refer to Group 12
Lubrication. B0599G
11-43
ID ENGINE - SERVICE PROCEDURES
Disassembly Procedure (3) Removal of Piston

(1) Piston Projection
The piston projection must be up to specification, as it
affects engine performance and is also necessary for
preventing interference with the valve.
�o
Measuring point
C2341A
When the withdrawing the piston from the crankcase

by pushing up together with the connecting rod.
C2339B
NOTE:
When removing the pistons, use care to
(a) Hold the dial indicator to the top surface of the prevent damage to the cylinder liner
crankcase and make zero adjustment. (4) Separating Piston from Connecting Rod
(b) Find the top dead center of piston with a dial
indicator.
Snap ring
(c) Measure three points on the top surface of piston
to find the average value.
(d) If the projection is out of specification, check the
connecting rod, bushing, piston pin, connecting rod
bearing, etc. and replace defective parts.
(2) Connecting Rod End Play
Remove the snap ring and, using a rod, tap piston pin
off.
If, however, the piston pin is hard to remove, heat the
piston with a piston heater or in hot water.
C2340A
Measure the end play of each connecting rod. If the

limit is exceeded, replace the connecting rod or
crankshaft.
11-44
(5) Removal of Piston Ring
(7) Removal of Main Bearing Cap

m
______ Slide hammer
Piston Ring Tool

31191-02900
80180A 801838
(6) Crankshaft End Play The rearmost main bearing cap is held in position by
dowel pins. Remove it by use of a slide hammer.
(8) Removal of Crankshaft Gear
Rear oil seal

slinger
I
I
/ Crankshaft gear
B0181C
Before removing the main bearing caps, measure the

end play in the crankshaft.
If the end play exceeds the limit, replace the thrust (a) Remove the rear oil seal slinger from the crank
plate with an oversize one. [Refer to Section 5.4.3 (3)] shaft by cutting it with a punch.
(b) Remove the crankshaft gear from the crankshaft,
using Gear Puller (special tool).
NOTE:
Do not attempt removing the crankshaft
gear by striking with a hammer or prying
with a lever.
11-45
m
5.4.2 Inspection
Open end clearance
0
NV 0.4 to 0.6
L 1.5
0
0
Clearance
BO 50 Piston ring groove 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 <6022>
0.07 to 0.10 <6022-T, 6022-TC>
L 0.15
Oil ring
NV 0.03 to 0.06
L 0.15
Clearance
BO 50
NV 0.02 to 0.05
L 0.1
Clearance
BO 130
NV 0.178 to 0.204 <6022>
0.173 to 0.199 <6022-T>
Bend or torsion 0.188 to 0.214 <6022-TC>
L 0.05 or less
Distortion of top surface

NV 0.07 or less
L 0.2
Flatness of cylinder liner

flange supporting surface
L More than 0.1
BO Basic Diameter
Projection of cylinder liner NV Nominal Value
from top surface of crankcase L Limit
NV O to 0.08
Inside diameter
NV 130.014 to 130.054
L 130.25
Out of roundness of cylindricity

NV 0.02 or less
Oil clearance
BO 84
NV 0.07 to 0.13
L 0.25
Tension when free

L Less than 90.5

C2760C
11-46
ENGINE - SERVICE PROCEDURES m
Bend
NV 0.04 or less
L 0.1
Out of roundness
NV 0.01 or less
L 0.08
Cylindricity
NV 0.006 or less
Tension when free

L Less than 106.5
BD ... Basic Diameter

Oil clearance L ... Limit
BD 100
NV 0.08 to 0.15
L 0.25
B0599F
Inspection Procedure (2) Crankcase Top Surface Distortion

( 1) Flatness of Cylinder Liner Flange Sup
porting Surface on Crankcase
Measurement points
C4417A
Measure the crankcase top surface distortion. If it

exceeds the limits, correct the distortion with a
Replace the crankcase with new one if the limit is surface grinder.
exceeded.
11-47
m
:==-
NOTE:
E'.NNGINE - SERVICE PR O CCIEDURES
------� --- ---�=-� �� ---------- --�
::
(4) Cylinder L",ner Flange Projection

When the crankca�e is ground, ma ke sure
that the piston proiection does not exceed
the nom·mal value.
[Refer t o Item (1) ' Section 5.4.1.]
(3) Cylinder Liner I.D.
�m �
A-. Cra n kshaft d'
di recti o:
."ection
B: Cran ksh ft right-an gl e
.
If the proJection
/
i ou t of specification ' replace the
cylinder liner or ran kcase. (For rep! acement of the
cylrnder liner ' refer to Item ISi.i
c"'" (5) Replacement of Cylinder Liner
(a) Removal
Measurn the c_Y 1·inder liner I.D at .".x positions as
.
shown in the nght flgurn If th. l.D . is more ti,an the
.
limits ' replace the cyl'm der liner or b ore It to oversl,e.
Cylinder Liner E xtractor
( For replacement of the cylinder liner, refer to Item MH061490
ISi.i
C4414B
11-48
m
--------- - ---- ----1
�
(b) Installation
Strike in.
Cylinder Liner Installer
MH061759
Size rnark Piston Cylinder liner
Cylinder liner
C4427B
C4813C
3) Securely seat the cylinder liner on the crankcase
1) When replacing the cylinder liner, use a cylinder by lightly striking the flange portion, using Cylinder
liner with the same size mark as that of the piston to Liner Installer {special tool).
be selected. NOTE:
1. Apply soap suds to the crankcase and
Size rnark of piston A 8 C cylinder liner fitting portions and make
Size mark of cylinder liner A 8 C sure that the rubber packing and O,ring
are not twisted when inserted.
2. After installation, conduct the leak test
to verify air-tightness. Apply thrust
force to cylinder liner flange.
0-ring
Rubber l]> Soap suds to

packing be applied EngineParts2@gmail.com Parts phone: 269 673 1638
0-ring
C44268
2) After a new rubber packing and 0-ring have been

installed to the cylinder liner, slowly insert the
cylinder liner into the crankcase.
11-49
(6) Selection of Piston and Cylinder Liner (b) Oversize piston

A piston may be standard or oversize, depending on Bore the cylinder liner as follows according to the
which the cylinder liner is to be selected as follows. type of piston ( +0.5, +0.75, + 1.00 mm).
(a) Standard piston
Cylinder liner I.D.
Size mark stamped

30
<6D22> or more ___,>---,<-....., 1-4-----
<6D22, 6D22-TC>
J
Weight
"T" mark
Weight
'><:?z-
(
� Size mark /
----------....
/� Part number
70
f'
Pa,< aornbe< or more // A: Axial direction of
/ crankshat
8: Direction at right angles
to crankshaft
Size mark
C4424A
Oversize piston O.D.
O.D. measuring position
C4428A
Cylinder liner Piston
842210
1) Determine the amount of metal to be bored from
1) Select the piston with the same size mark as that the cylinder liner by taking into account the portion
stamped on the cylinder liner. which wears most with reference to the measure
2) Make sure that the weight of pistons for one ments of 1.0.s of all cylinders.
engine (six pistons) is in the range of± 10 g of the 2) Bore and hone-finish the cylinder liner to obtain
weight stamped. the specified clearance between the oversize piston
and cylinder liner.
NOTE:
Whenever the piston is replaced, replace NOTE:
the piston rings. 1. Even when only one cylinder requires
boring, bore au· cylinders to the same
oversize.
2. Replace the piston rings to those cor-
responding to the oversize.
(7) Piston to Cylinder Liner Clearance
If the clearance is out of specification, replace the
piston or cylinder liner.
[Refer to Item (6)]
11-50
DI
(8) Piston to Piston Ring Clearance (9) Piston Ring Gap
0
Piston '-
-- -
- .-..
Piston ring Cylinder liner

C4806A 848078
Measure the piston to piston ring clearance. If the Measure the piston ring gap with the piston ring
,,
limit is exceeded, replace the piston rings or piston. horizontally pushed into a standard cylinder liner or
NOTE: actual one in the crankcase with a piston.
1. After carbon has been removed, mea· Replace the piston ring if the gap exceeds the limit.
sure the clearance all around the pis Standard cylinder liner I.D.: 130 ± 0
ton. NOTE:
2. Replace the piston rings as a set. Use the piston to push the piston rings
horizontally into a standard gauge.
Thickness gauge ( 10) Piston to Piston Pin Clearance
Piston
Straight
EB
1st Piston pin
compression ring edge
C4815A
The 1st compression ring should be measured by

C4811A
pressing the ring against the piston with a straight
edge.
If the clearance is over the limit, replace the piston pin
or piston.
NOTE:
Whenever the piston is replaced, be sure
to replace the piston rings.
11-51
(11) Piston Pin to Connecting Rod Small (a) Align the oil hole of the bushing with the oil hole
End Clearance of the connecting rod.
(b) Press the bushing in from the chamfered side of
connecting rod end.
Connecting rod (c) Aher the bushing has been pressed in, insert the
piston pin and check to ensure that it turns lightly
without play.
(13) Connecting Rod Bend and Twist
�
®
Piston pin
C4812C
If the clearance is over the limit, replace the bushing

in the connecting rod.
(12) Replacement of Connecting Rod
Bushing
C5205A C5206A
Replace the bushing by procedures shown in illustra
tion, using Connecting Rod Bushing Puller (special
tool).
Twist
100
Ii
·. --9J
1/
0
Piston rin
Connecting rod
aligner
Connecting Rod
Bushing Puller C5207A
.- MH061238
/Bushing
Measure the bend and torsion of the connecting rod
'r='==st./
__ ;- Oi I hole
. ·· , Connecting rod with Connecting Rod Aligner (measuring instrument) .
If the reading 1s in excess of the limit, replace or
To remove To install correct with a press.
NOTE:
1. Install the bushing and connecting rod
bearing to the connecting rod before
measurement.
2. Tighten the connecting rod and con
C5221B necting rod cap to the specified torque
before measurement.
11-52
(14) Tension of Connecting Rod Bearing
(16) Main Bearing to Crankshaft Journal

m
and Main Bearing when Free Clearance
Crankshaft iournal O.D.
Measuring direction Measuring position
C5209A C5523A
If the tensiori'is lower than the limit, replace the upper

and lower bearings as a set.
NOTE:
Do not use the bearing by artificially ex
panding it. Main bearing I.D.
(15) Connecting Rod Bearing to Crank

shaft Pin Clearance
Crankshaft pin O.D.
C5223A
Connecting rod bearing I.D.
C5524A
If the limit is exceeded, replace the upper and lower

bearings as a set.
C5214A
If the limit is exceeded, replace the upper and lower

bearings as a set.
11-53
(17) Crankshaft Roundness and Cylindri (19) Correction of Crankshaft to Under-

city size
If the journal or pin is damaged or seized, grind the
Roundness Cylindricity crankshaft by the following procedures. Replace the
Measuring direction Measuring position bearing with an undersized one.
+g- 2
H
42.0 54.0
0
+I
"
0
C5223A
Determine the out-of-roundness on the basis of the

crankshaft journal and pin O.D. measurements. C5527A
If the limit is exceeded, grind to undersize. [Refer to
(19)] (a) When the crankshaft is ground, take care not to
change the center distance of journal and pin.
(18) Crankshaft Bend (b) Grind the crankshaft in such a way as not to
change the width of journal and pin.
(c) Finish the fillet smooth to the specified R.
(d) Check for ground cracks by the magnetic particle
inspection method. The surface hardness (Hs 75 or
more) should also be checked to confirm that it has
not decreased.
C5526A
Measure the bend of the crankshaft. If the limit is

exceeded, correct with a press or grind to undersize.
NOTE:
Read the crankshaft center journal runout
with a dial indicator. One half of the read·
ing is the bend.
11-54
ENGINE - SERVICE PROCEDURES •
Grinciing Finishing
Whestone or
sand paper
Crankshaft
C5509A
(e) To grind the crankshaft with grinder, the grinder

and crankshaft should be turned clockwise as viewed
from the crankshaft front end.
(f) To finish the crankshaft with a grindstone or
sandpaper, turn the crankshaft counterclockwise.
Unit: mm
Undersize Journal O.D. Pin 0.0. Out-of- Cylind-

finish dimension finish dimension roundness ricity
-0.25 0·08 0·06 0.01 or 0.006 or

99 .75 - 83.75 -
- 0.10 - 0.09 less less
-0.50 0·08 0·06

99.50 - 83.50 -
- 0.10 - 0.09
-0.75 - 0·08 0·06

99. 25 83 . 25 -
- 0.10 - 0.09
-1.00 0·08 - 0·06

99 . 00 - 83.00
- 0.10 - 0.09
11-55
•
5.4.3 Reassembly
· -
--
----------------- - ---
Cylinder liner
flange protrusion
<Assembly sequence> NV O to 0.08
21
[
26---,22-25--- 24- 23-· 20-• 19--· 17 � 18 -· 16
}-· 2- 1
a-9-7-s-s-4 3-----�
,o_J
-,s-1£1-. 13-12-11
For assembly of parts with an encircled number,
see following items.
10
Locating
1st compression pin
Expander spring ends ring ends
Bend lock
washer
23 34 Nm
(3.5 kgfm)
2 ---+--*--!------!-'-:�\\ 24
��?,.,g!YU Lug direction
1 �-+--¥1-'I----L�--\-.
Piston projection
NV 0.87 to 1.33
370 Nm 115 Nm
22 (38 kgfm) (12 kgfm)
(Wet) (Wet)
/ 0J· Face arrow head up.

Align lug
direction.
14
20
Locating
NV Nominal Value
L Limit
Face side with oil groove

11 toward sliding surface
16 19 17
Crankshaft end play
Connecting rod end play NV 0.09 to 0.23
Apply lithium base L 0.4
grease to lips NV 0.2 to 0.5
L 1.0
C5835F
11-56
(3) Installation of Upper Main Bearing and

m
(1) Installation of Oil Spray Plug Thrust Plate
�--- - ---------
- -
- - -
-
Lug Upper main bearing
\� :
;_·.•1,
. I
f�is�
• . '• o, -;;..' ·r- �-"(

,.�. l(·-'1. I , II , 'I nly
• �� I Jj J.0_ ,/
��r'-Jt:, «·, ::.;�· ''.i, : ,r·

.:..('\-�'/ ;i,; -� mounting
:_. - ';:i)' :--::· (e l)f'i: I Thrust plate
pin
/' 1 Thrust plate
i
Lug groove .
e: , -- �011 groove
,
C2335B C5837A
Install the oil spray plug with the arrow stamped on NOTE:
the plug toward the top of the engine. 1. Install the thrust plate with the oil
grooveless side toward the crankcase.
(2) Installation of Oil Jet and Check Valve
2. Line up the lug of the main bearing and
the groove of the crankcase. ·
The upper main bearing is one with oil
Check valve
holes. Take care not to confuse it with
]\
m the lower one.
3. Oversize (0.15, 0.30, 0.45 mm) thrust
After assembf3l41n5gN,�f Lock
) washer bending portion
bend lock washer plates are available for adjusting the
tab.
end play in crankshaft [refer to Item (6),
0 ' 0 Section 5.4.1]. If any one of these is
used, ensure the correct of the thrust
6> plate to be installed to the main bearing
cap [refer to Item (7)].
C5836B
(4) Installation of Crankshaft Gear
(a) Install the oil jet, while making sure that its
Dowel pin
locating pin fits in the crankcase.
(b) Mount the lock washer in such a way that its
bending portion will fit the end of the oil jet.
(cl After the check valve has been tightened to the
specified torque, bend the lock washer to fit the
hexagonal portion of the check valve.
Crankshaft Crankshaft gear

84202A
°
(a) Heat the gear to about 100 C, using a piston
heater, etc.
11-57
(b) Locate the gear so that the dowel pin of the (7) Installation of Lower Main Bearings and
crankshaft will fit in the notch of the gear and fit the Main Bearing Caps
gear by lightly striking the gear end with a soft Follow the procedure given below.
hammer.
(c) Install the rear oil seal slinger.
[Refer to Item (7), Section 5.3.3.]
�o l lo� t
(5) Installation of Front Oil Seal Slinger
Oil Seal Slinger Installer

MH061817
Crankshaft
�7 �{fj)
Axial direction
of c,aaksf,aft
Dowel pin
81897A
(a) Drive the locating dowel pins into the rearmost

main bearing cap in the direction shown.
80596A
Install the front oil seal slinger, using Oil Seal Slinger
Installer (special tool).
(6) Installation of Crankshaft
C5838A
r �
0
Main bearing cap
C5833A embossed number
Lift the crankshaft with chain blocks, etc. While
·1
I�
keeping it in horizontal position, slowly lower it into
-=---
engine
the crankcase.
JL,,
0 0
---i
84222A
(b) Mate the lower main bearing with each main

bearing cap, making sure that the lug in bearing is
fitted into the lug groove in cap.
11-58
(c) Only to both sides of the rearmost main bearing

m
(f) Check to see if the end play of the crankshaft is
cap, install the thrust plates facing their oil grooveless within nominal value.
side toward the cap. [Refer to Item (6), Section 5.4.1.]
NOTE: (8) Installation of Connecting Rod Bolt
Bearing cap front

thrust plate Face top groove inside.
, Bearing cap rear
Press-fit with a press.
·,_�· ,t��-·,/
thrust plate
� Max 5.9 kN (600 kgf)
Apply engine oil.

-� ,� .� ''•-./ ·'
(
, ·�fl
'. , Use the same
. �i
r \�
size.
Crankcase rear thrust plate

C5838B 89007A
If an oversize thrust plate is used, use the After checking the connecting rod for damage and
bearing cap rear thrust plate of the same burr in the bolt hole, apply engine oil to the connect
size as that of the thrust plate in the ing rod bolt and press-fit it into the connecting rod.
crankcase rear end [Refer to Item (3)].
Note, however, that the bearing cap front
and rear thrust plates may be of different
sizes.
(d) Install the main bearing caps, making sure that
the side with the lug groove placed on the right-hand
side of the engine and they are installed in the order
of embossed numbers from the front of engine.
(e) Tighten main bearing cap bolts to specified
torque. Then, tighten main bearing cap side bolts to
specified torque.
After the bolts are tightened, make sure that the
crankshaft is free to rotate by hand.
11-59
(9) Reassembly of Piston and Connecting (1 O) Installation of Piston Ring
I
Rod
:�;�
,,.- Piston
Arrow showing front
Ends
Manufacturer
mark
stamped
Connecting rod
C5841B
Snap ring Piston pin
Etched cylinder
No.
Stamped or
etched weight
mark
Direct lug groove _-,,--,..,
Stamped alignment
mark toward
mark
front
C58408
Using Piston Ring Tool (special tool), install the piston
Connect the piston to the connecting rod with the rings in the following sequence.
piston pin so that the Front mark on piston and lug 1. Oil ring
groove mark in connecting rod are placed on the 2. 2nd compression ring
same side. 3. 1st compression
. ring
If the piston and piston pin are hard to insert, heat the
, piston with a piston heater or in hot water.
NOTE:
The parts for an engine must be of the
same weight mark.
Weight marks
Heavy-E------------------- Light
A B C D E F G H J K
11-60
ENGINE - SERVICE PROCEDURES ·111
(11) Installation of Upper and Lower Con NOTE:
necting Rod Bearings 1. Make sure that the size symbol of the
piston is the same as that of the cylin
Lower connecting der liner.
rod bearing gn these.
�li Align these.
- _
· Upper conn ct1ng · - 2. Make sure that the piston ring open end
v._ ;
· rod bearing
�
,
_
. J directions do not change.
'I
.
' _, .
. 3. Put a vinyl hose or something else on
the bolt of connecting rod for protec•
tion of the crankshaft pin against dam•
Rl
I '· . . age by the bolt.
. Using the Piston Guide Clamp and Piston
. Guide Lever (special tools) .
Connecting rod
cap B4223A Piston Guide Clamp
Install the upper connecting rod bearing, making sure

that the bearing lug is aligned with the lug groove in
the connecting rod.
Install the lower connecting rod bearing, making sure
that the bearing lug is aligned with the lug groove in
the connecting rod cap.
NOTE:
Piston Guide Lever
Note that the only the upper connecting Adjusting
bolt
rod bearing has an oil hole. B5291C
(12) Installation of Piston and Connecting

Rod Line up the Piston Guide with the piston skirt and set
the lever into position. Then, turn the adjusting bolt
so that the clamp 1.0. equals piston 0.0. After the
adjustment, apply engine oil to piston outer surfaces,
Piston Guide Piston Guide inner surfaces, and cylinder liner inner
Lever
MH061658 surfaces.
After these procedures have been completed, fit
Piston Guide onto the piston so that it is flush with the
pistonhead. Using a mallet or wood block, tap piston
into position with care not to damage it.
C5834B
Using Piston Guide Clamp and Piston Guide Lever

(special tools), install the piston and connecting rod
so that the front mark on piston head faces the front
of engine.
11-61
(13) Installation of Connecting Rod Caps 5.5 INSPECTION AND ADJUSTMENT OF

VALVE CLEARANCE
..
Connecting rod cap The valve clearance should be checked and adjusted
as described below while the engine is cold.
Front of
engine
)8 \\-
Alignment mark -
-co ' I'
-- _- I I
-----
- I
C5844B
_.--:;
Make sur� that the alignment marks and lug groove
marks on the connecting rod cap and connecting rod 85713A
are aligned.
(14) Check the connecting rod end play. (1) Crank the engine to align the pointer of the
inspection window of the flywheel housing with the
[Refer to Item (2), Section 5.4.1.]
inscribed mark 1.6 of the flywheel. Check the push
(15) Check the projection of the piston. rods, and the piston whose push rod is not pushing
[Refer to Item (1), Section 5.4.1.] up the rocker is at the top dead center of the
(16) Installation of Front Oil Seal compression stroke.
(2) When the No. 1 cylinder piston is at the top dead
center on the compression stroke, check and adjust
the clearance of valves marked "o" in the following
Front oil seal Press-fit
table.
Oil seal flange When the No. 6 cylinder piston is at the top dead
center on the compression stroke, check and adjust
the clearances of valve marked "x". Turn the crank
shaft through a rotation, and make sure that valve
clearance inspection and adjustment are performed
for all of the six cylinders.
Cylinder No. 1 2 3 4 5 6
84187A
Valve In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
arrangement
Evenly press the oil seal throughout its entire No. 1 at TDC
periphery to prevent it from tilting. Press-fit the oil on the compres- 0 0 0 0 0 0
sion stroke
seal into the front cover until the oil seal flange is held
No. 6 at TDC
tight up against the front cover. on the compres- X X X X X X
sion stroke
11-62
-- - - - . ------- - - - - ------ - - --
m
1 Valve clcar<1ncr. lwhr.n colcll
Inlet O 4 mm
Exhaust 0.6 mm
(3) Measure the rocker arm to valve cap clearance
with a thickness gauge to determine whether the
clearance is up to specification.
If the thickness gauge of the specified thickness is
somewhat hard to move, the clearance is good.
If the clearance is out of specification, loosen the lock
nut and adjust with the adjusting screw. After adjust
Thickness gauge ment, turn down the lock nut to lock the adjusting
MH061359
screws.
NOTE:
After the lock nut has been turned down,
857148
recheck the clearance.
11-63
•
6. TROUBLESHOOTING
ENGINE - TROUBLESHOOTING
Symptom Probable cause Remedy Ref. group
Engine will Inadequate oil viscosity Replace Group 12

not start
Incorrect fuel in use Group 13
Low compression pressure

• Incorrect valve clearance Adjust
• Defective head gasket Replace
• Worn valve and valve seat, carbon deposit
• Deteriorated valve spring
• Worn or damaged piston ring
• Worn or damaged pislon ring groove
• Worn piston and cylinder liner Change to oversize
Defective preheater
• Defective starter switch Correct or replace Group 16
• Defective heater relay
Incorrect injection timing Adjust Group 13
lnsutticient injection amount

• Defective injection pump Correct or replace Group 13
• Incorrect injection amount
Cooling system not functioning properly Correct or replace Group 14
Rough idle Inadequate oil viscosity Replace Group 12
Defective cooling system Correct or replace Group 14
Low compression pressure (See "Engine will not start".)
Defective fuel system

• Defective injection nozzle
• Air trapped in fuel system
Abnormal Incorrect fuel in use Replace Group 13

exhaust
gas color Cooling system not functioning properly Correct or replace Group 14
Intake/exhaust system not functioning properly

• Clogged air cleaner Correct or replace Group 15
• Clogged muffler
• Oil leaks to intake/exhaust pipes
Low compression pressure (See "Engine will not start".)

Incorrect injection timing Adjust
Excessive engine oil Adjust Group 12
Binding of major moving parts Correct or replace
11-64
ENGINE - TROUBLESHOOTING
m
Symptom Probable c,l\1se Remedy Ref. group
Low output Inadequate oil viscosity Replace Group 12
Defective cooling system Correct or replace Group 14
Intake/exhaust system not functioning properly

• Clogged air cleaner Correct or replace Group 15
• Clogged muffler
Low compression pressure ISee "Engine will not start".)

• Air trapped in fuel system
Large oil Oil leaks from lubrication system Check and correct Group 12
consumption
Oil leaks from engine and related parts
• Defective gasket and oil seal Replace
Oil entered to combustion chamber from piston side

• Worn cylinder liner and piston Correct or replace
• Worn, damaged or seized piston ring Replace as a set
• Clogged piston and oil ring oil holes Clean
Oil entered to combustion chamber from valve side

• Worn valve stem and valve guide Replace
• Worn valve stem seal
Abnormal Noise produced from around the engine

engine noise • Loose piping or hosing connection Check and correct
• Injection pump, alternator or other Check and adjust Group 13 and 16

auxiliary units defective or incorrectly mounted
• Loose or damaged V-belt Replace Group 14
• Crankshaft pulley incorrectly mounted Check and adjust
• Air cleaner, muttler not functioning propely Correct or replace Group 15
Noise produced from around rocker cover

• Incorrect valve clearance Adjust
• Defective valve spring Replace
• Defective rocker shaft and bracket Check and correct
• Poor lubrication in rocker shaft Check
Noise produced from around flywheel housing

• Incorrect timing gear backlash Replace
• Poor lubrication around timing gear and idler shaft Check
11-65
DI ENGINE - TROUBLESHOOTING
Abnormal Noise produced from cylinder head or crankcase

engine noise
• Low compression pressure !See "Engine will no! start" I
• Incorrect injection liming Adjust Group 13
• Incorrect spray condition Correct or replace
• Worn connecting rod small end bushing and piston pin Replace
• Worn or damaged crankshaft pin and connecting rod

big end bearing
• Worn or damaged crankshaft journal and main bearing
• Excessive crankshaft, to camshaft end play Replace thrust plate
• Worn tappet and camshaft Replace worn part
11-66
m
LUBRICATION
CONTENTS
1. GENER·AL •••••••.••••..•••.•.••.•..•.•.••••.••• 2 4.2 DISASSEMBLY, INSPECTION AND

2. SPECIFICATIONS •••••••••••••••••.•..••••• 10 REASSEMBLY ••••••••••••••••.•••.••.••.. 13
3. SERVICE STANDARDS •••••••..••••••••• 10 4.2.1 Oil Pump ................................. 1 3
3.1 SERVICE STANDARD TABLE •.••. 10 4.2.2 Oil Filter ••••••••••••••••••••••.••..••.••.. 16
3.2 TIGHTENING TORQUE TABLE .•. 11 4.2.3 Oil Cooler •••••••••••••.••..•...•..••.•••. 1 7
4. SERVICE PROCEDURES ••••.•.••••••••• 12 4.2.4 Regulator Valve ••..••••••..•.•••.•••• 18
4.1 REMOVAL AND INSTALLA· 4.2.5 Check Valve ..•.•••..•.••••..•.••••.••• 18
TION ........................................... 12 5. TROUBLESHOOTING •••••••••••••••••••. 19
12-1
lfJ LUBRICATION - GENERAL
1. GENERAL
Engine lubrication is accomplished by forced lubrica
tion system using gear pump. The engine oil in the oil
pan is drawn up through the oil strainer by the oil
pump and force-fed to the oil filter and oil cooler to
lubricate all parts.
Oil pressure
gauge
Warning lamp
"OIL" 0-----�
Oil pressure
gauge unit
Oil pressure
switch
Main oil gallery
Water
pump
Oil spray
plug
-oil Oil pan

B1539F
12-2
LUBRICATION - GENERAL
(1) Oil Pump

Oil pump gear
Oil pump
idler gear
Drive gear
Driven gear
From oil strainer
81541A
At the time, the engine oil is drawn in from the suction

side by the negative pressure produced as the gear
Oil pump
turns along the inside of the pump case, and is carried
(with built-in along the gear and case inside wall to the delivery
relief valve)
side.
The oil strainer at the suction port prevents entry of
foreign matter in the oil pan and air. The engine oil is
routed to the crankcase by the oil pipe connected to
the delivery port.
81540A
The oil pump, of a gear pump type, is mounted in the

rear bottom portion of the crankcase, driven by the
crankshaft gear.
An oil strainer is mounted at the suction port of the oil
pump; an oil pipe at the delivery port.
The crankshaft gear drives the oil pump idler gear and
oil yump gear to transmit rotation to the oil pump
drive gear. In the oil pump, the oil pump drive gear is Relief valve
in mesh with the oil pump driven gear. When the oil
pump drive gear is driven, the oil pump driven gear is 81542A
turned in the opposite direction.

Since the oil pump is driven at speeds proportional to
the engine's, the delivery pressure of the oil pump
increases during starting in cold weather. A relief
valve is provided in the oil pump to make sure that no
excessive pressure acts on the lubrication system.
12-3
•
(2) Oil Filter
- Oil filter
· head
Element
Oil filter
case
!Bypass filter! Center bolt Drain plug
!Full-flow filter!
815448
81543A
When the oil filter element is clogged and the
The oil filter is a double oil filter consisting of a difference in pressure between the filtered and unfil
full-flow filter made integral with bypass filter. Ele tered oil exceeds the limit specified, the valve in the
ment is a filter paper element. oil bypass alarm moves against the spring force,
Engine oil fed under pressure from the oil pump allowing the unfiltered oil to flow to the filtered oil
passes through the oil hole in the crankcase and flows path.
from the oil filter head into the full-flow filter and The oil bypass al·arm has electric contacts that are
, bypass filter. The engine oil filtered through the closed to turn on the pilot lamp, warning the driver of
full-flow filter is routed from the oil filter head through clogged element when the valve is opened.
the crankcase oil hole to the oil cooler. The engine oil
filtered through the bypass filter returns to the oil pan.
12-4
(3) Oil Cooler
m
Oil cooler element
Coolant�
To main oil
gallery
81545A
The shell-and-plate type (multi-plate type) oil cooler is (4) Bypass Valve
mounted in the coolant path on the left side of the
crankcase.
Engine oil forced through the oil filter flows inside the
oil cooler element; whereas the coolant forced from
the water pump flows around the element. The
engine oil in the element is then cooled or heated
be�ore it flows to the main oil gallery.
To main oil gallery
81530A
When the oil viscosity is high at low temperatures or

when the element has high resistance to flow because
of clogging, the bypass valve installed at the oil cooler
opens to allow engine oil to flow to the main gallery
bypassing the oil cooler.
12-5
DI LUBRICATION - GENERAL
(5) Regulator Valve (b) Camshaft
Main oil �1allery Regulator valve
81529A 81547A
The reguliJtor valve is mounted in the main oil gallery Lubrication of the camshaft bushings is accomplished
in the crankcase to make sure that no excessive by the oil flowing through the oil holes from the
pressure acts on the lubrication system. outside periphery of the crankshaft main bearing to
the individual camshaft bushing.
(6) Lubrication of All Parts
The engine oil routed to the main oil gallery lubricates (c) Valve mechanism
all parts as described in the following.
(a) Main bearing, connecting rod bearing,

and connecting rod bushing
Rocker shaft bracket
/ Piston Rocker
...- .. Connecting rod

Crankshaft main
bearing Rocker shaft From cylinder head
- Connecting
rod bearing
Crankshaft --
815468
The oil hole extends from the main oil gallery to the
crankshaft main bearing to lubricate the main bear
ing. Part of the engine oil that has lubricated the main
bearing passes through the oil hole in the crankshaft
81548A
to lubricate the connecting rod bearing, and then
through the oil hole in the connecting rod to lubricate
The engine oil that has lubricated the No. 7 camshaft
connecting rod bushing.
bushing flows through the oil hole provided at the top
On 6022-TC, there is a hole provided in top of
of the crankcase to each cylinder head.
connecting rod, from which oil spurts out to the
piston.
12-6
Engine oil fed to the cylinder head flows through the (e) Cooling the piston (oil jet)
oil holes in the rocker shaft bracket and rocker shaft to
lubricate each rocker bushing. The engine oil is also
sprayed out of the rocker arm oil holes for lubrication
of the sliding surfaces of valve cap and valve stem as
well as the sliding surfaces of push rod and adjusting
screw. The oil then flows through the push rod holes
in the cylinder head and crankcase to lubricate the
tappet and cam of the camshaft and returns to the oil
pan.
(d) Timing gears
Check valve
Oil spray
plug
815358
-Camshaft
bushing
section The oil jet provided under the main oil gallery for each
cylinder sprays engine oil against the reverse surface
Main oil of the piston to cool the piston.
gallery The oil jet is equipped with a check valve which opens
and closes at specified oil pressure, preventing the
decreased amount of ·oil at low oil pressure and loss
in oil pressure.
On the piston for the 6022-TC, a cooling cavity is
provided. The oil injected from the oil jet enters the
81549A cooling cavity to cool the piston.
The timing gear idler shaft are lubricated, as shown in

the figure, by engine oil flowing through the oil holes
routed from the main oil gallery and the crankshaft
main bearing in the rear end. Each gear is lubricated
by the engine oil sprayed from the oil spray plug.
12-7
•
(7) Lubrication of Turbocharger
The injection pump and air compressor are lubricated

as follows:
Oil m ain gallery
�---'n_ie c_ i_t on-pu_mP

�
�I l�____
_ ___ l
o_i_ co
--, r
e
-o-l _r___ _,
_
Air in=:> Crankcase Air compressor
Gear rt ain
Piston ring Oil pan

Exhaust B4363A
Part of the engine oil is directed through the oil pipe

from the ·�rankcase into the turbocharger. The engine
oil passes through the oil hole in the turbocharger
bearing housing to lubricate the bearings. It is then
returned through the oil outlet at the bottom of the
bearing housing back to the crankcase and to the oil
pan. A piston ring is installed on the outside of each
bearing, serving as an oil seal.
(8) Injection Pump and Air Compressor
12-8
(9) Lubrication of Water Pump
m
To oil pan
' From main oil gallery

00052A
The engine oil drawn by the oil pump is routed The engine oil is then forced back from the drain port
through the crankcase oil passage to the water pump. to the crankcase and returns to the oil pan.
The engine oil delivered to the water pump flows
through the oil hole of the water pump and lubricates
the bearings.
12-9
m
2. SPECIFICATIONS
LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS
Item Specifications
Engine oil Quality !Without turbocharger!

AP\ classification Class CC or better
IWith turbocharger!
AP\ classification Class CD or better
I For general powerl \For construction machinery!

Oil pan capacity Approx. 27 lit. Approx. 25 lit.
Oil filter capacity 4 to 4.5 lit. 4 to 4.5 lit.
Lubrication method Forced lubrication by oil pump
Oil pump Type Forced lubrication by gear pump
(with built-in relief valve)
Relief valve Type Ball valve
Oil filter
Full-flow filter element Type Filter paper type
Bypass filter element Type Filter paper type
Oil bypass alarm Type Piston valve type with built-in electric contacts
Oil cooler Type Shell and plate type (multi-plate type)
Oil bypass valve Type Piston valve type
Regulator valve Type Piston valve type
Oil jet
Check valve Type Piston valve type
Unit:mm

!Basic diameter!
Oil pressure At idle 145 kPa 49 kPa Inspection.

(Oil temper- (1.5 kgficm2 1 or more (0.5 kgf/cm2 1
ature at
70 to 90"C At maximum speed 295 to 490 kPa 195 kPa Adjust.
(3 to 5 kgf/cm2 1 12 kgf/cm2 1
Oil pump Backlash between crankshaft 0.13 to 0.25 0.4 Replace.

gear and oil pump idler gear
Backlash between idler gear 0.11 to 0.24 0.4 Replace.

and oil pump gear
Difference between pump case 0.05 to 0.11 0.15 Replace.

depth and gear height
Gear tooth tip to pump case 0.11 to 0.18 0.2 Replace.

clearance
Drive gear shaft to cover 1201 0.15 Replace.

Driven gear shaft to driven 1201 0.15 Replace.

gear clearance 0.04 to 0.07
Idler gear shaft to idler gear 1221 0.15 Replace bushing.

12-10
LUBRICATION - SERVICE STANDARDS
m
Description Nommal val11c Limit Correction and remarks
!Basic <i,amctcrl
Oil Relief valve 1180 kPa Replace spring.

pump valve opening pressure 112 kgflcm:)
Relief valve spring load 150 to 165 N

(Installed length: 46.3) 115.3 to 16.9 kgfl
Oil bypass alarm valve opening pressure 345 to 390 kPa Replace.
ION start pressure) (3.5 to 4 kgflcm'I
Oil cooler bypass valve opening pressure 175 to 215 kPa Replace.
11.8 to 2.2 kgflcm'I
Regulator Valve opening pressure 360 to 420 kPa Replace.

valve 13.7 to 4.3 kgflcm 1)
Spring load 76 to 80 N
(Installed length: 48.3) 17.8 to 8.2 kgfl
Check valve opening pressure 265 to 325 kPa Replace.

12.7 to 3.3 kgf/cm'I

0.0. x Pitch mm Nm lkgfml
Oil pump idler gear shaft nut M12 x 1.25 59 to 78 Apply LOCTITE
(6 to 81 No. 262.
Oil bypass alarm M20 x 1.5 44 to 54

(4.5 to 5.5)
Oil filter center bolt M16 x 1.5 59 to 69

(6 to 71
Oil cooler bypass valve M27 x 1.5 15 to 20

11.5 to 2.01
Regulator valve M27 x 1.5 98 to 115

(10 to 121
Oil pan drain plug M18 x 1.5 69 (7)
Oil jet check valve M12 x 1.75 ·34 (3.5)
12-11
•
LUBRICATION - SERVICE PROCEDURES
NOTE:
1. To remove the oil cooler, remove the
At idle injection pump beforehand.
NV 145 kPa (1.5 kgf/cm')
or more 2. After the element has been installed,
L 49 kPa (0.5 kgf/cm') start the engine and check connections
At maximum speed for oil leaks.
NV 295 to 490 kPa
(3 to 5 kgf/cm')
L 195 kPa (2 kgf/cm2 )
(2) Oil Pump, Oil Strainer
L Limit
89016A
With the .oil pressure switch removed and pressure

gauge installed, worm up the engine until the oil
temperature reaches 70°C _to 90°C.
Measure the oil pressure at idle and maximum
speeds. If the measurement is below the limit,
overhaul the lubricating system.
4.1 REMOVAL AND INSTALLATION

(1) Oil Filter, Oil Cooler
Bolt tightening sequence Oil pan

1:- 1 2)- !J
2 Oil strainer
After the installation has been
completed, make sure that 3 Oil pipe
the oil pump gear rotates smothly 4 Oil pump
when turned by hand.
5 Drain plug
C1160C
NOTE:
1. Measure the backlash in advance of
removal of oil pump.
2. The oil strainer and oil pipe should be
removed together with the oil pump
unless anything wrong is evident.
3. After the oil pump has been installed,
Regulator valve
verify that the backlash is within the
specified range.
C1158D
12-12
4.2 DISASSEMBLY, INSPECTION AND REASSEMBLY

4.2.1 Oil Pump
(1) Disassembly and Inspection
Clearance between idler Relief valve opening

shaft to idler gear pressure
BD 22 NV 1 180 kPa
NV 0.03 to 0.05 (12 kgf/cm')
L 0.15
'Backlash
Installed load of spring
NV 0.11 lo 0.24
(Installed length: 46.3)
L 0.4
NV 150 to 165 N
Worn or damaged tooth ( 15.3 to 16.9 kgf)
Clearance between shaft

to cover
BD 20 Clogged oil hole
NV 0.04 to 0.07
L 0.15 6 Worn bushing or worn or
c.. damaged tooth surface
�\\�, 9
4 tooth surface
or worn busing
2 'Clearance between gear
Worn busing Clearance tooth tip to oil pump case
Clogged or cracked BD 20 NV 0.11 to 0.18
NV 0.04 to 0.07 i L 0.2
L 0.15
BD . Basic Diameter 'Ditterence between oil pump
NV . Nominal Value . case depth and gear height
L Limit NV 0.05 to 0. 11
L 0.15
Oil strainer 6 Idler gear
(j) 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 disassembly of parts with an encircled number, see following items.

The part marked • must be inspected before disassembly.
NOTE:
1. Do not remove the driven gear shaft unless it is faulty.
Removal of the shaft may result in loss of allowance
for tightening the oil pump case.
2. The case and gear assembly is a non-disassembled
type. Replace the assembly if it is defective.
C9518D
12-13
m LUBRICATION - SERVICE PROCEDURES
Disassembly and Inspection Procedure

(a) Before disassembly, measure and record the
backlash between the oil pump gear and the idler
gear.
C9521A
2) Measure the clearance between the drive and

dri\len gear tooth end and the oil pump case with a
thickness gauge.
Oil pump cover C9519A
(b) Remove the oil strainer and drive out the oil pump
cover with a plastic hammer etc.
NOTE:
The oil pump cover is located by the dowel
pins installed to the oil pump case.
(c) Before the driven gears are removed, measure
and record the following items.
C9506A
(d) Measure and record the outside diameter of each

of the drive gear shaft, driven gear shaft and idler
gear shaft. Then, measure and record the inside
diameter of each of the oil pump case, cover and
driven gear bushings. Calculate the clearance be
tween each shaft and bushing. If the service limit is
exceeded, replace the assembly.
C9520A
1) Measure the difference between the drive and

driven gear height and the oil pump case depth with a
thickness gauge.
12-14
(2) Reassembly
•
Rernove oils or greases
Backlash between driven gear
from threaded area and
and idler gear Shaft oil hole should 6
then apply Loctite 262. Apply sealant to the
NV 0.11 to 0.24 be in this range
L 0.4 portion to be filled
59 to 78 Nm in bushing (Moly
(6 to 8 kgfml bdenum base grease)
5�- --- - �
-
C) Align oil hole

with arrow and
UP mark up
Align oil holes
Shaft end surface should be

flush with case end surface
I
7 1
(Wetl /
2 3 4
9
< Assembly sequence>
I10 -� 9 - a - 7 - 6 - s - 4 - 3 - 2 - 1
NOTE:
1. Before reassembly, apply engine oil to all parts unless
otherwise specified.
2. Temporarily tighten the oil strainer, taking into consid·
eration its installation to the crankcase.
C9525C
12-15
m
4.2.2 Oil Filter
Cracks
Clogging, deformation
Drain plug
2 Center bolt
------ 4 Cracks, deformation 3 Washer
4 Oil filter case
5 Oil filter element
6 Element retainer
7 Oil filter head
8 Oil bypass alarm
C9705C
Inspection of Oil Bypass Alarm
Pressure ga g e
u __
/ � _ _____
/ Valve opening pressure
NV 345 to 390 kPa

13.5 to 4 kgf/cm'I
U0700C
With no air pressure applied, check for continuity

across the terminals as shown and replace the oil
bypass alarm if there is continuity.
Next, with the air pressure applied and gradually
increasing, measure the air pressure when there is
continuity.
If the measurement is out of specification, replace the
oil bypass alarm.
12-16
4.2.3 Oil Cooler
m
Damage, cracks,
scale, oil leaks
Cracks, scale
3
Oil cooler element

2 Bypass valve
3 Oil cooler cover
. "
""' @@
@ @
@ @@ 2 .
�
Bypass valve opening
� NV ... Nominal Value
pressure
NV 175 to 215 kPa
(1.8 to 2.2 kgf/cm')
C9804C
( 1) Cleaning (2) Air Pressure Test

(a) Check for carbon or sludge deposited in the oil To check for oil leaks due to a broken or cracked
passage of the oil cooler element and bypass valve. If element, air pressure test should be performed.
contamination is evident, wash in a cleaning oil. Apply 1470 kPa (15 kgf/cm2 ) air pressure to the
(b) If there is much scale on the element and cover, element to check for leaks. If air leaks or other defects
wash with tap water (preferably hot water). are evident, replace ttie element.
NOTE:
Make sure that the specified air pressure
is not exceeded.
12-17
•
4.2.4 Regulator Valve
98 to 115 Nm
(10 to 12 kgfm)
Set load (set length: 48.3)

NV 76 to 80 N
(7.8 to 8.2 kgf)
Lost tension 3
1 Snap ring
2 Valve
Opening pressure 3 Spring
NV 360 to 420 kPa
(3.7 to 4.3 kgf/cm') 4 Body
C9902A
4.2.5 Check Valve
I �2
�� .
After assembling, ,,.
bend lock washer 0
tab against check =e,j._----1 34 Nm (3.5 kgfm)
valve. (mounted on crankcase)
Valve opening pressure

NV 265 to 325 kPa
(2.7 to 3.5 kgf/cm')
Check valve
2 Lock washer
3 Oil jet body
C9951B
For the check valve mounting position, refer to (e) in (6) in 1 General and (2) in 5.4.3 in Group 11 Engine.
12-18
5. TROUBLESHOOTING
LUBRICATIONS - TROUBLESHOOTING m
Oil pressure Abnormal oil level

does not increase • Oil leaks into coolant Correct and fill to
specified level
Oil leaks
Incorrect oil viscosity

• Oil out of life Replace
• Fuel in oil Replace !cause)
Oil pressure switch not functioning properly Replace
Loaded oil filter element Replace element
Loaded oil strainer, loose oil pump joint, cracked pipe Correct or replace
Relief valve, bypass valve not functioning properly
Worn or damaged oil pump proper Replace
Excessive oil Oil leaks from engine Correct or replace Group 11

consumption
Oil leaks from crankshaft front or rear oil seal Correct or replace
Leaks to cooling system

• Defective oil cooler water jacket Correct or replace
Abnormal compression pressure Check Group 11
12-19
FUEL AND ENGINE
CONTROL
CONTENTS
1. GENERAL ...................................... 2 5.3 FEED PUMP ................................ 81

2. SPECIFICATIONS .......................... 22 5.3.1 Disassembly, Inspection and
3. SERVICE STANDARDS .................. 23 Reassembly ............................ 81
3.1 SERVICE STANDARD TABLE ..... 23 5.3.2 Test and Adjustment .............. 82
3.2 TIGHTENING TORQUE TABLE ... 25 5.4 AUTOMATIC TIMER ................... 83
4. SPECIAL TOOL .............................. 27 5.4.1 SA Type Automatic Timer . ...... 83
5. SERVICE PROCEDURES ................ 30 5.4.2 SP Type Automatic Timer 88
5.1 INJECTION PUMP ...................... 31 5.4.3 Test and Adjustment .............. 92
5�1.1 Removal ................................. 31 5.5 PUMP DRIVE CASE .................... 93
5.1.2 AD Type Injection Pump ......... 32 5.5.1 Removal and Installation ....... 93
5.1.3 P Type Injection Pump ........... 40 5.5.2 Disassembly and lnspec·
5.1.4 Adjustment after tion ......................................... 93
Reassembly ............................ 49 5.5.3 Reassembly ............................ 94
5.1.5 Installation ............................. 57 5.6 INJECTION NOZZLE .................. 95
5.1.6 Bleeding the Fuel System 60 5.6.1 Removal and Installation ....... 95
5.1.7 Inspection and Adjustment of 5.6.2 Disassembly ........................... 95
Fuel Injection Start Timing 61 5.6.3 Cleaning and Inspection 96
5.1.8 Inspection and Adjustment of 5.6.4 Reassembly and Adjustment
No-load Minimum and (1-spring nozzle) ..................... 97
Maximum Speeds ................... 62 5.6.5 Reassembly and Adjustment
5.2 GOVERNOR ................................ 64 (2·spring nozzle) ..................... 98
5.2.1 RSV Type Governor ................ 64 5.7 FUELFILTER ............................ 104
5.2.2 RFD Type Governor ................ 67 5.8 WATER SEPARATOR 105
5.2.3 Adjustment after Reassembly 70 6. TROUBLESHOOTING .................. 106
5.2.4 Inspection and Adjustment of
No-load Minimum and Maximum
Speeds .................................... 80
13-1
DJ FUEL AND ENGINE CONTROL - GENERAL
1. GENERAL
- Injection
pipe
Injection
nozzle
Fuel feed
Fuel
pump
Governor filter
Fuel leak-off
pipe
Fuel
feed pipe
pipe
Fuel feed Fuel return Water

pump pipe separator
(Option!
Fuel tank
NOTE:
The figure shows the AD improved
version injection pump.
B2115A
The fuel system consists of the injection pump

general assembly (injection pump proper, governor,
timer, feed pump and coupling), fuel filter, water
separator, injection pipe, injection nozzle, fuel leak-off
pipe, etc.
The injection pump is driven at one-half the engine
speed.
13-2
FUEL AND ENGINE CONTROL - GENERAL
( 1) Injection Pump Proper

(a) Injection pump
AD type --6022> P type <6022· T, TC>

Delivery valve holder Delivery valve holder
--�
·'.] Delivery valve spring
Delivery valve seat
Delivery valve seat

Plunger barrel
Control rack
Oil sump
Control sleeve
Control rod
Lower spring seat
Tappet
Cam chamber
Camshaft
89082A 89083C
The camshaft driven at half the engine speed is 3) To prevent the fuel in the oil sump from leaking
supported by taper roller bearings at both ends. The into the cam chamber, an 0-ring is provided on the
camshaft has a cam for operating the plunger and a outer circumference of the plunger barrel, thereby
cam for operating the feed pump. maintaining its tightness.
A tappet operating with the pump housing as the 4) A deflector is provided on the outer circumference
guide is in contact with the camshaft. The tappet of the plunger barrel to prevent erosion of the pump
changes the rotary motion of the cam to up-and-down housing that may be caused by counter flow of fuel at
motion which is transmitted to the plunger. the end of an injection.
The P type injection pump offers the following
features.
1) The pump housing is a totally enclosed type.
2) The plunger barrel has an oblique hole made to
return the fuel that has leaked to the oil sump to
minimize the leakage of the fuel into the cam
chamber.
13-3
m
(b) Plunger
The plunger has an oblique groove and a vertical

groove, while the plunger barrel has 2 inlet-outlet
holes.
Pressurized feeding of fuel oil begins when the
plunger, pushed up by the cam of camshaft, closes
the inlet-outlet holes of plunger barrel. When the
plunger is further pushed up, fuel oil is discharged
through the vertical groove of plunger from the
inlet-outlet holes.
Fuel Beginning of Pressure End of
drawn in pressure feed feed pressure
feed
82204A
AD type injection pump P type injection pump
Control rod
Plunger barrel Plunger
Control sleeve
Driving face
82224A 82206A
A deflector is installed on the periphery of the plunger which engages with the control rod (or the control
barrel so that high pressure fuel oil discharged from rack and pinion). Since the driving face of plunger
· inlet and outlet ports will not erode the pump meshes with the control sleeve at the lower part
housing. Fuel injection volume is controlled by the thereof, the plunger turns with the rotation of control
governor which moves the control rod (or the control sleeve and injection volume is controlled through the
rack) left and right and rotates the control sleeve changing of the effective stroke.
13-4
DJ
A delivery valve stopper, provided on the top of the
delivery valve spring, limits the lift of the delivery
Eff P.ctive strokP. valve to prevent the surging of the valve during high
speed operation. It also reduces the dead volume
between the delivery valve and nozzle and stabilizes
the injection rate.
(d) Overflow valve
B2205A Spring
The effective stroke means the length of the plunger

stroke from the time when the upper end of plunger
pipe
closes the inlet-outlet holes of plunger barrel until the Steel ball
.
oblique groove of plunger opens to the inlet-outlet
holes. When the effective stroke stands at zero, it
indicates that no fuel injection takes place.
B2208A
(c) Delivery valve
When the fuel pressure in the injection pump exceeds
a predetermined pressure, the steel ball in the
Suction stroke
overflow valve is pushed up to let the fuel flow out
from the injection pump and return to the fuel tank,
thereby stabilizing the fuel temperature and tempera
ture distribution in the injection pump and maintain
ing the injection rate into each cylinder constant.
Beginning of Injection End of End of

injection injection injection
(beginning
of suction)
B2207A
The fuel highly pressurized by the plunger pushes the

delivery valve up and gushes out. When delivery of
the fuel under pressure by the plunger is completed,
the delivery valve is pushed back by the delivery valve
spring and closes the fuel passage to prevent counter
flow of the fuel.
The delivery valve is further brought down until it is
held against the seat surface tightly. The amount of
fuel corresponding to the stroke during the period is
drawn back from above to instantly lower the residual
pressure in the line between the delivery valve and
nozzle. The draw-back effect improves the cutting of
fuel from the nozzle and prevents after-injection
dripping.
13-5
(2) Governor
(a) RSV type governor
Supporting lever
Guide lever shaft
Governor housing
Tension lever
Start spring �Control rack
Shackle
-Adjusting lever
Control lever
Governor spring
Camshaft
Flyweight
Ungleich spring
Stop lever
Full-load stopper bolt

826578
The RSV type governor is a centrifugal type all-speed The governor, as shown, consists of flyweights
governor coupled to the camshaft of the injection mounted to the injection pump camshaft. When the
pump. The governor not only controls the maximum flyweights turning on the flyweight suppqrting shaft
and minimum speeds but also automatically controls open outward, the roller mounted to the end of
the engine speed at any intermediate speed position. flyweight arm pus.hes the end of the sleeve in the
axial direction. The governor sleeve, being made
integral with the control block through a bearing,
Slider
moves only in the axial direction.
The control block, mounted to the guide lever hung
on the supporting lever shaft of the governor cover,
prevents rotation.
Guide
lever
Supporting
shaft
Shifter Governor
sleeve Flyweight
82658C
13-6
DJ
When the governor spring receives tension, the
bottom end of the tension lever touches the adjust
Start spring
able full-load stopper bolt.
When the angle of the adjusting lever is changed, the
angle of the swivel lever is also changed and the
rack
tension of the governor spring changed. This is
because the turning center of the swivel lever and the
mounting position of the governor spring installed to
Control
lever the tension lever are eccentric to each other as
Guide lever
mentioned above.
An adjusting screw is also mounted to the swivel
lever. Adjustment of the screw changes the tension of
the governor spring, thereby making it possible to
adjust the speed regulation.
An Ungleich spring is provided in the bottom portion
of the tension lever. Adjust the tension of the spring
by adding or removing shims.
An idling sub spring adjustable from outside is
provided in the middle of the governor cover. During
idling, the spring always keeps in contact with the
Supporting Return Stop tension lever to maintain a constant idling speed.
lever spring lever
B2659A The stop lever, mounted through the supporting lever
to the bottom end of the control lever, returns the
The control lever is mounted to the middle of the control rack to the stop position with a slight pressure
guide lever by the shaft with the bottom end as the irrespective of the adjusting lever position.
fulcrum, whereas the top of the lever is coupled
through the shackle to the control rack. 1) Start of engine
The start spring, attached to the top end of the control
lever, always pulls the control rack in the direction Adjusting lever
that fuel is increased. Start spring
Control
Adjusting lever Adjusting

screw
Guide lever
Swivel lever
Governor spring
Full-load
stopper bolt B2660A
When the adjusting lever is moved to the start

B3970A position (until it touches the maximum speed stop
per), the swivel lever which moves with the adjusting
The turning shaft of the swivel lever is fitted into the lever pulls the governor spring and moves the tension
bushing of the governor cover and its center is lever until it touches the full-load stopper bolt.
eccentric with respect to the mounting position of the
governor spring installed to the tension lever. The
governor spring is installed to the end of the swivel
lever.
13-7
At that time, the flyweights are stationary, and the 3) Maximum speed control
start spring with weak tension pulls the control lever
---------------- - -
-------�
in the direction that fuel is increased.
At the same time, the control block and governor
Adjusting lever
sleeve push the flyweight roller to the left.
As the result, the tension lever and control block are
spaced that much apart, and the corresponding
amount of fuel is supercharged to facilitate starting.
2) Idling control
Start spring
Shifter Full-load stopper bolt 82662A
When the adjusting lever is moved to the full-load

Governor spring
position, the tension of the governor spring is in
Tension lever
Control creased and pulls the tension lever until it touches the
full-load stopper bolt.
Idling sub
I<*�� spring When the engine exceeds the specified speed, the
centrifugal force of flyweights becomes larger than
the force of the governor spring pulling the tension
82661A lever. So the tension lever is moved to the right and
moves the control rack in the direction that fuel is
Once the engine is started and the adjusting lever reduced, thereby preventing the engine from exceed
returned to the idling position, the tension of the ing the specified speed.
governor spring is drastically reduced. If the speed further increases, the centrifugal force of
Now the flyweights can move outward even at a low flyweight increases and pushes the tension lever to
speed, so the tension lever is pushed back until it the right and also compresses the idling sub spring to
touches the idling sub spring and places the control pull the control rack back to the no-load maximum
rack at the idling position. In this state, the centrifugal speed position, thereby preventing over-speed opera
force of the flyweights and the weak-state governor tion of the engine.
spring and idling sub spring achieve balance and The RSV type governor controls the entire speed
maintain smooth idling. range from idling to maximum speed. If load in
When the speed falls, the centrifugal force decreases, creases of decreases at a certain speed determined by
the flyweights move inward, and the idling sub spring the position of the adjusting lever, the governor
pushes the tension lever to the left and moves the automatically functions and maintains the engine
control rack in the direction that fuel is increased. speed constant at all times.
If the speed falls radically, the start spring with weak
tension acts and moves the control rack in the
direction that fuel is increased to maintain the idling
speed.
13-8
DJ
4) Ungleich operation The air intake rate of the engine falls as the engine
speed increases. The injection pump, on the other
hand, increases the per-stroke injection as the speed
When max. injection is set increases, even with the control rack at the same
at low-speed operation
njection matched position.
with air intake rate
\ Therefore, if full load is set at point A to derive
Injection/stroke
A -�----1 B B'
enough output at low speeds, the injection will reach
- T Bas the speed increases, and the engine will produce
A'._-,---- I
When max. injection is set
at high-speed operation
black smoke.
I If full load is set at point B' to prevent black smoke, the
Engine speed low speed injection will come down to A', allowing
combustion of more fuel.
82663A
So the Ungleich device accomplishes the function of
setting full load at point A to derive the largest
The Ungleich device controls fuel injection in such a possible torque in the low speed range, and changing
way as to ·match the engine performance (the re it to adjust the injection to point B' in the high speed
quired injection varies with engine speed). range.
t R2
R1 t Without
Ungleich effect
E
z
a,
:,
0
f-
N2 N1
N2 N1
Engine speed (rpm) _.
Pump speed (rpm) _....
82664A
When the engine speed is low and the centrifugal

force of flyweight smaller than the pressure of the
Ungleich spring, the control block is moved as much
as the Ungleich stroke to the left, so the control rack
moves in the direction that fuel is increased to
increase the torque of the engine at low speeds.
13-9
5) Stopping of engine
Full load
Adjusting lever
Tension lever
Control rack
Shifter
82665A Stop
Stop lever 82666A

As the engine speed increases, the centrifugal force of
flyweight increases. If it becomes larger than the When the stop lever is moved to the stop position, the
pressure of the Ungleich spring, the Ungleich spring control rack is moved to the stop position to stop the
is slowly compressed before the start of high speed engine regardless of the position of the adjusting
control, and the control rack moves in the direction lever.
that fuel is reduced. The Ungleich stroke is completed
at the position where the control block directly
touches the tension lever.
6) Operation of torque spring [Option]
t
E
C D
I D
.,,
a.. Governor operating range

0
-� -"'
·.;;
0
a. A 5
a.
-"'
u 5
0 A
P1 P1
Pump speed (rpm) --

P2
Engine speed (rpm) ----
P2
82667A
Construction machinery engines are often subjected often lead to stalls. To prevent this, a torque spring is
to a large load during operation, and reduced speeds provided.
13-10
DJ
When the adjusting lever is fixed in the lever set At the time, the tension lever pin pushes the bottom
position, a sudden increase of load, if no torque of the torque control lever, and the lever moves with
spring is provided, will move the control rack along the pin "A" as the fulcrum, whereas the portion "8" is
the 8-D curve as the speed falls. The rotational pushed to right. As the result, the torque spring
displacement at the time may be expressed as P 1 . performs the function of reducing movement of the
If a torque spring is provided, the control rack moves tension lever.
along 8-C, and the rotational displacement at the time
may be expressed as P 2. Therefore, large changes (b) RFD type governor [Option]
occur in P 2 and engine speed, and because of
increased fuel injection, the engine torque increases, Governor Stop lever Governor
Guide cover housing
and large combustion noise warns the operator of the lever \,
\
/
/
Go�ernor
�
increased load, enabling him to take proper action to Tension '\'
. \
/ spring
lever ', ·,, '
prevent stopping the engine. ,_ \
///
Floating ,, '·, ',,.,
lever link
Swivel lever
Camshaft
Speed control
lever
Idling
spring
Stroke Flyweight
/
adjusting
bolt Floating Sliding
lever lever
82682A
The RFD type governor is a minimum-maximum

governor which controls only the minimum and
Full-load stopper
maximum speeds.
82668A The RFD type governor make it possible to increase or
reduce fuel by the load control lever which operates
In an abrupt increase of load occurs when the engine the control rod. Any desired speed can be set as a
is running at continuous rating, the engine speed displacement of the speed control lever changes the
falls. So the flyweights are moved inward and the tension of the governor spring.
tension lever pulled to left by the control spring, Because of the construction described above, the RFD
causing the control rack to move in the direction that governor can be operated as an all-speed governor by
fuel is increased. holding the load control lever in the FULL position
and operating the speed control lever.
On the top of the governor, an engine stop lever is
provided which creates a no-fuel injection state for
stopping the engine. A cancel spring is provided to
make sure that when the lever is operated, no undue
force is applied to the link.
13-11
1) Start of engine and control of idling
Increase.- Injection rate --- Decrease
Increase� Injection rate - Decrease
Floating lever
Tension lever
/N•r-«:>'41:::::� Load cont ro I

lever C Load control
lever
Idling spring
Idling spring
B2605A
B2603A
If the load control lever is placed to the idling position
When the engine is stationary, the flyweight is in after the engine has started, the floating lever will
closed position, pushed by the governor spring, idling move the control rod back to a position where a fuel
spring and start spring. injection rate suitable for the idling speed is available,
If, in this condition, the load control lever is moved all with the point B as the fulcrum.
the way to the FULL position (in the direction of As the engine speed increases, the flyweights will
greater fuel delivery), the start spring and idling move outward by the centrifugal force and will shift
,spring will cause the control rod to move to the fuel the shifter by the point A until the shifter compresses
increasing position. the idling spring.

At this time, the fulcrum B will also slightly move
toward the tension lever and will move the control
rod back in the direction for reducing the fuel injection
rate.
As the engine speed decreases, the centrifugal force
of the flyweights will decrease and the flyweights will
move inward, so the point A will return toward the
pump housing. This will set the shifter in the free
state, pushing it back toward the pump housing by
idling spring force.
13-12
At the same time, the fulcrum B will also slightly As the engine speed increases, the centrifugal force of
m
move toward the pump housing to push the control the flyweight will increase, and the flyweight will
rod back in· the direction for decreasing the fuel push the shifter. In the normal speed range, however,
injection rate. the shifter will have only a thrust enough for com
In this manner, the idling speed is maintained stable pressing the idling spring and will not be able to push
by slight adjustment of the injection rate. the tension lever out by overcoming the tension of the
governor spring.
2) Normal speed operation In this manner, the fuel injection rate is increased or
reduced simply by operation of the load control lever
which moves the control rod.
3) Control of maximum speed

Increase .._ Injection rate ......, Decrease
Increase -4--- Injection rate � Decrease
Speed control lever
Tension lever
Eccentric shaft
Idling spring
82606A
Flyweight Shifter
If the control lever is moved toward FULL (in the
direction of greater fuel delivery), the eccentric shaft
coupled to the load control lever will cause the sliding 82607A
lever to turn with the point D of the tension lever as

the fulcrum. In addition, the floating lever will push If the engine speed exceeds a predetermined max
the control rod back in the direction of greater fuel imum speed because of changes in engine load, the
injection rate, with the point B as the fulcrum. centrifugal force of the flyweight will overcome the
tension of the governor spring and will push the
tension lever together with the shifter.
13-13
Movement of the shifter will move the point B, and

movement of the tension lever will move the point D,
and will also move the point C with the point E as the With smoke s'et
assembly
fulcrum.
Without smoke set
Movement of the point B and movement of the point ,)'mblv
C will combine to pull the control rod back in the
direction of less fuel injection rate, thereby preventing
the engine speed from increasing.
If an engine control mechanism which operates the
speed control lever adjusting the tension of the
governor spring is employed, the governor can be
operated as an all-speed governor which maintains a Rack
position
desired engine speed constant. (mm)
4) Start booster (smoke set assembly)
Pump speed (rpm)
826748
11111111
As indicated by the governor characteristics shown
above, when without the smoke set assembly, the
shifter and floating lever are pushed back by the
idling spring force, moving the control rack toward
fuel increasing direction when pump speed reaches
N,. Namely, N, is the smoke limit in this case.
When with the smoke set assembly, the spring force
of the smoke set assembly overcomes that of the
idling spring so that the floating lever motion is
inhibited until the speed reaches N,. Thus, the smoke
limit decreases from N, to N,.
It is also possible to secure rack position Rs needed at
time of start.
82763A
The smoke set assembly installed to the rear of the

governor has a spring with setting force and a stopper
as functional parts. It also has sleeve, stroke adjusting
nut, spring adjusting nut and cap.
13-14
FUEL AND ENGINE CONTROL - GENERAL DJ
5) Engine stop The floating lever A pushed by the floating lever link
turns in such a way as to make the cancel spring bend
Stop lever over the shaft B. So no load is placed on the floating
lever C blocked by the idle stopper bolt outside the
Normctl position governor.
Operation of the ungleich device is the same as the
RSV type governor.
(3) Feed Pump
/ Priming pump
Control rod
I
Floating lever link 82608A
To stop the engine, fuel is cut off by operating the

Outlet
stop lever on the top of the governor. check valve Inlet check valve
If the stop lever is operated, the internal lever pushes
the pawl of the floating lever link to force the control
rod out to the no-injection position.
Since the amount the control rod is moved by
operation of the stop lever exceeds the operating To fuel filter From fuel tank 83006A
range of the floating lever mechanism, damage to the

link and allied parts is prevented by the cancel Supply of fuel to the injection pump proper is
mechanism shown. accomplished by the feed pump mounted to the side
of the injection pump proper and driven by the cam of
the injection pump camshaft provided for the pur
pose.
�I
The priming pump mounted to the feed pump makes
it possible to lift fuel manually when the engine is
Internal lever
I stop lever I
J� stationary.
' Floating lever link
Control rod
spring
81631A
13-15
When the pressure of the pressure chamber or the

Outlet
Piston spring delivery pressure exceeds specification, the piston
cannot be brought back by the pressure of the piston
spring, so the pump action stops and the fuel
pressure in the fuel filter does not rise more than
necessary.
(4) Automatic Timer

The interval between fuel injection into the cylinder
and its ignition is called the ignition delay interval.
Pressure Stop The ignition delay interval is constant regardless of
feed
83002A
the engine speed. If the ignition timing is always
constant, changes in the engine speed will vary the
The feed pump feeds fuel under pressure as follows. relation between the piston position and ignition
When the piston is pushed up by the cam of the timing, making it impossible to obtain the best engine
camshaft.' the fuel in the suction chamber opens the performance. To maintain the relation between the
outlet check valve, so most of the fuel is forced out piston position and ignition timing constant at all
and drawn into the pressure chamber. When the cam times, the injection timing must be changed to match
is moved away by rotation of the camshaft, the piston the engine speed.
is pushed back by the pressure of the piston spring. At The automatic timer is a device which automatically
the time, the outlet check valve closes and the inlet changes the injection timing according to the engine
check valve opens. So fuel is drawn into the suction speed.
chamber, whereas the fuel in the pressure chamber is
forced out.
(a) SA type automatic timer [6D22]
Flyweight
Flange
Timer case
Flyweight holder
83210A
13-16
The two flyweights have a hole at one end. The pins

m
of the flyweight holder fit in the holes. The flange legs At maximum
Spring
touch the curved surfaces of the flyweights. Timer advance angle
springs are mounted to the flyweight pins and flange

legs.
Rotation of the engine is transmitted to the flange and
from there to the flange legs, flyweights and flyweight
holder and to the injection pump camshaft.
At high speeds
Flange leg 83212A
Flyweight
When the engine runs at a high speed, a centrifugal
Flyweight
holder pin
force acts on the flyweights and causes them to open
outward with the pins of the flyweight holder as the
fulcrums. The flange legs are pushed by the curved
surfaces of the flyweights in the direction of the timer
At low speeds spring compression, but they cannot be moved
8321 lA
because they are coupled to the drive side.
As a result, the pins of the flyweight holder are drawn
During low speed operation of the engine, no centri in the turning direction, while compressing the timer
fugal force acts on the flyweights, so the timer springs springs, and move the camshaft of the pump in the
have the longest installed length. turning direction to advance the injection timing.
If the engine speed changes from a high to low speed,
the centrifugal force of the flyweights will decrease
and the flyweights will return to their original posi
tions. At the same time, the pins of the flyweight
holder will be pushed back by the timer springs.
13-17
• FUEL AND ENGINE CONTROL - GENERAL
(b) SP type automatic timer [6D22· T, TC]
Oil seal
0-ring
Cover
Spring seat
Timer housing
B3201A
Two flyweights are fitted on the pins of the timer Timer springs are held between the spring seats fitted
housing and are held in the timer housing. On the on the timer housing pins which extend through the
other hand, the injection pump connection side flange flange and flyweight. These parts are housed in the
has a curved surface, and the roller fitted on the pin timer housing and are totally enclosed with a cover,
installed in the flyweight touches the curved surface. 0-ring and oil seal.
13-18
�-------- ----�-----------
-
- (5) Coupling
m
[For AD type]
Timer snring Flange
Cross coupling
Driving coupling
Air compressor
crankshah
Advance angle
Coupling
plate Cotter bolt
83405A
[For P type]
Cross coupling
"·
Driving coupling
83202A
Crankshaft,
air compressor
When the engine is running at a low speed, the timer
spring pressure is stronger than the centrifugal force
of flyweight, so the roller of flyweight is held down by
the flange, creating no advance state. Cotter bolt
When the engine reaches a high speed, the centrifug

83402A
al force of flyweight becomes stronger, the roller of
flyweight pushes the curved surface of flange with the
The coupling which transmits drive power from the
timer housing pin as the fulcrum, and the flyweight
air compressor crankshaft or injection pump drive
opens outward, while compressing the timer springs.
crankshaft to the automatic timer is a laminated
In this manner, the roller installed on the flyweight
coupling consisting of thin plates placed one upon
moves the flange in the turning direction and adv
another.
ances the injection timing.
The laminated coupling, thanks to the reversibility of
the plates, absorbs excess forces other than the
torque, thereby providing protection against applica
tion of forces other than necessary to the injection
pump.
Adjustment of the fuel injection start timing is made
by changing the installed condition of the driving
coupling.
13-19
(6) Pump Drive Case The high pressure fuel which has forced the needle
valve up is injected from the orifice at the end of the
nozzle into the engine combustion chamber.
Some of the high pressure fuel lubricates the needle
valve, etc. and is returned through the fuel leak-off
pipe to the fuel tank.
The injection pressure of the injection nozzle is
adjusted by changing the tension of the nozzle spring
with the adjusting screw.
(b) Hole type (2-spring nozzle) [Option]
B4191A
The pump drive case is mounted on the flywheel

housing on the left side of the engine and is driven by
the timing gear of the engine at half the engine speed.
The pump drive shaft, with its end connected to the Adjusting screw
coupling of the injection pump, drives the injection

lock nut
pump.
(7) Injection Nozzle Prelift adjusting shim
(a) Hole type (1-spring nozzle) Spacer

No. 2 pushrod
llfflll.--- Nozzle holder
Valve opening pressure
adjusting shim
No. 1 spring
-------
No. 1 push rod
Nozzle
Retaining nut
Adjusting screw
B3406A
Nozzle holder
The fuel delivered from the injection pump enters the

Nozzle spring
nozzle holder and overcomes the No. 1 and No. 2
springs, depending on its pressure, and pushes the
Needle valve needle valve up.
The high pressure fuel which has forced the needle
Nozzle valve up is properly injected from the orifice at the
end of the nozzle into the engine combustion cham
ber.
Some of the high pressure fuel lubricates the needle
valve, etc. and is returned through the fuel leak-off
B3407A
pipe to the fuel tank.
The fuel delivered from the injection pump enters the The injection pressure of the injection nozzle is
nozzle holder and has a pressure higher than the adjusted by changing the tension of the nozzle spring
specified pressure. So the fuel overcomes the nozzle with the shim and adjusting screw.
spring and pushes the needle valve up.
13-20
DJ
(8) Fuel Filter (9) Water Separator [Option]
� - - - - --
- --
- - ------
�
To injection pump
cover
From fuel
feed pump
1 11
�
�Element
B3501A B3551A
The fuel filter is a spin-on type. So the element is The sedimenter type water separator separates gas
easily replaceable. oil and water centrifugally by taking advantage of
The fuel filter separates the water contained in the their difference in specific gravity.
fuel fed under pressure from the feed pump of the The fuel that has flowed in from the inlet connector is
injection pump and removes dust and dirt by the squeezed by the fuel path of the head to increase the
element. flow velocity and spins. The separated water is
sedimented in the case, whereas the water-separated
fuel is drawn through the fuel path in the center of the
head into the feed pump.
The water separator sediments not only water but
also mud components.
A red float goes up and down with the water level in
the semi-transparent case, making it possible to
visually check the water quantity.
13-21
DJ FUEL AND ENGINE CONTROL - SPECIFICATIONS
2. SPECIFICATIONS
Item Specification
(Diesel Kiki Co., ltd. product)

[6D22[ \6022-T[ \6D22-TCJ
Injection pump proper (Standard) (Option) (Standard) (Option)
Type Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line
type type type type type
Model AD AD p p p
Turning direction Clockwise Clockwise Clockwise Clockwise Clockwise
(as viewed from drive side)
Plunger Diameter mm 10.5 10.5 12 12 12
Governor Type All speed Minimum All speed Minimum All speed
governor maximum governor maximum governor
mechanical mechanical
governor governor
Model RSV RFD RSV RFD RSV
Feed pump Model KE KE K K K
Automatic timer Type Mechanical Mechanical Mechanical Mechanical Mechanical

automatic timer automatic timer automatic timer automatic timer automatic timer
Model SA SA SP SP SP
Injection nozzle (Standard) (Option) (Standard) (Option)
Type Hole type Hole type Hole type Hole type Hole type Hole type
(1-spring nozzle) (1-spring nozzle) (2-spring nozzle) (1-spring nozzle) (1-spring nozzle) (2-spring nozzle)
Model OLLA OLLA OLLA OLLA OLLA OLLA

No. of orifices 4 4 4 4 5 5
Orifice 0.37 0.37 0.37 0.37 0.36 0.36

diameter mm
Orifice angle 154 154 154 154 150 150
Injection pressure 21.6 (220) 21.6 (220) 17.7 (180) 21.6 (220) 21.6 1220) 17.7 (180)
MPa (kgf/cm')
Fuel filter Type Spin-on type
Water separator Sediment trap type
13-22
SERVICE STANDARDS
(1) Injection Pump
Unit: mm
Description Nominal value Limit Correction and

!Basic diameter! remarks
Fuel injection start timing IBTDCI Dependent on - Adjust.

specification
Eccentricity with respect lo air compressor crankshah 0.2 or less - Adjust.

lor pump drive shaftl
Injection pump Injection spacing 60" :!. 30' - Adjust.

proper
Preslroke AD type 4.5 .t 0.05 - Adjust.
P type 4.8 :!. 0.05 -
Overall tappet clearance - 0.2 Replace.
Overflow valve opening pressure 6022 155 kPa - Replace.

,,
(for general 11.6 kgf/cm 2 1
power application)
6022 lfor 255 kPa -

construction 12.6 kgf/cm 2 1
machinery)
6022-T, 6022-TC
End play of camshah 0.02 to 0.06 0.1 Adjust shims.
Sliding resistance of control rack AD type 1.5 N or less - Check.

(when stationary) (150 gf or less)
Sliding resistance of control rod P type 1.3 N or less - Check.

!when stationary) 1130 gf or less)
Tappet clearance AD type 0.3 or more Adjust.
Full stroke of control rack lor control rod) 21 or more - Check.
Backlash between control rack and AD type 0.15 0.3 Replace.

pinion
Governor Dimension from governor housing RSV type 19 to 19.2 - Adjust shims.
to shiher
RFD type 33 to 33.4 -
13-23
SERVICE STANDARDS
Unit:mm

Feed Tightness !when 195 kPa (2 kgf/cm') of air pressure O cc/min. - Replace.
pump is applied!
Lifting No. of strokes required before 25 strokes or less

capacity lifting when operated at 60
to 100 strokes per minute
Delivery 100 rpm KE type 60 Replace.

(min.I
for 15 K type 60
seconds
cc 500 rpm KE type 340
K type 260
1000 rpm KE type 405
K type 530
1500 rpm KE type 430
K type 520
(2) Injection nozzle

Unit:mm

Injection nozzle injection One-spring nozzle 21.6 MPa (220 kgf/cm'I Adjust or replace
pressure nozzle.
Two-spring nozzle 17.7 MPa (180 kgf/cm 2)
Prelift 0.10 ± 0.02 Adjust.
2-spring regulated pressure (open pressure! 24.8 to 25.4 MPa Adjust.

(253 to 259 kgf/cm'I
2-spring regulated pressure !cover pressure) with 23 to 23.5 MPa Adjust.

a 0.05 needle valve lift (235 to 240 kgf/cm'I
13-24
SERVICE STANDARDS

0.0. X pitch Nm lkgfm)
Imm)
Injection pump bracket M10 x 1.5 35 to 53 13.6 to 5.41
Injection AD type injection Delivery valve holder 64 to 69 16.5 to 71

pump pump
Lock plate 4.4 to 5.9 I0.45 to 0.61
P type injection Flange sleeve nut 39 to 44 14 to 4.5)

pump
Delivery valve holder 110 to 115 (11 to 12) Tighten three times to
the specified torque.
Governor flyweight nut 49 to 59 (5 to 6)
SA type automatic timer Round nut 83 to 98 18.5 to 1O)
SP type automatic timer Round nut 125 to 145 113 to 15)
Cap screw 29 to 39 (3 to 4)
·'
Cover mounting bolt 22 to 24 12.2 to 2.41 ·
(For AD type injection pump) A bolt 49 to 54 15 to 5.5)
B B bolt 29 to 34 (3 to 3.51
=--- C bolt 29 to 34 (3 to 3.51
��c
-
9f
-
��
B
B3408A
(For P type injection pump) A bolt 74 to 83 (7.5 to 8.51
B bolt 59 to 64 (6 to 6.51
C bolt 59 to 64 16 to 6.5)
� B
·
1� ,'
(,,. (· -
I
,
�·(� I/
C I
B
B3401A
Injection One-spring nozzle Retaining nut M22 x 1.5 59 to 78 (6 to 81

nozzle
Inlet connector M14 X 1.5 69 to 78 (7 to al
Cap nut M14 x 1 39 to 49 (4 to 51
Two-spring nozzle Retaining nut M19 x 1 59 to 78 (6 to al
Set screw 49 to 59 (5 to 61
Lock nut 20 to 25 (2 to 2.51
Cap nut M22 x 1.5 39 to 49 14 to 51
Inlet connector M14 x 1.5 69 to 78 (7 to 81
13-25
DJ
SERVICE STANDARDS
Descriplion Thread size Tightening torque Remarks

0.0. X pitch Nm lkgfml
(mml
Injection nozzle bolt !for attaching to cylinder head) MS x 1.25 15 11.51
Injection On pump side P type M14 x 1.5 29 131

pipe union ---�
nut AD type M12 x 1.5 29 (3)
On nozzle side M12 x 1.5 29 (3)
Leak off pipe eye bolt MS x 1 9.8 to 15 (1 to 1.51
Fuel filter Connector bolt M14 x 1.5 25 (2.51
Water Ring nut - 5.9 to 7 .8 10.6 to 0.81

separator
Drain plug - 2.9 to 3.9 10.3 to 0.41
Air plug MS x 1.25 7.8 to 9.8 (0.8 to 1.0l
Connector bolt M14 x 1.5 25 (2.51
Injection Fuel inlet - 20 to 25 (2 to 2.51

pump
piping Fuel feed !feed pump) - 20 to 25 (2 to 2.51
tightening
eyebolt Fuel feed (pump proper! - 20 to 29 12 to 31
Fuel overflow - 20 to 29 (2 to 3)
Lubricant (inlet) AD type - 9.8 to 13 (1 to 1.3)
P type - 12 to 15 (1.2 to 1.51
Lubricant loutletl AD type - 15 to 18 (1.5 to 1.81
P type - 20 to 29 (2 to 31
Injection pump gear mounting nut of pump drive case M24 x 1.5 22 12.21
13-26
FUEL AND ENGINE CONTROL - SPECIAL TOOL
4. SPECIAL TOOL
Unit: mm
Tool name Part No. Shape Use
Injection pump centering tool MH061270 Centering of bracket of AD type

injection pump
B5032A
MH061340 Centering of bracket of P type

injection pump
B5031A
Filter wrench MH061572 Removal of fuel filter element
85222A
Diesel Kiki Products

(1) AD Type Injection Pump Proper
The part numbers are the DIESEL KIKI part numbers.
Special Tool Name Part No. Use
AD type injection pump special 105790-1060 Disassembly and reassembly

tool set
Universal vice 105794-0090 Mounting base
Tappet pin 157931-7320 Supporting of tappet
Measuring device 105782-4130 Measurement of camshaft end play
Wrench 157910-1120 Removal and installation of screw
Guide 157920-5400 Protection of oil seal
Roller pincers 157921-3020 Removal and installation of tappet
Tappet pincers 157931-6120
Plunger pincers 157921-6120 Removal and installation of plunger
Wrench 157914-0500 Removal and installation of delivery valve holder
Extractor 157925-6520 Removal of inner race
15 7925-0520 Removal of outer race (timer side)
157925-0120 Removal of outer race (governor side)
Reamer 157930-4620 Correction of pump housing
13-27
Stand 105781-0430 Test and adjustment of injection pump
Measuring device 105782-6010
105782-4020
Holder 157931-4400
Nozzle holder wrench 157916-8220
(2) P Type Injection Pump Proper

P type injection pump special 105790-7050 Disassembly and reassembly

tool
Universal vice 105794-0010 Mounting base
Fitting plate 157944-3620 Installation
Plate 157944-3820
Tappet holder 157931-4700 Supporting of tappet
Bracket 157920-9900 Removal of bearing cover
Extractor bearing cover 157920-7720
Tappet mounting device 157921-8020 Removal and installation of tappet
Plunger insert 157921-4820 Removal and installation of plunger
Plunger clamp device 157921-5620 Removal and installation of control sleeve
Extractor 105792-0030 Removal of plunger block assembly
Fitting plate 157944-3520 Disassembly and reassembly of plunger block assembly
Socket wrench 157914-0500 Removal and installation of delivery holder
Special wrench 157915-6500 Removal and installation of screw bushing
Inner race extractor 157925-7120 Removal of inner race
, Outer race extractor 157925-2020 Removal of outer race
0-ring insert 105792-0000 Installation of 0-ring
Plate measuring 157828·7200 Positioning of governor side taper roller bearing
Camshaft measuring device 105782-4140 Measurement of camshaft end play
Fixing stand 105781-0170 Test and adjustment of injection pump
Measuring device 105782-4210
105782-4270
13-28
(3) RSV Type Governor

Handle 157910-1120 Removal anrl installation of lock nut
Socket wrench 157914-0500
Wrench 157915-0100 Removal nnd installation of round nut
Extractor 157926-5320 Removal and installation of flyweight
Special wrench 157916-2620 Adjustment of Angleich
(4) RFD Type Governor

Handle 157910-1120 Removal and installation of lock nut
Socket wrench 157914-0500
Special wrench 157915-0100 Removal and installation of round nut
Extractor 157926-5320 Removal of flyweight
Special wrench 157916-2620 Adjustment of idle speed
Guide screw 157976-3100 Adjustment of rack limit
(5) SA Type Automatic Timer

SA type automatic timer special tool set 105790-5010 Disassembly and reassembly
Special spanner 157916-5320 Removal and installation of round nut
Extractor 157926-6210 Removal
Guide boll 157924-0200 Disassembly and reassembly
Base 157924-0110
Hanel spanner 157916-6120 Removal and installation of timer case
Thrust bushing 157924-1500 Installation of oil seal
Guide bushing 157924-1200
Block 157924-0800
Guide bushing 157924-1300
Guide 157924-0900
Support 157932-0100 Installation of flyweight
Guide 157924-0400
Thrust bushing 157924-0500 Installation of flange
Oil seal guide 157914-0600 Insertion of timer case
13-29
DJ
FUEL AND ENGINE CONTROL - SPECIAL TOOL,
SERVICE PROCEDURES
(6) SP Type Automatic Timer

The part numbers are the DIESEL KIKI part numbers
SP type automatic timer special tool set 105790-5050 Disassembly and reassembly
Box spanner 157915-2320 Removal and installation of round nut
Box wrench 157916-2800
Special spanner 157916-5320 Removal and installation
Extractor 157926-7220
Base 157924-2520 Disassembly and reassembly
Special spanner 157916-8320
(7) Injection Nozzle

The part numbers are the DIESEL KIKI part numbers
Nozzle cleaning tool 105789-0010 Cleaning of nozzle
Nozzle tester 105785-1010 Adjustment and testing
Adjusting device set 105789-0500 Adjustment and testing of 2-spring nozzle

( •: Components)
Adjusting device '157892-0220
Dial gauge '157954-3800

--
Pin I = 50 '157892-1200
Pin I = 60.5 *157892-1100
Connector '157892-1320
Base '157892-1800
Gasket '157892-1500
Retaining nut '157892-1420
Gasket '026508-1140
5. SERVICE PROCEDURES Scrupulous care must be exercised when disassemb

Wherever possible, test the fuel system parts before ling and reassembling critical parts.
disassembly to precisely know their conditions. Use the specified special tools for disassembly and
Select a clean site for disassembly and reassembly reassembly; never apply excessive force or handle
work, as even small dust particles on the fuel system parts carelessly.
parts can adversely affect engine performance. When Before disassembly, test the system to know exactly
disassembling the injection pump, keep work bench the trouble spots.
clean and disassembled parts neatly arranged for
each cylinder. Use special care to ensure correct
combination of plunger and plunger barrel and of
delivery valve and delivery valve seat.
13-30
5.1 INJECTION PUMP
SERVICE PROCEDURES
m
5.1 .1 Removal
<P type>
5
1 Fuel hose 89147A

2 Injection pipe
3 Overflow pipe
4 Oil pipe Note:
(5.J Injection pump Never remove the injection pump bracket unless it is
6 Injection pump bracket unavoidable due to cracks, etc.
B9153C
86120C Wooden block C0596A
(1) At removal, first loosen bolts indicated by arrows (2) Use a wood block to store injection pump lest
in figure from coupling. excess force might be applied to timer.
13-31
DJ
SERVICE PROCEDURES
5.1 .2 AD Type Injection Pump

( 1) Disassembly
NV ... Nominal value

L ... Limit
Damage, worn seat
Damage, seizure
1 ��';'0'!��0 :'"�I
�
Bend,
broken tooth C ��
,,b.,.,.-c�
*Sliding resistance
' ;1
(when stationary) 5 4
1.5 N (0.15 kgf) or less
6 Damage, wear, seizure
of cam surface
Backlash
NV 0.15 mm *End play
L 0.3 mm <E> NV 0.02 to 0.06 mm
26 L 0.1 mm
Overflow valve opening pressure Cracks, damaged thread n
NV 155 kPa (1.6 kgf/cm') � � �--------'
3
Remarks For general power application
f::
Broken tooth 8
NV 255 kPa (2.6 kgf/cm') Seizure, wear, peeling
Remarks For construction machinery
15
�
1 Housing cover Cracks, deterioration
<2) Screw
Damage, seizure,
3 Screw gloss of lapped surface
(D Bearing cover �12
5 Oil seal
e::=,o
�:
6 Camshaft
7 Taper roller bearing
8 Center bearing
Damage, break
® Tappet
10 Shim 20 Delivery valve spring
@ Plunger 21 Delivery valve
@ Lower spring seat 22 Delivery valve seat
13 Plunger spring 23 Plunger barrel
14 Upper spring seat 24 Screw
15 Control sleeve 25 Control rack
16 Pinion 26 Pump housing
17 Lock plate
@ Delivery valve holder For disassembly of parts with an encircled number, see following
items.
19 Stopper The part marked • must be inspected before disassembly.
D15668
13-32
- -�---
- -- - --- ---
SERVICE PROCEDURES
--·------ --------
m
Tappet Pin
157931-7320
B9089A
'----- - - - - -
--- - -
--- - -
- --�-
(a) Install the injection pump in Universal Vice (spe (f) Remove the housing cover.
cial tool). Insert Tappet Pins (special tools) into the tappet holes
(b) Remove .the feed pump. of all the cylinders to space the tappets away from the
(c) Remove the coupling and automatic timer. [Refer camshaft.
to 5.4.1.]
(d) Remove the governor. (Refer to 5.2.1 or 5.2.2.)
Measuring Device
105782-4130
B9092A
01572A (g) Measure the end play of the camshaft with

Measuring Device (special tool). If the end play is in
(e) Measure the sliding resistance of the control rack excess of the limit, adjust by using shims or replace
with a spring balancer. the bearing.
Turn the camshaft and measure the sliding resistance Shim thickness: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50,
in all of the rising and falling positions of the cam. 1.00 mm
If the readings are in excess of the nominal value, the
following causes are probable.
NOTE:
1) Damaged control rack, abnormal teeth Select timer and governor side shims so
2) Abnormal teeth of pinion, contact with housing that their thicknesses will be about equal.
3) Overtightened delivery valve holder
13-33
SERVICE PROCEDURES
,--------- -------
- --- - -- -
- -,
i
Wrench
157910-1120
89093A 89095A
(h) Remove the screws at the bottom of the injection (j) Push the tappets up from the bottom of the
pump with Wrench (special tooll. injection pump with Roller Pincers (special tool) and
remove the Tappet Pins (special tools).
Tappet Pincers
157931-6120
89094A
89096A
(i) Insert a screwdriver into the groove in the bearing

cover to remove the bearing cover and oil seal. (k) Hold a tappet in Tappet Pincers (special tool),
·NOTE: remove the Roller Pincers (special tool), and then take
1. To prevent damaging the oil seal, re· out the tappet and shim.
move the woodruff key from the cam
shaft and put Guide (special tool) on the
threaded portion.
Plunger Pincers 157921-6120
2. To remove the camshaft, direct the first
cam lobe on the removal side of cam
shaft toward the top of the pump to
prevent the camshaft lobe from
touching the tappets, and then lightly
strike.
(I) Remove the plunger together with the lower

spring seat, using Plunger Pincers (special tool).
(ml Measure the backlash between the control rack
and pinion. If the backlash is in excess of the limit,
13-34 replace.
SERVICE PROCEDURES
(n) Use Wrench (special tool) to remove the delivery

m
valve holder.
Wrench NOTE:
157914-0500
Immerse the delivery valve combined with
delivery valve seat and the plunger com·
bined with plunger barrel in gas oil without
changing their combinations.
B9098A
(2) Inspection and Correction
Use Reamer {157930-4620)

to correct damaged pump
housing, or replace. Air tightness
-
-
(ffi'""
-
- -
i -c
Slid gn o�,
o ,,
m o
/
"-.. r�;�?
,,_
�)
'"-.""----- (��--=i
t�,·,
� !
(,')
u BO .. Basic Diameter
Overall lappet clearance ----.. NV.. Nominal Value
(',:,
L 0.2 mm ----- ,.c·.• L Limit
8
---- --'._i--:-:'\
D1555B
(a) Plunger and plunger barrel After cleaning in gas oil, check to see that the plunger
falls smoothly in the plunger barrel under its own
weight.
Check by the following procedure.
1) Tilt the plunger barrel approx. 60° .
2) Pull the plunger about 20 mm out.
3) Turn the plunger and check several points.
01584A
13-35
DJ
SERVICE PROCEDURES
(b) Delivery valve (d) Replacement of taper roller bearing

Inner race
Extractor
157925-6520
01525A
B9105A
Clean theyalve and valve seat portions of the delivery
valve in gas oil and check worn condition. To remove, use Extractor (special tool).
Seal off the bottom of the valve seat portion with a To install, put the ring and shims and then install the
finger tip and press down the valve portion with a taper roller bearing.
finger. If the valve portion bounces back when
released, the valve portion is good. If it does not Outer race
bounce back, the valve portion is badly worn.
Replace the delivery valve.
Bearing cover
(c) Tappet ./ Bearing outer race
Extractor
157925-0520 (timer side)
157925-0120 (governor side)
Pin 01531A
Bushing
Roller The bearing cover side outer race should be removed
Tappet body
by use of Outer Race Extractor (special tool).
01526A
To install, put a new oil seal in position, and then
install the outer race.
Hold a dial gauge to the roller portion of tappet and
check the overall clearance by moving the roller up
and down.
If the overall clearance is in excess of the limit, replace
the tappet assembly.
13-36
(3) Reassembly
SERVICE PROCEDURES
m
--------------- --- - ·-- ·-- ·----·-·-··-·--- ------------ ----;
., 17 4.5 to 5.8 Nm
(0.45 to 0.6 k\j(ml
�jq.-:i·
l]
---
18 64 to 68 Nm
\J ..__ 19 (6 5 to 7 kgfml
21, l--20
�!--:B:��\ /
',l!:)
..----td "'X'l
1
24_.&/r:::.=;.,;;;i. • L.-;;-"�-'r\
':) 'r\..,;1� 7 . {];��· 7
' ,r(if; ; ,,,,.;" ',.,
0
25
I ·f> :·1\g /<·11'
,
� ------=
- ='--,,
JJ �
'3
Sliding resistance of control
rack (when stat,onaryl
71·
i\,,.,. l£_\,--_,,.;...\
'i�\ J !7/y)
'{,; ._:! •
6___
End play
_____
_
� <··) \ -?-""
NV 1.5 N (0.15 kgfi or less
---�.
26 8. o -il .
NV o 02 1o 0.06 mm
/ L 0.1 mm
�� 3
�........_ 16
��15
ii_", 14 <Assembly sequence>
26 -· 25 -· 24 ·- 23 -• 22 - · 21 -· 20
- 19 - 18 •• 17 -- •16 - ·15 - 14 ·-
�� 13 -· 12 - 11 .• 10 -· 9 -- 8 -· 7 ·-
� ·-12 6 - 3 - 5 - 4 -- 2 - 1
['>� 10 For reassembly of parts with an

NV .. Nominal Value
i.�: .'�·,. 2
encircled number, see following items.
L Limit 9
D15678
Positioning
groove
89107A D1590A
(a) Mount the pump housing in Universal Vice (spe (b) Insert the plunger barrel into the housing.
cial tool). After the control rack has been inserted, NOTE:
thread the screw into the back of the pump housing. 1. Align the notch of the plunger barrel
Check to see if the control rack lightly operates. with the dowel pin of the housing.
2. Do not lightly strike the plunger barrel
but securely push in by finger.
13-37
SERVICE PROCEDURES
!-------�
Manufacturer mark
inscribed
Plunger number
inscribed
89109A 89111A
(c) Place the pump housing on its side and set the NOTE:
control rack so that the punched marks of the control Install the plunger with the stamped model
rack will be positioned the same dimension away number toward you (the housing cover).
from the ends of the housing. After the pinion and
control sleeve have been combined, put the pinion in
mesh with the teeth of the control rod. Tappet Pincers
157931-6120
NOTE:
1. Install the pinion and control sleeve so
that the joint of the pinion and notch of
the control sleeve will be faced toward
you.
2. After each pinion has been installed,
move the control rack to confirm that it
can be moved the same amount to right
and left. 89096A
(e) Hold the tappet and shim in Tappet Pincers

Plunger Pincers (special tool) and insert into the housing.
157921-6120
Tappet Pin
157931-7320
89097A
(d) Install the lower spring seat and plunger together,

using Plunger Pincers (special tool). 89095A
(f) Push the tappet inserted into the housing up with

Roller Pincers (special tool) and insert Tappet Pin
(special tool) into the hole in the tappet.
13-38
SERVICE PROCEDURES
�----------�--��--- ----�
Wrench
Inscribed 157910-1120
line
89114A 89093A
NOTE: (h) Install the screws, using Wrench (special tool).

when the camshaft is inserted, face the (i) Install the following parts.
inscribed line on the end of the camshaft Governor (Refer to 5.2.1. or 5.2.2.)
toward the timer. Feed pump
(g) Confirm the following items. Automatic timer (Refer to 5.4.1.)
Coupling
1) End play of camshaft [Refer to 5.1.2 (1)(g).]
(j) After the reassembly has been completed, adjust
2) Sliding resistance of control rack [Refer to 5.1.2
the injection pump.
( 1 He). I
Check after removal of Tappet Pin (special tool).
13-39
DJ
SERVICE PROCEDURES
5.1.3 P Type Injection Pump

( 1) Disassembly
----------------------------�
16
Rotating condition 1
I
Cracks, 33
damage
7�
Overflow valve opening pressure

NV 255 kPa (2.6 kgf/cm')
1 Overflow valve (i�Plunger block assembly

2 Bottom cover 19 Deflector
3 Screw plug 20 Delivery valve holder
4 Shim 21 Stopper
® Bearing cover 22 Delivery valve spring
6 Oil seal 23 Delivery valve
7 Center bearing 24 Delivery valve seat
8 Camshaft 25 Plunger barrel
9 Roller bearing 26 Distance ring
@ Tappet assembly 27 Flange sleeve
@ Lower spring seat 28 Screw bushing
© Plunger 29 Pin
13 Plunger spring 30 Bushing
14 Upper spring seat 31 Control rod
@ Control sleeve 32 Bushing
16 Cover 33 Pump housing
17 Nut
items.
01568A
13-40
SERVICE PROCEDURES
(a) Remove the feed pump. ··- -··- -· ---··--- -- - -- - - -

�
r-- - - ---- ·-· ----------·-

- -
--·-----
D1507A
(e) Remove the screw plug, turn the camshaft to

(b) Install Fitting Plate (special tool) in Universal Vice place the tappet at the top dead center position, and
(special tool)·. insert Tappet Holder (special tool) into the screw plug
hole to space the tappet away from the camshaft.
r--- - - - - - - - -
------ --
- - -
�
(f) Remove the coupling.
(g) Remove the automatic timer.
(Refer to 5.4.2)
(h) Remove the governor.
(Refer to 5.2.1 or 5.2.2)
D1504A
(c) Utilizing the threaded hole, install Plate (special

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

Bearing Cover Extractor (special tools).
NOTE:
1. When the bearing cover is removed, use
care not to lose the end play adjusting
shims.
2. Check the oil seal and do not remove it
D1505A unless defective.
(d) Install the injection pump in Universal Vice (spe

cial tool).
13-41
SERVICE PROCEDURES
.----- - - - -- -
-··------ (I) Remove the plunger, using Plunger Insert (special
too!).
NOTE:
Put the removed plungers orderly in a tray
containing clean gas oil.
Plunger Clamp Device

157921 ·5620
(j) Install Tappet Mounting Device (special tool) to

the pump housing.
Then operate the lever to push the tappet up, remove
Tappet Holder (special tool), and take out the tappet
assembly.
(ml Remove the upper spring seat and control sleeve.

The control sleeve can be easily removed by use of
Plunger Clamp Device (special tool).
NOTE:
The control sleeve cannot be removed
unless the ball mounted on the flange of
the control sleeve and the tappet guide
groove in the pump housing are in align·
ment.
Extractor
105792-0030
(k) Remove Tappet Mounting Device (special tool),
install a wire in the hole of the lower spring seat, pull
it together with the plunger until the lower spring seat
can be removed, and remove only the lower spring
seat.
01517A
(n) Mount Extractor (special tool) to the delivery

holder and remove the plunger block assembly.
01513A
13-42
SERVICE PROCEDURES
Fitting Plate
157944-3520
(o) Disassemble the plunger block assembly by the (q) Remove the governor side screw bushing with
following procedure. special Wrench (special tool) and remove the pin and
a) Mount Pitting Plate (special tool) in the vice. bushing.
Then remove the control rod and bushing from the
timer side.
NOTE:
1. Arrange all removed parts orderly by
cylinders.
Socket Wrench 2. Be sure not to change the combination
157914-0500
of the paired plunger barrel and plunger
and that of delivery valve and delivery
valve seat.
D1519A
(p) Secure the plunger block assembly to the Fitting

Pla,te (special tool) and loosen the delivery valve
holder with Socket Wrench (special tool).
13-43
DJ
SERVICE PROCEDURES
(2) Inspection and Correction

The inspection procedure is the same as that for the
AD type except the following.
Sliding condition check
NV... Nominal Value

L ... Limit
Overall tappet clearance

of roller portion
L 0.2 mm
D1523C
Replacement of taper roller bearing Outer race

Inner race
Bearing cover
Bearing outer race

Outer Race Extractor
157925-2020
01531A
Remove the bearing cover side outer race by use of

Remove inner race by use of Inner Race Extractor Outer Race Extractor (special tool).
(special tooll. To install, install a new oil seal and then install the
To install, use press. outer race.
13-44
SERVICE PROCEDURES
(3) Reassembly
Control rod
sliding resistance
(when stationary) 16
NV 1.3 N
(0.13 kgO or less
Align guide
groove with
4
9
1
I
33 .,.J�
7�
A
End play adjusting shim
Camshaft end play

NV 0.02 to 0.06
L 0.1
Overall clearance
of roller area
NV ... Nominal Value L 0.2
L ... Limit
y
<Assembly sequence>
(27-25-----,24----.23-,22-,21-+Q(l)-,26-, 19) 18
17-,15-----,14----.13
33-,32-+ 30-+31--, 29-,28-·______,
--,(12,>-> 11->(lcf'--' 7_,9_,(�6-,5-----,4----,3-,2-, 1-> 16
For disassembly of parts with an encircled number see following
items.
D15698
13-45
SERVICE PROCEDURES
110 to 115 Nm
(11 to 12 kgfm)
(Tighten in three stages.)
D1540A
(a) Mount the pump housing in Universal Vice (spe (c) Using Socket Wrench (special tool), tighten the
cial tooll. delivery valve holder to the specified torque (tighten
Then install bushings and control rod, pin and screw in three stages).
bushing with Special Wrench (special tooll. Check to NOTE:
see that the control rod lightly operates. If the tightening torque is smaller than the
specified torque, oil leakage or damage to
the related parts could result.
If the tightening torque is excessive, un
smooth plunger movement or damage to
the related parts could result.
0-ring Insert
105792-0000
D1537A
(b) Install the 0-ring on the upper side of the plunger

barrel, and insert the lower side 0-ring into the pump
housing with 0-ring Insert (special tool).
NOTE: 01513A
Make sure that the lower side 0-ring is not

set on the plunger barrel and slided along (d) Mount the plunger to Plung er Insert (special tool)
the wall surface of pump housing. and insert it into the plung er barrel.
13-46
SERVICE PROCEDURES
-------------------- ----
(e) Mount Tappet Mounting Device (special tool) to (g) Install the governor housing. At this time, perform
the pump housing. the following operation. Mount Measuring Plate (spe
Then install . the tappet by operating the Tappet cial tool) to the timer side taper portion of the
Mounting Device. camshaft, and install and position the governor side
At this time, compress the plunger spring and insert taper roller bearing outer race in the ring so that the
the mitt portion of the plunger into the guide groove dimension from the end of the pump housing to the
in the control sleeve, and insert Tappet Holder end of the Measuring Plate will be 13.85 ± 0.5 mm.
(special tool) into the screw plug hole. The operation
of inserting the mitt portion of the plunger into the
guide groove of the control sleeve can be easily
performed by inserting the mitt portion, while moving
the control rod to right and left.
Installation of the taper roller bearing outer race will

produce a clearance between the governor housing
and taper roller bearing outer race. Change shims to
eliminate the clearance.
Shim thickness: 0.6, 1.2, 1.5, 1.8, 2.0 mm
(f) Insert the camshaft from the timer side.
When the camshaft is installed, face the inscribed line
of the end of the. camshaft toward the timer side.
13-47
SERVICE PROCEDURES
01550A
(h) Measure the camshaft end play. (i) Install a spring balance to the control rod and
Install Camshaft Measuring Device (special tool) to check to see that the control rod slides smoothly over
the timer' side of the camshaft to measure the end the entire stroke without exceeding the standard
play. sliding resistance value.
Remove the Tappet Pin (special tool) before checking.
(j) Install the following parts.
Governor (Refer to 5.2.1 or 5.2.2.)
Feed pump
Automatic timer (Refer to 5.4.2.)
Coupling
(k) After reassembly has been completed, adjust the
injection pump.
Bearing cover
Shim
D1551A
,If the camshaft end play is out of the nominal value,

adjust by changing shims between the bearing cover
and pump housing.
Shim thickness: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50
mm
13-48
SERVICE PROCEDURES
5.1.4 Adjustment after Reassembly

For fuel injection rate adjusting standard, see Service
Information published separately.
(1 ) AD Type Injection Pump
Total stroke of control rack

NV 21 or more
Injection start interval

NV 60° ± 30'
(a) Install the pump on the injection pump tester

Fixing Stand (special tool) and secure it.
NOTE:
Make sure that the center of coupling is
aligned with that of injection pump so that
the coupling and injection pump turn
smoothly.
Tappet clearance
NV 0.3 or more
B9143A
NOTE:
1. Supply oil to the injection pump cam
chamber.
2. · Adjust the injection amount after ad
justing the governor.
Injection sequence
1-5-3-6-2-4
13-49
SERVICE PROCEDURES
(c) Checking stroke of control rack
Move the control rack to confirm that the total stroke

is over the specified value.
Measuring Device In addition, check to see that the start spring and
105782-6010
idling spring smoothly move the control rack in the
maximum injection direction.
03423A
(b) Setting position O of control rack
Mount Measuring Device (special tool) to the injection

pump.
<With RSV governor>

Measuring Device
1) Keep the pump running at 750 rpm. 105782-4020 03425B
2) Loosen the stopper bolt and pull the adjusting

lever toward the non-injecting direction. (d) Adjusting prestroke
3) Press the end of the measuring device all the way
1) Pull the control rack out to the total injection
toward the governor and adjust the position of point position and secure it there.
"O" on the scale of the measuring device. 2) Place the plunger of the No. 1 cylinder in the
<With RFD governor> bottom dead center position and mount Measuring
1) Fix the load control lever at the idling position. Device (special tool). Set the contactor on the tappet.
2) Let the pump run at 500 to 600 rpm and tempor 3) Couple the injection pump and tester nozzle.
arily fix the speed control lever so that the governor
will begin to provide control at the speed.
,toward the governor and adjust the position of point
"O" on the scale of the measuring device.
NOTE:
Nozzle holder wrench
If the injection pump is not running at the 157916-8220
speed mentioned above, position O won't
be obtained even if the control rack is
pressed with a strong pressure, and there
will be danger of damage to the link
mechanism of the pump. 03426B
4) Send a high pressure fuel into the injection pump

to let the fuel flow out from the overflow pipe of the
nozzle holder.
13-50
SERVICE PROCEDURES
NOTE:
The pressure of the fuel forced into the
injection pump must be higher than the
delivery valve opening pressure.
Inscribed line
of timer
81912A
7) After adjustment of the prestroke, check to see

that, at the static injection beginning, the inscribed
b Slalic injection beginning D3427A
lines of the pointer and timer are in alignment.
If they are out of alignment, restamp a line on th.e
5) Slowly turn the camshaft until the fuel ceases to automatic timer.
flow from the overflow pipe of the nozzle holder (until
static injection begins).
NOTE:
Make measurement by turning the cam
shaft clockwise.
Angle scale
Preslroke 819138
(e) Adjustment of injection start interval

1) Couple tester nozzles to all the cylinders of the
injection pump as in the case of adjustment of the
89144A
prestroke.
2) Force fuel into the injection pump to let the fuel
6) Read the prestroke from the bottom dead center flow out from the tester nozzle.
to the point where the fuel ceases to flow (static 3) On the basis of the static injection beginning of
injection begins), using a dial gauge. the No. 1 cylinder, measure the interval when the fuel
If the prestroke is out of specification, adjust by ceases to flow out according to the injection sequ
shims. [Refer to (e).] ence, using an angle scale.
NOTE:
Injection sequence
1-5-3-6-2-4
13-51
SERVICE PROCEDURES
3) Measure the stroke of the tappet from the top

dead center to the point where the plunger barrel is
touched.
4) If the tappet clearance is less than the nominal
value, adjust within the extent permitted by the
injection start interval.
If correction within the permitted extent is impossible,
set the prestroke of the No. 1 cylinder to the
maximum of the set value and readjust.
Holder
157931-4400 D34718
4) If the prestroke and injection start interval are out

of specification, insert a Holder (special tool) between
the tappet and lower seat and then adjust by chang
ing the shim thickness.
Shim thickness: 0.2 to 1.60 mm, 29 types in 0.05 mm
increment
034728
Control sleeve
(g) Adjustment of fuel injection amount

To check whether the injection amount is up to
specification at the specified rack position and speed,
"'- Plunger measure with a measuring cylinder.
driving face
If the injection amount is out of specification, adjust
""Adjusting by the following procedures.
shim
1) Loosen the screw of the pinion.
Tappet 2) While blocking movement of the control rack, turn
D3522A
the control sleeve with an adjusting rod.
3) Tighten the screw of the pinion.
(f) Adjustment of tappet clearance
NOTE:
1) Place the tappet in the top dead center position. 1. A maladjusted injection amount will
2) Raise the tappet with a screwdriver, etc. until the
produce marked effects on engine per
driving face of the plunger touches the bottom end of formance. Make sure the injection
the plunger barrel. amount is carefully adjusted.
13-52
SERVICE PROCEDURES
2. The injection amount varies on diffe. (h) Adaptation to engine

rent nozzles and pipes. Make sure that After the governor has been adjusted, measure the
the measuring conditions are observed. fuel injection rate adaptable to the engine.
3. Injection amount uneven ratio
(i) Inspection of fuel and oil leaks
Maximum injec- Average injec
tion amount in - tion amount of • Fuel leaks from delivery valve attaching position
each cylinder each cylinder and other parts
Uneven ratio (+I x 100 (%) • Oil leaks from oil seals and other parts
Average injection amount of
each cylinder (j) Inspection of parts
Check parts for unusual noise and bearings for
Minimum injec- Average injec•
tion amount in - tion amount of
excessive heat.
each cylinder each cylinder
Uneven ratio(-) x 100(%1
each cylinder
(2) P Type Injection Pump
Adjustment of injection
start interval
NV 60' !:30"
Adjustment of prestroke
NV 4.8 ± 0.05 mm Checking stroke of control rod
NV 21 or more
NOTE:
1. Supply oil to the injection pump cam chamber.
2, Adjust the injection amount after adjustment of the
governor.
B9146A
13-53
SERVICE PROCEDURES
<With RFD governor>

1) Fix the load control lever at the idling pos1t1on.
2) Let the pump run at 500 to 600 rpm and tempor
arily fix the speed control lever so that the governor
will begin to provide control at the speed.
toward the governor and adjust the position of point
NOTE:
1. If the position "0" of the control rod is.
set by operating the load control lever,
there is danger of damage to the link
mechanism and other parts of the gov
(a) Mount two Fixing Stands (special tools) to an ernor. Do not set the position "0" by
injection pump tester. operating the load control lever.
Secure th�
· injection pump firmly to the special tools. 2. When the position "0" is set, remove the
NOTE: damper spring beforehand.
To make sure that the coupling and injec
tion pump rotate smoothly, align the cen
ters of the coupling and injection pump
accurately.
Stroke 21 mm or more
D3410A
(c) Checking stroke of control rod

Move the control rod to confirm that the total stroke is
D3409A
more than the specified value.
Check to see that the control rod is moved smoothly
(b) Setting position "O" of control rod in the maximum injection amount direction by the
Mount Measuring Device (special tool) to the injection start spring and idling spring.
pump.
<With RSV governor>
1) Keep the pump running at 750 rpm.
2) Loosen the stopper bolt and pull the adjusting
lever toward the non-injecting direction.
toward the governor and adjust the position of point
13-54
SERVICE PROCEDURES
m
I
5) Slowly turn the flywheel of the pump tester
clockwise until the fuel ceases to flow out from the
overflow pipe (until static injection begins).
Prestroke
035188
(d) Adjustment of prestroke

1) Remove the governor side No. 1 cylinder delivery 03414A
valve holder; spring, delivery valve and gasket.

2) Mount Measuring Device (special tool) to the 6) Measure the prestroke of the plunger from the
flange sleeve. bottom dead center to the point where the fuel ceases
3) Turn the flywheel of the pump tester to detect the to flow out (static injection beginning).
bottom dead center of the plunger with a dial gauge.
035198
03412A
7) If the prestroke is out of specification, adjust by

4) With the control rod set in the full position, force a changing the shim thickness between the flange
high pressure fuel into the injection pump to let the sleeve and pump housing.
fuel flow out from the overflow pipe. Shim thickness: 0.50 to 1.975 mm, 59 types in 0.025
increment
If the prestroke is smaller, increase the thickness. If
the prestroke is larger, reduce the thickness.
NOTE:
To install the plunger block, apply grease
to each 0-ring. After inserting the 0-ring in
the lower part of the plunger barrel into the
pump housing in advance, apply grease to
the skirt portion of the plunger barrel and
then install the plunger barrel.
03413A
13-55
SERVICE PROCEDURES
Static injection beginning

03427A
8) After adjustment of the prestroke, check to see 3) Slowly turn the flywheel of the pump tester
that the inscribed line of the timer and that of the clockwise until the fuel ceases to flow out from the
pointer are in alignment. tester nozzle.
If they are out of alignment, inscribe another line on Read the rotation angles (injection start intervals)
the timer. When the automatic timer was replaced where the fuel ceases to flow, according to the
with a new one, proceed in the same way. injection sequence.
4) If the injection start interval is out of the standard
angle, adjust by the same procedures as for prestroke
adjustment.
NOTE:
Injection sequence: 1 - 5 - 3 - 6 - 2 - 4
�----·---------- - ---- ---,

-
Pressure feed stroke

03426A
(e) Adjustment of injection start interval

1) Set the static injection beginning position of the
No. 1 cylinder on the pump tester scale plate.
2) Force a high pressure fuel into the injection pump 03520A
to let the fuel flow out from the overflow pipe of the
tester nozzle. (f) Adjustment of fuel injection amount
NOTE: At the specified rack position and speed, measure the
The pressure of the fuel forced into the injection amount and uneven ratio with a measuring
injection pump must be higher than the cylinder to check whether they are up to specification.
delivery valve opening pressure. If the injection amount is out of specification, adjust
by the following procedures.
13-56
SERVICE PROCEDURES
DI
1) Loosen the two nt1ts tightening the flange sleeve. Minimum injec- Average injec
2) Turn the flange sleeve by lightly striking. tion amount in - tion amount of
3) Tighten the nuts to the specified torque to secure
Uneven ratio (-1 - x 100 (%)
the flange sleeve. [39 to 44 Nm (4 to 4.5 kgfm)] Average injection amount of
Perform the operations repeatedly. each cylinder
NOTE:
(g) Adaptation to engine
1. A maladjusted injection amount will
produce considerable effects on engine After the governor has been adjusted, measure the
performance. Make sure that the injec fuel injection rate adaptable to the engine.
tion amount is carefully adjusted. (h) Inspection of fuel and oil leaks
2. Since the injection amount varies on • Fuel leaks from delivery valve attaching position
different nozzles and pipes, make sure and other parts.
that the measuring conditions are • Oil leaks from oil seals and other parts
observed.
(i) Inspection of parts
3. Injection amount uneven ratio
Check parts for unusual noise and bearings for
Maximum injec- Average injec
tion amount in - tion amount of excessive heat.
Uneven ratio ( ! I
each cylinder
5.1 .5 Installation
2 <P type>
G) Injection pump bracket

(2) Injection pump
3 Oil pipe
4 Overflow pipe
5 Injection pipe
6 Fuel hose B9147A
13-57
DJ
SERVICE PROCEDURES
(1) Adjustment of Injection Pump Bracket

� -----------
- -- ---------·
-
[AD type] [P type]
Injection Pump
Injection Pump Centering Tool
Centering Tool
MH061270 \
MH061340
'·,
Air compressor
Air compressor
--......._ Injection pump bracket

Injection pump bracket
C0603A 89148A
L-____ _
_ _______ ______ _ _____
(a) Place Injection Pump Centering Tool (special tool) (b) Slide the dial indicator of the centering tool
on the injection pump bracket, hold a dial indicator to toward the air compressor (or injection pump drive)
the mandrel of the centering tool, and perform and measure the positions of the compressor crank
0-point adjustment. shaft (or injection pump drive shaft) shown in the
illustration with the dial indicator.
C0597A
13-58
SERVICE PROCEDURES
Keyway
COGOOA
(c) If the eccentricity between the mandrel and air (b) At this point, check to ensure that the keyway of
compressor crankshaft is in excess of the nominal the crankshaft of the air compressor (or injection
dimension, adjust by adding or removing injection pump drive) is in the uppermost position.
pump bracket shims. If the keyway is not in the uppermost position, turn
Shim Inserting Condition the engine crankshaft.

• The number of shims inserted into a single point
must not exceed three.
• The front and rear shims must be equal in
number.
• The difference in number between the top and
bottom shims must not exceed one.
(d) After adjustment, tighten the tightening bolts to

the specified torque before confirmation.
(2) Installation of Injection Pump

line
861198
(c) Align the pointer of the injection pump and the
) inscribed mark of the auto timer. (On engines with no

auto timer, align the inscribed mark on the pump
bearing cover with that on the pump side coupling.)
C0599A
(a) Crank the engine to adjust the No. 1 cylinder to

the fuel injection timing. For this purpose, align the
angle scale inscribed on the outer periphery of the
flywheel with the pointer of the inspection window of
the flywheel housing.
13-59
SERVICE PROCEDURES
9.8 to 13 Nm
(AD type]
Cross coupling - (AD type] 29 Nm (3 kgfml
(: to 1.3 kgfm)
Driving coupling 20to 29 Nm
"- /,:·- --
� (2to 3 kgfm) \ 20to 29 Nm
. \ /I
/Nfi· /y,A
.,,.
(2.0to 3.0 kgfm)

"//� ,?/�- \ /
//J;// \ _ � 'n -
!( l I /(/ /�
29to 34 Nm
(3to 3.5 kgfm)
� \t ,- ,s-�-.1,a
'[!i!/, 'lf)l
')f 1 Air
l
compressor .. 'iJ'irl ·... : i�
{. �\
< ,,<, cran; shaft _J :"=' ' ,.�
"'
� f" • c;-=,
?\ L .__
.
r�z_\�
\' V I
I Jcl � l--------i..____
I '1
' >( �- .1
( 4'9\
\
c'.__ } 5'ci
Coupling plate 7=tter bolt ·------...1 \-i ,./ '.\ L___)
\/ 15to 18 Nm
,/
49to 54Nm
(5to 5_.5kgfm) 20to 25 Nm (1.5to 1.8 kgfm)
(P type] 83405C (2to 2.5 kgfml 84390B
Cross coupling
'· (P type] 20to 29 Nm
(2.0to 3.0 kgfml
Driving coupling
20 to 29 Nm i / 29 Nm (3 kgfm)
59to 64Nm
(6to 6.5 kgfm) j�"-J �
(2.0 to 3.0 kgfm) JJ
""
/
u u,n_,ri_ff
"-- 1 -co�rry,n.,ri. u u
/
20to 29 Nm
<
d1c (2.0to 3.0 kgfm)
l �
Air compressor
cranksha ft
(
� 1:) 1tr'.�I
� ' ��
-
c,iL.L..__
20 to 2;-Nm
(2.0to 2.5 kgfm)
7·-\\ L_·�
\
"-�
r ,
Coupling� Cotte bolt 12to 15Nm 20to 25Nm
p l ate 74to 83 Nm
(7.5to 8.5 kgfm) B3402D (1.2to 1.5 kgfm) (2.0 to 2.5 kgfm)B4308C
(d) Install the driving coupling on the crankshaft of (el Tighten each pipe to the specified torque.
the air compressor, and put it a little toward the air
compressor. 5.1 .6 Bleeding the Fuel System
Install the injection pump on the injection pump Bleed the fuel system as described below.
bracket. Move the driving coupling toward the cou
pling plate and tighten it with the timing adjusting
bolt.
Then tighten the cotter bolt to the specified torque to
'reduce the clearance between the driving coupling
and coupling plate to less than 0.5 mm.
NOTE:
After the injection pump has been instal·
led, be sure to check and adjust the fuel
injection start timing. (Refer to 5.1. 7 .)
B5909A
(1) Loosen the air plug of the fuel filter.

(2) Turn the priming pump knob of the injection
pump counterclockwise to let the knob float up.
13-60
SERVICE PROCEDURES
5.1. 7 Inspection and Adjustment of Fuel

m
Injection Start Timing
,;- \
-------- - - - - - - - - ---�
.'··'fl '
/ .
f/! -......._,
, -r--
I·
-/ ,'·i '\ \/,
J I
-r .
,,
__
I
--... ,,,,,:.,
J
--- ) ---
85908A
(3) Move the priming pump knob up and down by C0599A

hand to force the fuel out until no air bubbles come
out from the air plug. (1) Crank the crankshaft more than 180° in normal
(4) After air bubbles have ceased to come out in the direction to align the fuel injection start timing angle
fuel, firmly tighten the air plug. scale inscribed on the periphery of the flywheel with
(5) Move the priming pump knob several times up the pointer.
and down and turn down the knob, while pressing it
NOTE:
down.
If the engine is reversed (by cranking or
NOTE: when it is stopped), the automatic timer
Make sure that fuel split around is thor will stay operated in advancing direction
oughly wiped away. and will not readily return to normal even if
(6) Operate the starter to exhaust the air from inside it is made to resume normal operation by
the injection pump and injection pipe. turning the engine in normal direction for a
NOTE: while. Make sure that the crankshaft is
Do not operate the starter continuously for cranked more than 180° in normal direc,
more than 1 5 seconds. tion by hand.
861198
(2) If, under the condition of Item (1), the pointer of

the injection pump and the inscribed line of the
automatic timer are in alignment, the injection start
timing is correct.
13-61
DJ
SERVICE PROCEDURES
[AD type injection pump) 5.1 .8 Inspection and Adjustment of No

load Minimum and Maximum
Speeds
( 1) RSV Type Governor
/J�'I
Idling positi on Full speed positi o n
\\-r11 7 ,; ontrol leve r

,L\
Stopper / o / .
bolt ".A" Stopper
1 I / bolt "8"
j
'"- r, =
� ,O
c�i=: ·
.�
86120A
[P type injection pump)

��
St op lever 863106
Adjusting bolt
59 to 64 Nm
(al Inspection and adjustment of idling
(6 to 6.5 kgfm)
Run the engine at idle and check to ensure that the
control lever touches the stopper bolt "A", and
measure the engine speed at the time.
If the idling speed is not within the specified limits,
adjust with the stopper bolt "A",
(b) Inspection and adjustment of no-load maximum
speed
86117A
Push the control lever until it touches the stopper bolt
"B". If the engine speed is out of the maximum speed
(3) If the fuel injection start timing is not correct,
limits, adjust with the stopper bolt "B".
loosen the two timing adjusting bolts and adjust the
,timing by turning the automatic timer. NOTE:
Tighten the adjusting bolts to the specified torque. After idling adjustment, quickly move the
Recheck the fuel injection start timing by the proce control lever from the full load position to
dure described in Items (1) and (2). the idling position to verify that the engine
does not stall and no hunting occurs. If
NOTE:
abnormal condition occurs, make adjust
Do not loosen any other parts than U1e
ment as far as the specified idling limits
adjusting bolts.
allow. If adjustment is impossible, dis
assemble and inspect the injection pump.
13-62
SERVICE PROCEDURES
m
(e) In the above condition (d), measure the maximum
speed to determine whether it is within the specified
limits.
(f) If it is not within the specified limits, adjust the
fixed position of the speed control lever with the
Idle stopper stopper bolt.
bolt
NOTE:
1. If the fixed position of the full load
Stopper bolt stopper bolt is changed, the amount of
Full load
stopper bolt
Speed control fuel injection will change. Be careful
lever
not to change the fixed position.
Load control lever
2. Check to ensure that even if the load
863128 control lever is quickly returned from
the full load position to the idling posi·
(a) Check to ensure that the load control lever is tion, the engine does not stop and is
touching the' idle stopper bolt. free from hunting.
(b) In the above condition (a), measure the idling
speed to determine whether it is within the specified
limits.
(c) If it is not within the specified limits, adjust with
the idle stopper bolt.
(d) Operate the load control lever to the full load
position (until it touches the full load stopper bolt).
13-63
DJ
SERVICE PROCEDURES
5.2 GOVERNOR
5.2.1 RSV Type Governor
(1) Disassembly, Inspection and Reassembly
Cracks, deterioration
23 Cracks,
deterioration
6
Damaged or unevenly worn

18 contacting surface
� 17 Worn chrome plating of
shifter portion
. -��
�
29
12
24
1 Closing cover 11 Tension lever shaft 21 Bushing
@ Ungleich spring capsule 12 Control lever 22 Oil seal
3 Idling subspring capsule 13 Collar 23 Swivel lever
4 Torque spring capsule 14 Shim 24 Stop lever
5 Governor cover 15 Governor spring 25 Shim
6 Start spring 16 Tension lever 26 Spring cap
7 Round nut 17 Guide lever assembly 27 Return spring
® Flyweight @ Sleeve 28 Bushing
9 Governor housing 19 Floating lever link 29 Sliding lever
10 Plug 20 Snap ring 30 Bolt
31 Snap ring
32 Spring
For disassembly and reassembly of parts with an encircled number, 33 Torque control lever
see following items.
For reassembly, reverse the order of disassembly. 34 Adapter
B9150A
13-64
SERVICE PROCEDURES
NOTE: (b) Removal of flyweight

1. Do not disassemble the shackle and Using Special Wrench (special tool), remove the
governor sleeve from the guide lever, round nut tightening the flyweight. At this time, hold
unless replacement is necessary. the drive side to prevent it from turning.
2. Do not remove the governor housing
unless removal is necessitated for cor·
rection of oil leaks, parts replacement,
etc. Extractor
Before removing the housing, use Tap· 157926-5320
pet Insert (special tool) to separate the

camshaft from the tappet.
D2051A
Thread Extractor (special tool) into the flyweight.

After the bolt end has touched the camshaft, lightly '
strike the bolt head and turn down the bolt to remove
the flyweight.
Handle
157910-1120
NOTE:
B9151A
Do not attempt disassembly to remove the
swivel lever except when replacement of
(a) Removal of ungleich spring assembly
parts is necessary or when unsmooth op·
Using Socket Wrench (special tool), loosen the nut eration is evident. In addition, disassem•
tightening the ungleich spring assembly to the ten bly of parts for the stop device and torque
sion lever, and remove the ungleich spring capsule. spring mechanism of the governor is not
generally required.
Special Wrench
157915-0100
B9152A
13-65
SERVICE PROCEDURES
Shim
Sleeve
Bearing
Shifter
Chrome plated surface

81357A 19 to 19.2 02054A
(c) Replacement of sleeve or guide lever assembly 6) When the shim has to be replaced, assemble all
1) Remove the bearing from inside the shifter, using related parts correctly and select the right shim
a press. thickness to make sure that the dimension from the
2) Using a press, remove the shifter of the guide end of the housing to the shifter complies with the
lever assembly from the bearing. specified value.
Shim thickness (6 types):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
NOTE:
Measure the assembly dimension without
lifting the flyweights.
81358A
3) Install the bearing in the sleeve.

4) Then install the shifter of the guide lever assem
bly in the bearing.
5) Check to ensure that the sleeve rotates smoothly.
NOTE:
1. Do not replace the shim, as it has a
thickness determined by adjustment of
Item 6).
2. During the removal and installation op
erations, use care not to damage the
chrome plated surface of the shifter.
13-66
5.2.2 RFD Type Governor
SERVICE PROCEDURES
m
(1) Disassembly, Inspection and Reassembly
---------�---- ------ ----

- - --- ----------- -- ---- - - - - �
-
Cracks, deterioration
Cracks. deterioration
13
23 14 11
Oil leaks
22 21 9
26
Cracks, damage
4 5
Damaged contacting surface
ar
L�
�18
19
16
Governor cover 15 Governor spring
0 Lock nut 16 Load control lever
@ Idling spring assembly 17 Bushing
4 Cap nut 18 Lever shaft
5 Lock nut 19 Sliding lever
6 Damper spring 20 Speed control lever
7 Governor cover 21 Snap ring
8 Start spring 22 Bushing
9 Tension lever plug 23 Swivel lever
10 Tension lever shaft @ Round nut
@ Guide lever assembly @ Flyweight
© Sleeve ® Governor housing
13 Floating lever link
For disassembly and reassembly of parts with an encircled number,
14 Tension lever see following items.
For reassembly, reverse the order of disassembly.
89155A
13-67
DJ
SERVICE PROCEDURES
NOTE: (b) Remove the flyweight by the following procedure.

1. Do not disassemble the shackle and Using Special Wrench (special tool), remove the
sleeve from the guide lever, unless round nut of the flyweight.
replacement is necessary.
- -
- -
-- - -
-- -
- -
- - -- --�
2. Do not remove the governor housing
unless removal is necessitated for cor,
rection of oil leaks, parts replacement,
etc.
Before removing the housing, use Tap,
pet Insert (special tool) to separate the Extractor
157926-5320
camshaft from the tappet.
Using Extractor (special tool), remove the flyweight.
Handle
157910-1120
89156A
� - - - --- -
----- - -
- - �
-
(a) Remove the lock nut with Socket Wrench and

Handle (special tools).
Furthermore, remove the idle spring capsule.
Tappet Pin
NOTE: 157931-7320 <for AD type pump>
Tappet Holder
Check the speed setting lever. Bf there is I--- -
- - 157931-4700 <for P type pump>
---- 89159A
nothing wrong, do not disassemble it.
(c) Remove the governor housing by the following
procedure.
Using Tappet Holder or Tappet Pin (special tool),
disconnect the tappet from the camshaft.
Then remove the governor housing tightening bolts,
Special Wrench
157915-0100
and remove the governor housing, while striking with
a plastic hammer, etc.
NOTE:
Do not remove the stop lever assembly on
the top of the governor housing from the
governor housing.
89157A
13-68
SERVICE PROCEDURES
--- - - -
- -
- ----------
- - -
Shim
Sleeve
Washer Washer
Bearing
Snap ring
02023A 33 to 33.4 02025A
(d) Replacement of sleeve or guide lever assembly (e) Assembly dimension of shifter
To disassemble the shifter and sleeve, remove the When the shifter and sleeve are assembled, be sure
snap ring in 'the sleeve, and the shifter and sleeve can not to change the adjusting shim, as the assembly
be separated. dimension of the shifter has been adjusted by the
shim.
If readjustment is necessary, assemble all related
parts correctly and select the right shim thickness to
make sure that the dimension from the housing end
to the shifter complies with the specified value.
Bushing
Shim thickness (6 types):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
NOTE:
Shifter
Measure the assembly dimension with all
flyweight lifted.
� Chrome plated surface
02024A
Use a press to remove the shifter and bushing.

NOTE:
When the shifter and bushing are installed,
use care not to damage the chrome plated
surface of the shifter.
13-69
DJ
SERVICE PROCEDURES
5.2.3 Adjustment after Reassembly

( 1) RSV Type Governor
For governor performance curve, see Service In
formation published separately.
Adjustment of torque
spring
Adjustment of high speed

control
Adjustment of idling
spring or ungleich
spring
Adjustment of stopper
bolt
NOTE:
1. Supply engine oil to the injection pump cam chamber.
�®� :.)
2. Loosen the adjusting lever stopper bolt.
3. Remove the idling s.ub spring.
� (?speed
Adjustment of intermediate
control
4. Do not allow the Ungleich spring or idling sub spring
and torque spring to work.
B9163A
'----- - ------ - -- - - - -
----·-------
· - -- -- --- --- �
-
(ai "O" position setting of control rack

Ungleich spring [Heter to Item (1) (b) or (2) (b), Section 5.1.4.]
a
Ra1-----,.... (b) Install the angle scale plate for fixing the adjusting
Re 1---- -
-1-
b C j d
lever.
Rg / High speed
g
t control
Re
E -·-·· e
Ri
E
C
0
·;:;
·.;;
0
Ng Ni Na Nb Ne Nd Ne
a.
Pump speed (rpm)-�

-"'
()
"'
a:
D34748
Adjust the relationship between pump speed and the

rack position to specified governor performance
curve by the following procedure.
13-70
SERVICE PROCEDURES
Full position
Special Wrench
157916-2620
Maximum speed
stopper bolt
89169A 89166A
(c) Temporary adjustment of high speed control (e) Adjustment of Ungleich spring (governor with
With the adjusting lever in full position, adjust the Ungleich spring only)
maximum s'peed stopper bolt so that high speed 1) Keep the pump running at a speed which is a
control starts to work when the pump speed is "Nd". littler lower than "Na" (speed at which Ungleich
spring starts to work).
2) Fix the adjusting lever at the full position.
3) Using the special tool, Special Wrench, tighten
the Ungleich spring so that the rack will move from
"Re" to "Ra". Fix the spring with lock nut.
4) Check that the pump speed is "Na" and "Nb"
when the rack position is "Ra" and "Rb", respectively.
E Re K
89164A E
0
(d), Adjustment of intermediate speed control 0
With the pump speed at "Ne" ( c point) which is a little

lower than "Nd", adjust the full load stopper bolt so
that the rack is positioned at "Re".
Pump speed (rpm)
84070A
(f) Adjustment of idling spring (governor with idling

spring only)
Adjust the idling spring so that the rack starts to move
from "Re" to direction to increase fuel rate at point k.
13-71
DJ
SERVICE PROCEDURES
-- -·---- -------- --------------------

(g) Adjustment of low speed control
--·-------------------'
89170A
(i) Adjustment of speed regulation

89167A
Check that the rack is pulled back to position "Re"
1) Adjus.tment of stopper bolt when the pump speed is increased from "Nd" to
"Ne".
Adjust the stopper bolt so that the rack is positioned
at "Rg" when the adjusting lever is set at idling
position with the pump stationary. Governor spring
Swivel lever
Adjusting bolt
D3482A
------·--------- -------------�
If the pump fails to.do so, adjust tightening amount of
the swivel lever adjusting screw.
89168A
Tightening gives better speed regulation.
Loosening gives poorer speed regulation.
2) Adjustment of idling sub spring
Ne - Nd
Adjust the idling sub spring so that the rack is Speed regulation X 100 (%)
Nd
positioned at "Ri" when the pump speed is "Ni". NOTE:
Check that the rack is positioned at "Rh" when the 1. If the speed regulation is poor, the
pump speed is further increased. engine will e.xceed the specified max
(h) Adjustment of high speed control imum speed at no load and will enter a
hazardous condition.
Adjust as in (c) and fix the maximum speed stopper
2. The maximum extent to which the ad
bolt in position.
justing screw can be loosened is 20
notches (5 turns) from the fully tight
ened position. Loosening it any further
can be dangerous.
3. If 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
DJ
SERVICE PROCEDURES
1) Fix the adjusting lever at the full position and set

the pump speed at "Nk".
2) Screw in until the torque spring contacts the lever
and fix temporarily.
3) Adjust the torque spring so that the rack is
positioned at "R/" when the pump speed is lowered
to "N/ ".
4) Check that the pump speed is "Nj" when the
0
. " pump speed is lowered to position the rack at "Re".
0'9" Stop
[_// position
5) After the adjustment, check that the rack position
Normal is as specified at each pump speed.
position 89171A If the rack position is out of specification, readjust the
torque spring and full load stopper bolt.
(j) Stop lever operation check (m) Adjustment of adaptation to engine
With the adjusting lever fixed at the full position, pull After the governor has been adjusted, measure
the stop lever all the way to the stop side and check overall injection amount at the same lever angle as in
that the rack is positioned at O mm. the high speed control and in accordance with the
(k) Adjustment of full load adjustment standard and readjust as necessary.
(n) Locking with wire
84055A
81370D
1) Install the lever to the governor cover.
2) With the adjusting lever at the full position, adjust After adjustments, lock the governor with wires.
the full load stopper bolt so that the rack is positioned
NOTE:
at "Re".
Locking of the sections marked with *
(I) Adjustment of torque spring must be done after adjustment of no-load
minimum and maximum speeds.
t��f--------�
f---------+---t-1 k
E
E
C
0
U)
0
a.
-"'
()
a:
Ni N/ Nk
Pump speed lrpm)---s-
891728
13-73
DJ
SERVICE PRCEDURES

For governor performance, curve, see Service In
formation published separately.
Adjustment of high speed

control start point
Adjustment of damper spring
I Adjustment of idling k
'-- ------
- ·,-._
., Adjustment of idling spring
I
Adjustment of stopper bolt
Load control lever angle
Adjustment of flyweight lift NV... Nominal Value

B9174A
'-- ------- - ------------------------------------ �
NOTE: Adjust the relation between pump speed and the rack
1. Remove the damper spring. position to specified governor performance curve by
2. Remove the idling spring. the following procedure.
3. Keep the stopper bolt of the speed (a) "O" position setting of control rack
control lever loosened. [Refer to Item ( 1) (b) or (2) (bl, Section 5.1.4.]
' 4. Keep the stopper bolt of the load con· (b) Install the angle scale plate for fixing the control
trol lever loosened. lever.
5. Supply engine oil to the injection pump
cam chamber.
Set by start booster

Ra'
E Ru
_§ Ra
C
Rf
High
:�
_speed
Re ' control
Rb
Re
Rt
Nv NeNuNdNc Na Nb Nt
Pump speed lrpml
03486C
13-74
SERVICE PRCEDURES m
1 Ra
.g
·;;;
'ii Rt
0 Nu 700 to 800 Nt
Pump speed lrpml -
84061A 819158
(c) Adjustment of flyweight lift and full load position 3) Lower the pump speed to "Nu" and adjust the
Divide the flyweight full lift into the lift necessary for high speed lift "L" with the stroke adjusting screw.
high speed ·control and the lift necessary for idling (d) Adjustment of high speed control
control.
1) With the load control lever fixed at the full load
position, temporarily set the speed control lever so
that high speed control works when the pump speed
is 700 to 800 rpm.
81917A
1) Adjustment of high speed control start point

Set the control lever at the full load position and set
the speed control lever at the maximum speed
81916A position.
Increase the pump speed slowly and adjust the speed
2) Increase the pump speed slowly and adjust the control lever stopper bolt so that the rack starts to
full load stopper bolt so that the rack is positioned at move from "Ra" toward fuel decreasing direction
"Rt" when the pump speed reaches "Nt". when the pump speed reaches "Na".
13-75
m
c---------
- --- - ---- --
SERVICE PRCEDURES
Ra
E
E
0
Rb
·.;
0
Na Nb
Pump speed (rpm) 04434B
2) Check of speed regulation 2) Lower the pump speed to "Ne" and adjust the
Increase t_he pump speed slowly until the control rack idling spring using the special tool, Wrench so that
is pulled back to "Rb" position. the rack is positioned at "Re".
Upon reaching "Rb" position, check that the pump 3) When the pump is stopped the rack should be at
speed is "Nb". "Rf" or higher position. Also check that the rack is
Further increase the pump speed and check that the positioned at "Re" when the pump speed is increased
rack pull back amount "L" is as specified. to "Nd".
NOTE:
1. If the speed regulation check point
(point b) is where the damper spring
acts, check the speed regulation aUer
idling and damper spring adjustment.
2. If the value is out of specification,
replace the governor spring.
(e) Adjustment of idling spring (governor with idling
spring only)
D4506A
1) Set the pump speed at "Ne" (Nd + 100 rpm) and

adjust the stopper bolt so that the rack is positioned at
"Re".
13-76
SERVICE PRCEDURES
(f) Adjustment of Ungleich spring

(Vehicles with Ungleich spring only)
E Ra + (
E Ra
a: 0 Nf NgNh N�
Pump speed (rpm)
84581A
Pump speed (rpm)
84580A
B4582A
Special Wrench
157916-2620
84317A
3) Slowly increase the pump speed from "Nf" to
"Ng" and adjust the screw position so that the
1) Set the pump speed at "Nf" and place the load Ungleich spring will start working.
control lever in the full load position. 4) Increase the pump speed to check that the
2) Using the special tool, Special Wrench, adjust the Ungleich spring stops working at "Nh".
Ungleich spring capsule position so that the Ungleich 5) Change the pump speed between "Nf" and "Na"
stroke tin the state of Step 1 will have the specified to check that the Ungleich stroke has the specified
va�ue. After the adjustment, firmly tighten it with the values.
lock nut. NOTE:
1. If the Ungleich stroke is out of speci•
fication, readjust the Ungleich spring
capsule position.
2. If the speed at which the Ungleich
spring stops working is out of specifica
tion, replace the Ungleich spring cap
sule.
13-77
DJ
SERVICE PRCEDURES
(g) Measurement of load control lever angle

Check that when the load control lever is held at the
idling position· and the full load position, the lever
angle at the respective positions is up to specification.
If the lever angle is out of specification, replace the
shim installed between the shifter and sleeve.
NOTE:
If the shim was replaced, repeat adjust
ment of the governor from the beginning.
(h) Adjustment of damper spring
03495A
2) Adjust the damper spring tightening amount so

Damper spring set
that the rack is positioned at "Rg - 0.1 mm".
point
E Rg
1--
_§ Rg-0.1 ---+---....
g Rg-0.2
- .,
·;;;
·;;; Ri
I
'
-"
u
"' \
a:
\
0 Ne Nh
Pump speed (rpm) - B4062A
--·
1) Holding the load control lever at the idle position
(point el and slowly increase the pump speed from
"Ne" until the rack is positioned at "Rg - 0.2 mm".
Hold the pump speed "Nh" when the rack is so
positioned. 3) After adjustment, stop the pump and loosen and
adjust the stopper bolt so that the rack is positioned at
"Ri".
13-78
DJ
SERVICE PRCEDURES
(i) Adjustment of rack limit After adjustment, install the cap nut securely.
1) Cap type 2) Screw type
/t ())
�
Guide Screw
157976-3100 \
�
B3767A B4583A
a) Remove· the guide screw from the back of the a) Place the load control lever in the full load
pump housing and install the special tool, Guide position and keep the pump speed at "Nv".
Screw. b) Adjust the screw of the rack limiter so that the rod
position and fuel injection (point E) will be up to
specification, and secure it with the lock nut.
(j) Adjustment of start booster (smoke set assembly)
B3768A
b) Using a depth gauge, measure the rack cap depth.

03496A
B3769A
c) Adjust the adjusting nut mounted to the tip of the

rack for the same depth as the rack cap depth
measured above. Fix the nut in position with the lock
nut.
13-79
DJ
SERVICE PRCEDURES
1) With the load control lever set at the full load (I) Locking with wire
position, set the smoke set assembly adjusting nut at
O to 4 mm from the stopper tip.
2) Adjust to make sure that when the pump speed is
changed to "Nd", the rack position will change from
·,""'·
To be locked with wire
"Ra" to "Ra"'.
To be cap locked B4320C
After adjustments, lock the governor.
NOTE:
Lock parts marked with * after adjustment
03497A of no load maximum speed.
3) Set and fix the nut so that the rack is positioned at 5.2.4 Inspection and Adjustment of No
"Ru" when the pump speed is "Nu". load Minimum and Maximum
(k) Adjustment of adaptation to engine Speeds
After the governor has been adjusted, measure [Refer to 5.1.8.)
overall injection amount at the same lever angle as in
the high speed control and in accordance with the
adjustment standard and readjust as necessary.
13-80
SERVICE PRCEDURES
5.3 FEED PUMP

5.3.1 Disassembly, Inspection and Reassembly
Eye bolt (suction side: with gauze filter) 7 Plug

2 Eye bolt (delivery side) 8 Piston spring
3 Priming pump 9 Piston
4 Check valve plug 10 Snap ring
5 Check valve spring 11 Tappet
6 Check valve 12 Feed pump housing
For reassembly, reverse the order of disassembly.
NOTE:
Before disassembly, know the trouble spots throughly by
making tests.
89175A
13-81
DJ
SERVICE PRCEDURES
5.3.2 Test and Adjustment

The feed pump tests are as follows.
Lifting capacity Air tightness test

Condition
No. of strokes
required before No leaks from
Air push rod sliding
lifting when
pressure area
operated at
195 kPa
60 to 100
strokes per (2 kgf/cm')
-tg::?f
minute
Delivery NV 25 strokes
Condition or less Feed pump
Fuel passed through 1.54-dia.
nozzle for 15 seconds when ·
pump is operated at 1 000 rpm
NV Refer to 3.1 Service Standard Table.
Test conditions
Fuel pipe
1.0. 8
Length 2 000
Cam lift
6 (eccentric cam) [KE type]
4 (double cam) [K type]
Height from oil level 1 000
Test bench FPT-1
Test oil
SAE Standard Test Oil (SAE J967c)
06401A
13-82
SERVICE PRCEDURES
5.4 AUTOMATIC TIMER

5.4.1 SA Type Automatic Timer
(1) Disassembly and Inspection
For disassembly and reassembly of the automatic
timer, use SA Type Automatic Timer Special Tool
(105790-5010).
Wear of
pin section
Damage on 10
curved surface
CD Round nut
2 Timer plug
0 Timer case
4 Oil seal
5 Flange
6 Oil seal
7 Spring
8 Shim
9 Flyweight
pin section 10 Holder
1 4 3
Wear,
damage
items.
03152A
(a) Remove the coupling from the automatic timer.
13-83
D]
SERVICE PRCEDURES
Special Spanner
/157916-5320
y/
89176A 89179A
(b) Mount Special Spanner (special tool) in the cou (e) Remove the timer plug and place the automatic
pling mounting threaded hole to prevent turning, and timer on Base (special tool).
remove th'e round nut. NOTE:
Line up the hole in the timer plug with the
pin of the base.
@
Hand Spanner
157916-6120
Extractor
157926-6210
_____ , �'n==
89177A
'---- 6:il�
--- - - - - - -- - - - -
-
(c) While holding the automatic timer with Special 89180A

Spanner (special tool) to prevent it from turning,
remove the automatic timer with Extractor (special (f) Using Hand Spanner (special tool), remove the
tool). timer case by turning clockwise.
Guide Bolt
157924-0200
Base
157924-0110
89178A
(d) Mount Base and Guide Bolt (special tools) in the

vice.
13-84
SERVICE PRCEDURES
(2) Reassembly
9 3
After reassembly,
pack AUTOMATIC
TIMER GREASE
(Diesel Kiki product)
or equivalent
150 g.
10
8
0-ring 5
<Assembly sequence>
10 -· 9·
03153A
Thrust Bushing
157924-1500
Guide Bolt Guide Bushing
157924-0200 157924-1200
Base
157924-0110
Oil seal
Flange
Block
157924-0800
B9178A B9182A
(a) Mount Base and Guide Bolt (special tools) in a (b) Install the oil seal in the flange.
vice. 1) Mount Block (special tool) to the base.
2) Put the flange so that its pins will fit in the holes in
the block.
3) Apply NEJI LOCK to the oil seal installing hole in
the flange.
4) Put the oil seal in the hole in the flange. Install the
oil seal by turning down Thrust Bushing (special tool)
with Guide Bushing (special tool) in between.
13-85
SERVICE PRCEDURES
(e) After placing Support (special tool) on the
Thrust Bushing
flyweight, install the shim and spring.
157924-1500 Thread Guide (special tool) onto the guide bolt.
Guide Bushing
157924-1300
NOTE:
Select the proper shim thickness suitable
Timer case.___ � -- for the advance angle of the automatic
.........___ -::,__..,S< timer.
Guide
157924-0900
Oil seal
Block
157924-0800
Special Spanner
157916-5320 Thrust Bushing
B9183A 157924-0500
(c) Install the oil seal in the timer case.
1) Moun� Block and Guide (special tools) to the base.

2) Put the timer case on the guide.
3) Apply NEJI LOCK to the oil seal installing hole in
the timer case.
4) Put the oil seal in the hole in the timer case. Install B9186A
the oil seal by turning down Thrust Bushing (special
·tool) with Guide Bushing (special tool) in between. (f) Put the flange so that the pin of the flange will
touch one end of the spring.
Mount Special Spanner (Special tool) to the coupling
mounting hole of the flange.
Furthermore, mount Thrust Bushing (special tool)
with a bolt.
Oil Seal Guide

157914-0600
B9184A
(d) Place the holder on Base (special tool).
B9187A
(g) After placing Oil Seal Guide (special tool) on the

flange, insert the timer case
B9185A
13-86
SERVICE PRCEDURES
m
(i) Inject approx. 150 g of automatic timer grease
from the timer plug hole.
After grease has been injected, tighten the timer plug.
Special Spanner
157916-5320
89180A
(h) After the oil seal guide has been removed, turn
down the timer case onto the holder with Hand B9190A
Spanner (sp.ecial tool), and punch it.
NOTE: (j) After the automatic timer has been installed on
Turn down the timer case until the injec the camshaft, fit Special Spanner (special tool) into
tion start timing lines inscribed on the the coupling mounting hole. While holding it to
timer case and flange are in alignment. prevent turning, tighten the round nut to the specified
torque.
B9189A
13-87
DJ
SERVICE PRCEDURES
5.4.2 SP Type Automatic Timer

( 1) Disassembly and Inspection
For disassembly and reassembly of the automatic
timer, use the special tool, SP Type Automatic Timer
Special Tool (105790-5050).
Wear
1 Cap screw
3 Deformation
0 Round nut
Damage on Deterioration, 3 Cover
curved surface wear
4 Oil seal
11 9
® Washer
® Roller
(j) Bushing
8 Flange
9 Retainer
1 14 10 Timer spring
11 Spring seat
12 Shim
13 Flyweight
14 Timer housing
For disassembly of parts with an encircled number. see following items.
D3103A
(a) Remove the coupling from the timer.
Extractor
157926-7220
�
"-, Box Spanner
' 157915-2320
"" D3105A
Box Wrench
157916-2800 D3104A
(c) Mount Special Spanner (special tool) by taking
(b) Remove the cap screw of the timer. While using advantage of the coupling mounting thread. While
Box Spanner (special tool), remove the round nut holding it to prevent turning, remove the timer from
with Box Wrench (special tool). the injection pump, using Extractor (special tool).
13-88
SERVICE PROCEDURES
Base
L
157924-2520
8�
8
-
--
D3106A
(d) Mount Base (special tool) in a vice. (f) Mount Special Spanner (special tool) to the
flange. With the timer spring compressed, remove the
washer, roller and bushing.
(e) Fix the timer to Base (special tool)
13-89
DJ
SERVICE PROCEDURES
(2) Reassembly
,--------- - --------- ---- - - -- --�
-------------- -
After reassembly, fill

250 to 270 cc engine oil
9
22 to 24 Nm
(2.2 to 2.4 kgfm)
Apply engine 4
oil to rip.
1 29 to 39 Nm
(3 to 4 kgfm)
Gasket
0-rin� 8 14
<Assembly sequence>
14--> 13--> 12--> 11__, 10-->9-->8--> 7--, 6--> 5--,4__, 3-� 2--> 1
D31128
Base
157924-2520
_;_
B�G
(a) Mount Base (special tool) in a vice and secure the (b) Mount Special Spanner (special tool) to the
timer housing to the base. flange. With the timer spring compressed, install the
bushing, roller and washer.
13-90
SERVICE PROCEDURES
m
Cover side
Roller side
03113A
NOTE: (d) Remove the plug at the rear end of the timer and
When the washer is installed, direct it as supply 250 to 270 cc of engine oil.
shown.
03114A
(c) Install the key to the injection pump camshaft and

install the automatic timer. While using Special
Spanner (special tool) to prevent turning, tighten the
round nut to the specified torque.
13-91
13-92
DJ
SERVICE PROCEDURES
5.5 PUMP DRIVE CASE For removal and installation of the pump drive case,
5.5.1 Removal and Installation refer to 5.1.1 in Group 61 Special Equipment.
Pun1p drive case
J ""'"
5.5.2 Disassembly and Inspection
Cracked
5 Worn 4 10
L
Sensor plate 6 Shatt

2 Injection pump gear 7 Bearing
3 Collar 8 Bearing 2
Cracked or worn
4 Bearing holder 9 Cover
5 Oil seal 10 Crankcase 84196A
13-93
DJ
SERVICE PROCEDURES
5.5.3 Reassembly
215 Nm
(22 kgfm)
<Assembly sequence>
10 -• 8 � 6 � 3 �
10
4�7-5J 2
For assembly of parts marked o, refer to the following section. B4197A
Installation of Injection Pump Gear
Align marks "O" and "U"

when installed
D92748
Install the injection pump gear, sensor plate and nut

as shown.
13-94
SERVICE PROCEDURES
5.6 INJECTION NOZZLE 5.6.2 Disassembly

5.6.1 Removal and Installation
(1-spring nozzle)
[}- -1
�� Settling
Wear 4 f' �5
�9
S� 7 Wear
8 Carbon
deposited
w-- -
©
@)
6
1 Cap nut 5 Connector
2 Adjusting screw 6 Retaining nut
3 Spring 7 Needle valve
4 Push rod 8 Nozzle
NOTE: 9 Nozzle holder
When installing, tighten two nozzle attaching I
bolts alternately and little by little.
07027A
C05778
(2-spring nozzle)
,-fj
Gasket--------0 Disassembly sequence
Cap nut
3�
I
2 Adjusting screw
2
Cracks,
d""''""'" :
---I -----G 3 Lock nut
4 No. 2 spring
5 Set screw
6 No. 2 push rod
Wear 6--t 7 Spacer
8 No. 1 spring
Shim _ �
(for prelift) � 9 No. 1 push rod
10 Retaining nut
�
Shim J 11 Nozzle
(for valve opening--®
pressure)
-t /j
_____fl
12 Needle valve
Cracks, 8 --� 13 Nozzle holder
deterioration
14 Connector
9
07015A
13-95
•
5.6.3 Cleaning and Inspection
SERVICE PROCEDURES
(1) Cleaning
Nozzle Cleaning Tool

105789-0010
07004A
(b) Insert, while turning, a cleaning needle into the

07012A
injection orifice of the nozzle to remove carbon. Use
the needle of proper size for injection orifice.
After washing the nozzle in gas oil, remove deposited
carbon using the Nozzle Cleaning Tool (special tool)
by the following procedures.
NOTE:
Never change the combination of the noz•
zle and needle valve.
07029A
(c) Clean the nozzle seat using the cleaning needle.

(d) To remove burnt and hardened carbon, use FUSO
Carbon Remover or equivalent.
(2) Inspection
D/003A
(a) Remove the needle valve from the nozzle and

clean the needle valve with the needle valve cleaning
wood piece.
D70058
Clean and immerse the nozzle in gas oil, slide the

needle valve and check that it moves smoothly.
13-96
SERVICE PROCEDURES
Next, pull up the needle valve vertically about 1/3 of ( 1) Injection Pressure
its entire stroke and check that it falls under its own
Injection pressure (lever opcratin�J

weight. If it does not fall, replace the nozzle.
at 60 to 100 strokes/minute)
5.6.4 Reassembly and Adjustment ( 1-
spring nozzle) Test pressure
21.6 MPa (220 kg
39 to 49 Nm
1 (4 to 5 kgfm)
/
69 to 78 Nm
- 2
(7 to 8 kgfm) 5 ---
9
3 07007A
----- 4
(a) Remove the cap nut and install to the nozzle
_ .- Locating pin
tester.
-8
59 to 78 Nm 6 ---- :; (b) Loosen the adjusting screw and operate the
(6 to 8 kgfm) nozzle tester two or three times for bleeding.
(c) Operate the nozzle tester at specified speed,
Assembly sequence
adjusting the adjusting screw for specified injection
9-+5-+4-+3-+2-1
pressure.
6-+8-+7-J
NOTE:
NOTE: Never let yourself exposed directly to the
1. Never touch the sliding surface of the needle atomized fuel injected from the nozzle.
valve by hand.
2. Install the cap nut after injection pressure
adjustment.
07028A
07008A
(d) After adjustment, tighten the cap nut to specified

torque. Fix the adjusting screw with a screwdriver
inserted through the cap nut hole to prevent turning
of the adjusting screw.
(e) After tightening the cap nut, check again the
injection pressure.
13-97
DJ
SERVICE PROCEDURES
(2) Spray Condition 5.6.5 Reassembly and Adjustment (2·

spring nozzle)
Adjust while assembling the parts by the following
2 3 4 5 6
procedures.
Good Good Poor Poor Poor Poor
I
As the prelift is adjusted in 1/100 mm increments, use
i clean detergent to thoroughly remove dust and dirt
�
l
before adjustment.
i: I )
i
For adjustment, the following special tools are re
quired.
� ('I' Special tool Diesel Kiki part No.

\
Nozzle tester (500 kglcm2) 105785-1010
Adjusting device 105789-0500

Good Poor
Evenly sprayed from four (five with

6D22-TC) injection orifices
2 Even and symmetrical
3 Asymmetrical
4 Branched
5 Thin
6 Irregular 2
D7009A
'°'
When adjusting the pressure with a nozzle tester,
check also for clogged injection orifices, spray condi
tion, and fuel leaks from the orifices. Replace the
nozzle if defective.
(3) Fuel Tightness Test 6
Test pressure
19.6 MPa (200 kgf/cm')
� 8
7
B3942A
1 Adjusting device assembly 157892-0220
2 Dial gauge 157954-3800

D7010A
3 Pin, f = 50 mm 157892-1200
4 Pin, ( = 60.5 mm 157892-1100

Install a nozzle that has been adjusted to specified
5 Connector assembly 157892-1320
injection start pressure to the nozzle tester. Slowly
6 Base 157892-1800
increase the pressure to the test pressure and keeping
this condition, check for fuel leaks from the bottom of 7 Gasket (for retaining nut) 157892-1500
the nozzle. The nozzle is functioning normally if there 8 Retaining nut for adjustment 157892-1420
is no leak. 9 Gasket (for bolt of retaining nutl 026508-1140
13-98
DJ
SERVICE PROCEDURES
(1) Adjustment of Nozzle Valve Opening

1 39 lo 49Nm (4 lo 5 kgfm)
: I ! ·1 Pressure
, III 2
iH,\:[ '!_. 1·._,

1 1
3 20 to 25Nm ( 2 to 2.5 kg fm)
1
iI 1, :1 5 49 10 59Nm 15 ,o 6 kglml
4 .
1
��' i.�J�1 �
<. R-1 1 111 ) I 7 Nozzle holder
·,1 , \ filI 1,·111T
,
i!·t I . · s
- 13 r _
I, •\\ I� �-_ _I -
L -��
· Shim (for valve opening pressure)
14
I
69 to 78Nmj,i[�
(7 to 8 kgfml t1J.
:11 8
I'\t1l,P*'"
;\ \�J�
, i 9 Needle valve
J
12 RetainingNut for
Locating pin Adjustment
J--157892-1420
c
Assembly sequen e ��--
��78Nm
II\ 1 · 1I (6 to 8 kgfm)
, \ 11
i
I 13_,9-,B-,7-,5-,6
�mI ' � 10 _,4-,2_,3 1

�
� 10-14-,1
l i 59 to 78 Nm
(6 to 8 kgfm) 11-12
W') -"------. Gasket
NOTE: 157892-1500
Never touch the sliding surface of the needle
valve by hand. D7016C
Adjusting steps 07017A
CD Adjustment of nozzle opening pressure

(2) Selection of prelift adjusting shims (a) Using the Retaining Nut for Adjustment (special
(�) Adjustment of 2-spring adjusting pressure tool) install the nozzle and needle valve to the nozzle
*(<1) Check of needle valve full lift holder.
(_s) Installation of prelift shims NOTE:
*(�) Checking of prelift 1. Make sure that the knock pin has sea
*(D Checking of 2-spring adjusting pressure ted completely in the nozzle before
® 'Inspection tightening the retaining nut for adjust
Inspection make operations marked with * as neces ment. Tighten the retaining nut finger
sary for inspection or confirmation. tight and then tighten to specified tor·
que using a torque wrench.
2. Remove the bolt from the tip of the
retaining nut.
13-99
SERVICE PROCEDURES
NOTE:
1. When using a shim, be sure to check its
Set screw
49 to 59 Nm thickness by a micrometer.
(5 to 6 kgfm)
2. Use same shim for prelift adjustment.
3. Use of a 0.02 mm thick shim changes
the valve opening pressure by about
235 kPa (2.4 kgf/cm2)
Spacer
(2) Selection of Prelift Adjusting Shim
Shim (for valve (a) 0 point adjustment of adjusting device
.opening pressure)
1st spring
1st push rod

Dial Gauge
157954-3800
Adjusting Device
157892-0220
/ Pin f = 60.5
157892-1100
2nd push rod
D7018A Base
157892-1800
(b) Insert 1st push rod 1st spring, valve opening

pressure adjusting shim (f!rst use about 1 mm thick
one) and spacer to the nozzle holder.
Then tighten the setscrew to specified torque.
Operate lever at 60 to 100

strokes/minute
D7030A
Injection pressure
NV 17.7 MPa (180 kgf/cm')
Install the Dial Gauge (special tool) to the Adjusting
Device (special tool).
Install the 2nd push rod to the Base (special tool) and
install the assembly to a vice.
Set the pin and adjusting device as indicated in the
Keep bolt removed above illustration and adjust O point of the dial gauge.
D70190
Use a 60.5 mm long pin.
(c) Install the nozzle holder to the Nozzle Tester (b) Install the 2nd push rod to the nozzle holder.
(special tool) and adjust the shim thickness for NOTE:
nominal injection pressure. Do not install the 2nd spring and prelift
Shim types: adjusting shim.
0.50 to 1.54 mm (by 0.02 mm)
13-100
SERVICE PROCEDURES
(e) Remove the adjusting device from the nozzle

holder.
(3) Adjustment of 2-spring Adjusting Press·

ure
Dial Gauge holder
(hold this holder to
stroke up and down)
20 to 25 Nm
�
- --1
(2 to 2.5 kgfm) \bi
Intermediate screw Adjusting screw
Set screw of Adjusting Device
2nd spring ----@
Set screw
Nozzle holder
2nd push rod D7032A
Install the 2nd spring, adjusting screw and lock nut to

the nozzle holder.
D7031A
NOTE:
Do not install the prelift adjusting shim.
(c) Install the adjusting device to the set screw using
its intermediate screw. Operate lever at
60 to 100 strokes/minute
After installation, holding the dial gauge at its holder,
move it up and down to check that the gauge operates Injection pressure
NV 24.8 to 25.4 MPa
smoothly. (253 to 259 kgf/cm')
Push down the gauge, holding its holder and read its
Nozzle Tester
lift h. 105785-1010
NOTE:
Read to 1/100 mm.
(d) Selection of prelift adjusting shim
Keep bolt removed
t = t + h 070190
Where t: Shim thickness (measured)

Adjust the 2-spring adjusting pressure (open press
(: Prelift (0.10 + 0.02 mm)
ure) to the nominal value, using the adjusting screw
h: Dimension selected in (c) and nozzle tester.
T t ± 0.015 mm After adjustment, tighten the lock nut to specified
torque.
T: Thickness of shim to be used
Type of shims
0.75 to 1.50 mm (by 0.01 mm)
13-101
m
(4) Checking Full Lift of Needle Valve
SERVICE PROCEDURES
NOTE:
Never loosen the lock nut as loosening it
changes the 2-spring adjusting pressure.
,r--l1
( \ "0-
, \'' Dial Gauge (b) Install the prelift shim selected in (2) between the
'. ;J 157954-3800
spacer and 2nd push rod.
39 to 49 Nm · ·� ';:! Connector
157892-1320 (c) Install the 2nd push rod and 2nd spring and
(4 to 5 kgfm)--v
0
Pin / = 50 mm tighten the setscrew, lock nut and adjusting screw as
157892-1200
an assembly to specified torque.
(d) Check again that the needle valve full lift dimen
sion "S" with the dial gauge by the procedures_
Retaining Nut for
Geske< [ Adfustment described in (4).
026508-1140 �
157892-1420
12, - - Bolt (6) Checking Prelift
D7033A
Check the prelift based on dimension "L" measured
in (4) and dimension "S" measured in (5).
(a) Install the special tools indicated in above illustra
tion anl set O point of the Dial Gauge. L - S = 6f
(b) Install the nozzle to the nozzle tester and operate where /' - 0.02 < 6 {' < f + 0.02 mm
the tester lever to bleed the inside of the retaining nut.
6 t: Prelift (measured)
Also check for fuel leaks.
t: Prelift (0.1 mm)
(c) · Operate the tester lever to increase the pressure
L: Needle valve full lift dimension (mea
to about 34.5 to 44 MPa (350 to 450 kgf/cm') so that
sured)
the needle valve of the nozzle is fully lifted. Read this
S: Needle valve lift dimension (measured)
lift dimension "L" off the dial gauge.
with prelift subtracted
(d) Remove the Dial Gauge, Connector and Pin
(special tool). If 6 t is outside of specified dimension e ± 0.02
mm, replace the prelift adjusting shim as de
(5) Installation of Prelift Shim scribed in (5) and repeat steps (4) and (5) so that
6 f will fall within t ± 0.02 mm.
Select thickness t' of shim to be used as follows.
Adjusting screw
t' t + ({' - !:,{')
Lock nut T t' ± 0.015 mm
Set screw where t: Thickness of existing shim

49 to 59 Nm t': Shim thickness
(5 to 6 kgfm)
T: Thickness of shim to actually replace
existing shim
t: Prelift (0.1 mm)
D7034A
(a) Remove the setscrew, lock nut and adjusting

screw as an assembly from the nozzle holder.
13-102
SERVICE PROCEDURES
(7) Checking Adjusting Allowance of 2- (b) Spray condition

spring
2-spring adjusting
pressure (lift 0.05 mm) I 3 5 ,;
NV 23 to 23.5 MPa
Good Good Poor Poor Poor Poor
(235 to 240 kgf/cm') I
I
l
Nozzle Tester ! '
)
I
105785-1010
..-�,
D7035A
� ;J
'!
�
(a) After checking the prelift in Item (6), increase the Good Poor
pressure again to about 34.5 to 44 MPa (350 to 450
kgf/cm') so that the needle valve of the nozzle is fully Evenly sprayed from 3 Asymmetrical
lifted. four (five with 6022-TC) 4 Branched
injection orifices 5 Thin
NOTE:
2 Even and symmetrical 6 Irregular
The Retaining Nut for Adjustment (special
tool) must have a bolt fitted at its tip.
07009A
(b) When the nozzle tester lever operation is stopped
with the nozzle needle valve fully lifted, the pressure
When adjusting the pressure with a nozzle tester,
will start to drop and the needle valve will go down.
check also for clogged injection orifices, spray condi
(c) At the moment the nozzle lift has dropped to 0.05
tion, and fuel leaks from the orifices. Replace the
mm, read the pressure gauge indication.
nozzle if defective.
(d) If the 2-spring adjusting pressure !cover pressure)
(c) Fuel tightness test
is out of specification, adjust the 2-spring adjusting
pressure as described in (3).
NOTE:
Adjust without installing prelift shim. Test pressure
15.7 MPa (160 kgf/cm')
(e) Remove special tools.
(8) Inspection
(a) Tighten the retaining nut and cap nut to specified
torque.
NOTE:
1. Make sure that the knock pin has sea
ted completely before tightening the
07010A
retaining nut.
2. Tighten the retaining nut finger tight
Install a nozzle that has been adjusted to specified
and then tighten to specified torque
injection start pressure to the nozzle tester. Slowly
using a torque wrench.
increase the pressure to the test pressure and keeping
this condition, check for fuel leaks from the bottom of
the nozzle. The nozzle is functioning normally if there
is no leak.
13-103
m
5.7 FUEL FILTER
SERVICE PROCEDURES
<Standard> <Option>
Cracks, damaged
threaded portion
Fuel filter head

Fuel filter head
Cracks, damaged 25 Nm
thread
,,,,.sec�� Before installation, apply

.-�-
_if"6�0)'\� ato thin coat of engine 011
gasket.
"- Fuel filter

Fuel filter
element
element
'·"----------/./
I I I I __ I
D7301E D73090
NOTE:
1. When removing the element, check for
the gasket left behind on the head side.
2. To mount, apply a thin coat of engine oil
to the gasket, and then secure the
element by tightening 3/4 to 1 turn aHer
the gasket comes in contact with the
fuel filter head.
3. After installation, bleed the fuel sys
tem.
4. After bleeding the air, start the engine Filter Wrench
MH061572
and check for fuel leaks. B9181C
To remove the element, use Filter Wrench (special

tool).
13-104
SERVICE PROCEDURES
5.8 WATER SEPARATOR
1 Drain plug
2 Ring nut
4-
3 Case
7----Q
:�
4 Baffle plate
5 Isolation plate
6 Screen assembly
7 Water level ring
8 Cover
1--®
07405C
If the red water level ring in the translucent case rises

to the level of the red line marked on the outer
circumference of the case, immediately loosen the
drain plug to discharge water.
It is not necessary to completely remove the drain
plug, as water is discharged gradually through the
groove of the loosened plug.
NOTE:
Drain plug
After draining, tighten firmly the drain plug
before bleeding the fuel system.
07404A
13-105
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
6. TROUBLESHOOTING
Engine is Defective feed pump

hard to start
• Clogged gauze filter Clean
• Check valve inoperative Replace
• Binding or worn piston Replace
• Binding push rod Replace
• Worn tappet Replace
Defective injection pump

• Binding or won ·plunger Replace
• Binding control rack or control rod Replace
• Binding delivery valve Replace
• Worn tappet Replace
• Worn camshaft Replace
Defective injection nozzle

• Binding needle valve Replace
• Valve opening pressure too low Adjust
• Clogged injection orifice Clean
• Nozzle not air-tight Correct or replace
Fuel tank empty Supply fuel
Clogged fuel pipe or fuel leak from connections Correct or replace
Air or water trapped in fuel system Bleed or replace Group 11
Clogged fuel filter or secondary filter Replace
Engine stops Clogged fuel filter or secondary filter Replace

immediately
after starting Air or water trapped in fuel system Bleed or replace Group 11
Defective feed pump Check
Engine knocks Injection timing too early Adjust

• Valve opening pressure too high Adjust
Poor quality fuel in use Replace
Smoky exhaust gas Defective injection pump

and engine
knocking
• Incorrect injection timing Adjust
• Worn plunger Replace
• Defective valve seat of delivery valve Replace
13-106
DJ
Smoky exhaust gas Poor quality fuel in use Replace

and engine
knocking Defective injection nozzle
•
.
Valve opening pressure too low Adjust
Broken spring Replace
Unstable
engine output .
Insufficient plunger sliding stroke Replace
• Broken plunger spring Replace
• Control rack or control rod not sliding smoothly Correct
.
• Worn or sticky tappet Replace
Broken delivery valve spring Replace
• Loss of air-tightness due to loose delivery valve holcJer Correct
• Delivery valve not functioning normally Replace

• Needle valve not sliding smoothly Replace
• Broken spring Replace
Defective feed pump

• Check valve not functioning normally Replace
• Worn piston Replace
Air or water trapped in fuel system Bleed or replace Group 11
Clogged fuel filter· or secondary filter Replace
Control lever not in contact with full speed set bolt Adjust
Loss of Defective injection nozzle

engine output • Nozzle not air-tight Correct or replace
• Broken spring Replace

• Worn plunger Replace
• (Broken) Damaged delivery valve spring Replace
• Defective delivery valve seat Replace
• Loss of air-tightness due to loose delivery valve holder Correct
Loss of Defective governor

engine output
• Too early rotation control due to weak governor spring Adjust
• Faulty full load stopper position Adjust
• Adjusting lever (or load control lever) poorly adjusted Adjust
Poorly adjusted injection timing Adjust
Incorrect timing advance of automatic timer Adjust
Poor quality fuel in use Replace
13-107
• Symptom
Probable cause Remedy Ref. group
Engine cannot Defective governor

develop maximum
speed
• Governor spring too weak Adjust
• Adjusting lever (or load control lever! poorly adjusted Adjust

Engine maximum Injection pump control rack or control rod not sliding smoothly Correct
speed to high
Defective governor
• Governor spring too weak Adjust
• Flyweight not functioning effectively Correct
Idling is not Defective injection pump

smooth • Binding, sticky or worn plunger Replace
• Loose control pinion Correct
• Plunger spring not seating correctly Replace
• Delivery valve holder too tight Correct
• Uneven fuel injection rate among cylinders Adjust
• Broken plunger spring Replace
• Air or water trapped in fuel system Bleed or replace Group 11
Defective governor
• Idling spring too weak Adjust
• Bent linkage Correct
• Large friction or play in linkage Replace
• Loose round nut Correct
• Poorly adjusted idling set bolt Adjust
Idling is not Defective feed pump

smooth • Defective check valve Replace
• Worn piston Replace
• Clogged gauze filter Clean
Clogged fuel filter or secondary filter Replace
Poorly adjusted injection timing Adjust
Defective automatic timer Correct

• Weak spring Replace
Engine will Broken or elongated engine stop cable Replace

not stop
Engine stop cable poorly adjusted Adjust
Damaged governor stop mechanism Replace
Poor supply Cracked fuel hose or pipe Replace

of fuel
Fuel tank not air-tight Replace
13-108
ID
COOLING
CONTENTS
1. GENERAL •.••..•••••••.•..••••.•..•...•••...... 2 5.4 FAN DRIVE ................................. 9

2. SPECIFICATIONS ••.•.••.•.•....•..••...... 3 5.4.1 Disassembly and lnspec-
3. SERVICE STANDARDS .....••...••...•.• 4 tion ......................................... 9
3.1 SERVICE STANDARD TABLE •.•.• 4 5.4.2 Reassembly •.••.•.••.••.•••••••.••••••• 9
3.2 TIGHTENING TORQUE TABLE ... 4 5.5 TENSION PULLEY ...................... 9
4. SPECIAL TOOL ••••.........•...•••..•....•.. 4 5.5.1 Disassembly and lnspec-
5. SERVICE PROCEDURES ................ 5 tion ......................................... 9
5.1 REMOVAL AND INSTALLATION 5.5.2 Reassembly ••••••••••••..••..•...••••.. 1O
OF COOLING FAN ....................... 5 5.6 RADIATOR ................................. 10
5.2 WATER PUMP ............................ 5 5.6.1 Inspection .............................. 10
5.2.1 Removal and Installation ••••••. 5 5. 7 INSPECTION AND ADJUSTMENT
5.2.2 Disassembly and lnspec· OF V-BELT TENSION .................. 11
tion ••...••.••.•.•••.•.••••.••.••..••.•••.••. 5 5.8 CLEANING OF COOLING
5.2.3 Reassembly ••.•...•.•.••••••.•.••••.... 7 SYSTEM ..................................... 11
5.3 THERMOSTAT ........................... 8 5.9 GAS LEAK TEST ......................... 14
5.3.1 Removal and Installation ••.••.. 8 5.10 BLEEDING THE COOLING
5.3.2 Inspection ...•••....•.•......•....••.••• 8 SYSTEM ..................................... 14
6. TROUBLESHOOTING .................... 15
14-1
ID COOLING - GENERAL
1. GENERAL (2) Thermostat

The engine is cooled by forced circulation of coolant
by the water pump. The illustration below shows the
coolant flow.
Radiator cap
When coolant
temperature
is high
(bottom bypass
,--- -,- -, valve is closed I
,---, r---, ,---, ,---, ,---, l
Oil cooler
L
o � � �
·, Water pump /{::i
I ..
/
I •,
Drain cock ) :
\ i'-.... /�
Dram cock "--__) B9017A
To water pump
( 1) Water Pump
When coolant temperature is low
(bottom bypass valve is open)
B1747A
The thermostat is a bottom bypass type with a special

wax enclosed in a pellet. When the wax is heated, it
changes from solid to liquid and its volume also
changes. This change in volume changes the opening
t of the valve and changes the quantity of coolant

From radiator flowing into the radiator and water pump (bypass
B1746C
side), thereby controlling the coolant temperature.
(3) Radiator
The water pump is a centrifugal pump. Mounted on
the left side of the crankcase, the pump is driven by
the crankshaft pulley via a V-belt. Pressure cap
An impeller having a b lade is mounted at one end of

the water pump shaft and coolant is sealed off by a
unit seal.
For lubrication of the water pump, refer to "Group 12
Lubrication".
B9018A
The radiator cooling capacity varies depending on

applications (installation in an enclosed generator
room of a building, operation in stationary state, etc.).
14-2
COOLING - GENERAL, SPECIFICATIONS
Considerations are, therefore, paid to the fan dia The pressure cap regulates the pressure in the
m
meter, radiator capacity and other factors. Some units cooling system. When the pressure builds up in the
for construction plants are equipped with an oil cooler system that exceeds a predetermined level, the
to cool hydraulic oil. pressure valve compresses the pressure spring, re
(4) Pressure Cap leasing the excessive pressure through the overflow
pipe into the atmosphere.
<With pressure release lever> If equipped with a reserve tank, the coolant that has
overflowed is channeled into it.
, . , -1
Pressure
release
lever When the coolant temperature drops and negative
Pressure :-.
spring · ,i pressure builds up in the system, the vent valve
--------'--
opens to take in air to prevent the radiator from
f"E�6:=- fl-
f-1· ;��j
�T. Jj,..."""- --,.;:-
becoming deformed.
If equipped with a reserve tank, coolant is taken from
�:"
---
�-
:· To overflow pipe the reserve tank to prevent the radiator from becom
��
ing deformed and to keep the quantity of coolant in
Pressure' ·· : ""-,,. · Vent valve
valve Vent valve ',;.. operation the system constant .
. spring condition
�
If equipped with a pressure release lever on the cap,
,....�ll�
� 817168
raising the lever upright opens the pressure valve and
releases the pressure in the cooling system.
<Without pressure release lever>
Under positive Under negative

pressure pressure
From
reserve
tank
80295A
2. SPECIFICATIONS
Item Specification
Cooling method Water-cooled, forced circulation

Cooling water quantity !Engine proper! 6022. 6022-T: 22 lit.
6022-TC: 24 lit.
Water pump Type Centrifugal type

Drive V-belt drive
V-bell Type x quantity !With fanl
Low edge cogged 8 type x 1 lfor water pump)
Low edge cogged C type x 2 !for fan drive)
!Without fanl
Low edge cogged C type x 1 lfor water pump)
Thermostat Type Wax pellet, bottom bypass

Valve opening temperature x q'ty 76.5"C x 2
Fan Type Pusher type or suction type
Radiator Type Tube and corrugated fin type or tube and plate fin type
14-3
•
COOLING - SERVICE STANDARDS, SPECIAL TOOL

Unit:mm

!Basic diameter!
Thermostat Valve opening start 74.5 to 78.5"C - Replace.

temperature
Valve lift/temperature 10 or more/90"C
Water pump Interference between pump 1251 - Reassembling up

shaft and flange 0.05 to 0.08 to two times
lnterferen_ce between pump 111.81

shaft and impeller 0.03 to 0.06
Radiator pressure valve opening pressure 39 to 59 kPa - Replace pressure

(0.4 to 0.6 kgf/cm') cap.
Radiator check pressure 98 kPa - Correct or replace.

(1.0 kgf/cm')
Tension of V-belt w/fan drive 10 to 15 - Adjust.

(deflection of V-belt
when pressed down at w/o fan drive 17 to 22 -
middle under approx.
98 N (10 kgfl pressure)

0.0. X pitch Nm (kgfm)
mm
Fan drive flange nut M20 x 1.5 145 (15)
Tension pulley shaft nut M16 x 1.5 98 (10)
· 4. SPECIAL TOOL
Unit:mm
Water Pump Impeller Puller MH061417 Removal of· pump impeller
48
B5251A
14-4
COOLING - SERVICE PROCEDURES
5.2 WATER PUMP

m
5.1 REMOVAL AND INSTALLATION OF 5.2.1 Removal and Installation
COOLING FAN
B9019B
Tightening margin
BO 11.8
1 NV 0.03 to 0.06
Reassembly up to
Tightening margin
BO 25
NV 0.05 to 0.08
Reassembly up to
two times allowed
1 Water pump pulley ® Water pump shaft
@ Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 Water pump cover 13 Unit seal
0 Impeller 14 Water pump case
For parts with an encircled number, refer to Disassembly and
Inspection Procedures that follow. 00044C
14-5
ID COOLING - SERVICE PROCEDURES
Disassembly and Inspection Procedures
Impeller
Water pump
Impeller Puller
MH061417
Water pump shaft

00031C
000138
(3) Impeller to Water Pump Shaft Tighten•
(1) RemQval of Impeller ing Margin
Using two threaded holes (MB x 1.25) in the impeller If the tightening margin exceeds specification, replace
and the Water Pump Impeller Puller (special tool). pull the impeller or water pump shaft.
off the impeller. NOTE:
Do not reassemble more than three times
Water
even when the specification is met.
pump
flange
Water pump shaft
000318
(2) Flange to Water Pump Shaft Tightening

Margin
If the tightening margin exceeds specification, replace
the flange or water pump shaft.
NOTE:
Do not reassemble more than three times
even when the specification is met.
14-6
ID
5.2.3 Reassembly
Apply engine
oil to lips.
12
Apply engine oil
to external cylinder.
13
Installation load
39.2 kN (4000 kgO
Impeller must be flush

with water pump shah
when installed.
5
Apply engine <Assembly sequence>
oil to lips. 121
8--> 11--> 10--> 9-->14--> 7 -
@J
NOTE:
1. After reassembly, turn the water pump pulley by hand
to make sure that the impeller is not in contact with
the case and cover.
2. When press-fitting the impeller and flange, make sure
that they cannot be installed with a load of 4.9 kN (500
kgf). 000470
Installation of Unit Seal To install the unit seal, use the press-fit jig as shown
and press-fit the unit seal until the installed dimen
Unit seal sions shown are obtained.
Installation load
31 to 44 N (3.2 to 4.5 kgt)
Installation speed
14 to 28 mm/sec
84153A
14-7
5.3 THERMOSTAT Agitate water in the container with the stirrer to

5.3.1 Removal and Installation obtain uniform temperature. For the inspection, use
the following procedures.
(1) Slowly heat water to the thermostat valve open
ing temperature.
The valve opening temperature is stamped on the
thermostat. Its nominal value is the stamped temper
ature ± 2°c.
Keep this condition for about five minutes and make
sure that the valve is open.
(2) Raise the temperature further to heat the water to·
the valve lift measuring temperature corresponding
to the valve opening temperature. (See the table
690216
above.)
Keep this state for five minutes and measure the
bypass valve lift.
5.3.2 Inspection (3) Lower temperature down to 65°C or below and
ensure that the valve is fully closed.
If the thermostat is found defective in any of the
Thermostat stamping 76.5 above items, replace it with a new one.
Valve opening 74.5 to 78.5 NOTE:
temperature ( °C)
Support the thermostat so that the heat
Valve lift/
temperature (mm!°C)
More than 10/90
will not directly transfer to it.
Bypass valve lift
Stirring rod Valve opening

temperature
stamped position
Thermostat
��
Heat source ----fl 003016
14-8
5.4 FAN DRIVE
m
�---- -
---- ----- - - -
----- -
-- ------------------,
8
6 <Disassembly sequence>
Fan pulley
2 Flange
1 3 Snap ring
4 Fan drive shaft
5 Ball bearing
6 Spacer
7 Ball bearing
8 Bearing case
890230
5.4.2 Reassembly 5.5 TENSION PULLEY

Sealing side to
be faced outward.
To be packed with grease
(multipurpose grease)
145 Nm
(15 kgfm)
To be packed with
approx. 86 g of grease 6 Rotating condition
<Assembly sequence> Adjusting bolt

9_,5_,3_,2_,1 2 Tension pulley bracket
4_,7_,5J 3 Snap ring
4 Tension pulley shaft
890240 5 Tension pulley
6 Ball bearing
EngineParts2@gmail.com Parts phone: 269 673 1638 89023E
14-9
5.5.2 Reassembly
Inspection pressure
98 kPa (1.0 kgf/cm')
Sealing side to
be faced outward.
To be packed with grease
98 Nm
3 (10 kgfml
004098
4
(2) Connect a hose to one of the radiator ports, cap
the other port, and immerse the radiator into water.
To be packed with Using a radiator cap tester, force the compressed air
approx. 6 g of grease
under the specified inspection pressure from the hose
end to check for leaks.
If there is a leak, resolder the point of leakage or
<Assembly sequence> replace the radiator.
5 _, 6i
4 -, 3 ...... 2 -, 1
89024E
5.6 RADIATOR Radiator

cap tester
5.6.1 Inspection
Inspection
pressure
39 to 59 kPa
(0.4 to 0.6 kgf/cm 2 )
Radiator
cap 00420A
(3) Inspection of radiator cap

Check the spring tension and sealing condition of the
pressure valve and vent valve. If defective, replace.
Check the pressure valve opening pressure, using a
00402A radiator cap tester.
(1) Using a copper wire or similar device, remove

dirt, mud, and bugs from the front of radiator core
with care to prevent damage to turbings.
14-10
5. 7
INSPECTION AND ADJUSTMENT OF (a) Alternator section

m
V-BELT TENSION Slightly loosen the alternator mounting bolt and
(1) Inspection adjusting bolt, then move the alternator to right or left
by inserting a tool such as wrench handle.
< With (an drive:::.,
NOTE:
When moving the alternator, try not to
damage the stator coil section between
the front and rear brackets. The same
applies to the bolts.
Adjusting bolt
, Without fan �rive>
E0166
(b) Tension pulley section

E0164 Loosen the idler pulley mounting nut, then adjust
moving the idler pulley by means of the adjusting
Adjust the belt tension to obtain the specified belt bolt.
deflection when the center of each belt is pressed
with a force of approximately 98 N (10 kgtl. 5.8 CLEANING OF COOLING SYSTEM
NOTE:
1. A slack belt can be a cause of overheat
ing and undercharge.
2. An excessively tight belt may result in
damaged bearings and belts.
(2) Adjustment
Adjusting bolt
80429A
If the radiator is used for a long time, rust, scale, mud,

etc. are deposited inside, resulting in overheat. Clean
the cooling system with city water by using the
following procedures.
E0165 The city water to be used should have the following
properties.
Required properties of city water
14-11
(a) Discharge coolant from the radiator, and crank

Total hardness 300 ppm or less
case.
Sulfate SO-, 100 ppm or less
(b) After draining the system, fill it with tap water
Chloride Cl 100 ppm or less (preferably hot water) and, with the water tempera
Total dissolved solids 500 ppm or less ture kept at around 90° C, run the engine at idle for
PH 6 to 8 about 10 minutes. Then, discharge water.
Continue flushing until the drained water runs clear.
NOTE: (2) Washing with Cleaning Solution (When
1. Use a cleaning solution if the radiator is radiator clogging or coolant contamina
seriously obstructed or coolant is tion are serious)
seriously contaminated.
2. When the cooling system is cleaned or
washed with water, make sure that the
coolant temperature is maintained at
90°C; the coolant temperature below
the valve opening temperature closes
the thermostat resulting in poor
coolant circulation.
3. For quicker rise of water temperature,
you may cover the radiator front with
cardboard, etc.
4. If much rust is found, water may leak 80427A
from the radiator after cleaning. Check
carefully each section of the radiator (a) Discharge coolant from the radiator, crankcase,
after cleaning. and reserve tank.
(b) Ready a mixture of Fuso Radiator Cleaner
Coolant in use Cleaning interval
(Radipet-7 or equivalent: 5 to 10%) and cooling water.
Pour the specified amount of mixture into the
FUSO Diesel Long Life Every 2 years
Coolant radiator.
Anti-rust, anti-freeze At time of coolant replacement of
every 6 months or before and
after use of anti-freeze
(1) Washing with Water
80428A
(cl Run the engine to raise the solution temperature

to around 90°C. Let the engine run at idle for another
30 minutes, then remove the solution.
80426A
14-12
m
Replace the coolant once every two years to retain its
anti-freeze and anti-rust effects.
For usage of Long Life Coolant, refer to its instruction
manual.
NOTE:
1. Be sure to use FUSO Diesel Long Life
Coolant.
2. Never mix it with DIAQUEEN Long Life
Coolant or other commercial long life
coolants, anti-freezes or anti-rusts.
B0426A
� - -
- - -
------ - -----
- - --
- -
(d) After discharging the solution, fill the system with

tap water (preferably hot water) and with the water
temperature. kept at around 90"C, run the engine at
idle for about 10 minutes. Then, drain water.
Continue flushing until drained water runs clear.
NOTE:
1. If the inside is heavily stained, washing
with tap water before charging radiator
detergent will be effective. B13\0A
2. Running the engine at idle for longer
than an hour with detergent left in (b) When Anti-rust and Anti-freeze are
engine could cause damage to the cool used:
ing system. Be sure to observe speci
1) After cleaning, add Fuso Radiator Anti-rust
fied cleaning time.
(Radipet-98 or equivalent) at a ratio of 5% to the
3. After cleaning with detergent, fill with
coolant quantity to prevent corrosion in summer.
coolant as soon as possible.
(3) Cooling Water
81322A
D13228 2) In winter, add the Fuso Anti-freeze or equivalent

at a ratio of 30 to 60% to prevent freezing.
(a) When Long Life Coolant is used: For usage of anti-rust and anti-freeze, see respective
instruction manuals.
In order to prevent freezing of cooling water and
corrosion of the cooling system, add FUSO Diesel NOTE:
Long Life Coolant at a ratio of 30 to 60% of quantity of When the anti-rust or anti-freeze is used,
water. never use with other long life coolants.
14-13
5.9 GAS LEAK TEST 5.10 BLEEDING THE COOLING SYSTEM

Air or exhaust gas leaked into the coolant promotes ( 1) With the pressure cap removed from the radiator,
corrosion and rust formation. Perform the following let the engine run at idle with coolant temperature of
check and, if defects are found, take remedial action. about 90° C to bleed the system completely.
(2) After the system has been bled of air, add coolant
to radiator and reserve tank as required.
(1 ) Inspection
Remove the pressure cap from the radiator, and run
the engine to raise the coolant temperature up to
around 90°C.
If bubbles continue forming in the coolant under the
condition, it indicates that air or exhaust gas has
leaked into the coolant.
(2)Causes
(a) If air is trapped in coolant, check cylinder head
bolts, water pump mounting bolts, and hose and its
connections for looseness. Check also hoses for
damage.
· (b) If the exhaust gas has leaked into coolant, check
the cylinder head gasket or nozzle tube end stake for
damage. Check also cylinder head for cracks.
14-14
6. TROUBLESHOOTING
COOLING - TROUBLESHOOTING m
Overheating
.
Defective V -bell
Adjust
.
Incorrect tension
I Broken bell Replace
Clogged cooling system Clean
Defective thermostat Replace
.
Defective water pump
Loose shaft to flange engagement Replace
• Loose shaft to impeller engagement
.
.
Incorrect impeller to case clearance
Damaged impeller
Clogged radiator fins Clean
Damaged cooling fan Replace
Low coolant level Replenish
Overcooling Defective thermostat Replace
Quick loss Defective radiator hose

I
of coolant
• Poor hose connection Correct
• Cracked or damaged hose Replace
I•
Defective radiator
• Radiator proper not air tight Replace
Defective pressure cap
Defective water pump

• Defective unit seal Replace
• Defective oil seal
• Poor pump installation (defective gasket!
Defective oil cooler Re.place Group 12
Poor thermostat case installation (defective gasket! Replace
Poor thermostat cover installation (defective gasket)
Poor bypass hose installation
Defective heater hose

• Poor hose connection Correct
• Cracked or damaged hose Replace
Defective cylinder head gasket Replace Group 11
14-15
INTAKE AND EXHAUST
CONTENTS
1. GENERAL ••••••••••.•••••••••.•••••.•••••..•••• 2 5.3 AIR CLEANER ............................ 13

2. SPECIFICATIONS •••.•••••••••••••••••••••• 5 5.3.1 Disassembly and
3. SERVICE STANDARDS •••••.•••••••••••• 6 Reassembly •••••••••.•••••.•••••••.•••• 13
3.1 SERVICE STANDARD TABLE ••••• 6 5.3.2 Inspection and Cleaning •••.•••• 14
3.2 TIGHTENING TORQUE 5.4 TURBOCHARGER ...................... 15
TABLE ........................................ 7 5.4.1 TD08 Type Turbocharger •••••.• 15
4. SPECIAL TOOL .............................. 7 5.4.2 4LF Type Turbocharger •••••.•••• 25
5. SERVICE PROCEDURES ••••••••••..•••• 8 5.4.3 3LM Type Turbocharger .•••.••.• 30
5.1 REMOVAL AND INSTALLATION 5.5 AFTER COOLER ......................... 35
OF INTAKE SYSTEM .................. 8 5.5.1 Disassembly, Inspection
5.2 REMOVAL AND INSTALLATION and Reassembly ••••••••••••••••.•••• 35
OF EXHAUST SYSTEM ............... 11 5.5.2 Air•pressure Test ••••••••••••••••••• 35
15-1
m
1. GENERAL
INTAKE AND EXHAUST - GENERAL
Air
( 1 ) Air Cleaner
<Single element type>

Air
To engine
Vacuator
valve
Guide vane 80620A
80618A The air cleaner uses a filter paper type element.

Because of plastic coating and heat treatment, the
Air
element is highly resistant to water and oil. Even if it
is contaminated, its functions can be regained by
cleaning.
The intake air is given a spin by the element vanes for
centrifugal separation of large particles of dust and
dirt. Small particles of dust and dirt are filtered out by
To engine
the filter paper element so that a clean air is drawn
t--1---vacuator into the engine.
valve
Guide vane The standard air cleaner is a single element type, and
89004A
the double element type can be effective or operation
safety under unusual conditions with a lot of dust and
<Double element type>
dirt.
Inner element (2) Precleaner
B0608C
Outside air
To air cleaner 80610A
The precleaner, coupled with the air cleaner, collects

relatively large particles of dust contained in the air
drawn in by engine.
The air entering the precleaner is made to spin by the
guide vanes of the precleaner to centrifugally sepa
rate large particles of dust before the air is drawn into
the air cleaner.
15-2
(3) Vacuator Valve
After the element has been cleaned or replaced,

m
depress the reset button on the top, and the signal
will return to its original position.
Warning lamp
Starter switch
Electrical
dust indicator
�
l Battery
80624A
The centrifugally separated particles of dust and dirt 81824A

are collected at the bottom of the air cleaner. The
collected particles of dust and dirt are discharged In the electric dust indicator, its electric contact points
outside by pulsations of the vacuator valve mounted close at a negative pressure of 6.23 kPa (635 mmH 2 0)
in the air cleaner. or 7.47 kPa (762 mmH 2 0) to turn on the warning lamp,
In the engine speed increases (to 800 rpm or more), indicating to the driver the time to clean or replace the
the vacuator valve will be closed by a high negative element.
pressure in the air cleaner, so no outside air will be (5) Turbocharger
drawn in.
(4) Dust Indicator
Reset button
Indicator body
Compressor
wheel
Signal
Exhaust
outlet
Transparent
section
Inlet
manifold
806058
The dust indicator is directly mounted near the outlet

of the air cleaner.
The dust indicator operates on the negative pressure
of the air drawn into the engine performing the
function of indicating the time to clean or replace the
element.
If dust is collected in the element, the suction 81215A
resistance increases. When the negative pressure
reaches 7.47 kPa (762 mmH 2 0), or 6.23 kPa (635 The turbocharger utilizes the energy of the engine
mmH 2 0) the signal is pulled down against the spring exhaust gas to feed more air into the engine, thereby
pressure, and the transparent portion of the body offering advantages such as boosted engine power
changes to red, indicating the time to clean or replace output, thriftier fuel consumption, and reduced en-
the element. gine noise.
15-3
TDOB Type 4LF Type
Bearing housing
Turbine
cover
wheel
,'l\.j�� Back
plate
Turbine
wheel
B1213A B1202A
The exhaust gases discharged from the engine cylin

3LM Type Compressor cover ders are delivered through the exhaust manifold to
the turbocharger, accelerated in the turbine housing,
and blown against the turbine wheel. As a result, the
Compressor
Back plate
wheel
turbine wheel turns at a speed of several tens of
I thousands of revolutions per minute, which spins the
compressor wheei. As the compressor wheel spins,
the amount of air far larger than that supplied when
no turbocharger is installed is forced into the engine
cylinders, allowing more fuel to be burnt in the
cylinders. This increases the effective pressure during
combustion (the pressure forcing pistons down), thus
boosting the power output.
The turbocharger is divided into two basic sections:
the turbine wheel that is driven by the exhaust gases
and the compressor wheel which is supported by the
bearing and forces intake air into cylinders. A thrust
bearing is mounted on the compressor end.
Turbine The lubricating oil is supplied from the oil main
wheel
gallery at the front end of the engine and routed
through oil holes in the bearing housing to lubricate
Turbine housing B9026A the bearings. The oil is then returned to the engine oil
pan through the drain port at the bottom of the
bearing housing.
[Refer to Group 12 Lubrication.]
15-4
(6) After Cooler
INTAKE AND EXHAUST - GENERAL, SPECIFICATIONS
The intake air cooler system, incorporating a plate

•
and-corrugated-fin type heat exchanger with a built-in
inlet manifold, transfers heat from the intake air to the
engine coolant.
The system cools off the intake air, whose tempera
Turbocharger
ture has gone high due to compression by the
turbocharger, through heat exchanging with the
engine coolant. This allows the density of intake air to
After cooler
be increased, admitting more air into the engine,
which in turn increases the fuel injection rate and
improves the combustion efficiency. Thus the fuel
.,
economy and output are improved and the exhaust
gases are reduced to a minimum.
Jf
,.,
Water pump
80627A
2. SPECIFICATIONS
Item Specification
Air cleaner (Nippon Donaldoson Ltd. productl

Element Type Cyclone type paper element
Turbocharger [6022-T[ [6022-TCJ

(Standard I (Option)
Model Mitsubishi TD08 Mitsubishi Schwitzer Mitsubishi TD08
3LM or 4LF
After cooler Type Engine-coolant-cooled,

with built-in inlet manifold
15-5
m
INTAKE AND EXHAUST - SERVICE STANDARDS

Unit:mm

(Basic diameter!
Turbocharger 1.0. of bearing inserting portion - 19.06 Replace.

(3LM) of bearing housing
Shaft and Bearing journal - 11.18 Replace.

turbine wheel 0.0.
Shaft concentricity - 0.015 Replace.
Piston ring open en.d clearance 0.015 to 0.18 - Replace insert.
Shaft and turbine wheel to turbine 0.53 to 1.04 - Replace.

housing clearance
Shaft and turbine wheel end play 0.05 to 0.13 - Replace.

in axial direction

back plate clearance
Turbocharger 1.0. of bearing inserting portion of - 20.506 Replace.

(TD-OB) bearing housing
Shaft and Bearing journal - 11.996 Replace.

turbine wheel 0.0.
Shaft concentricity - 0.015 Replace.
Bearing 0.0. 20.382 Replace.
I.D. 12.042
Length 11.94
Clearance between compressor wheel 0.08 to 0.28 - Replace.

and compressor cover
Piston ring end gap in insert 0.05 to 0.25 - Replace.

housing clearance
Shaft and turbine wheel end play 0.075 to 0.155 - Replace.

in axial direction

Turbocharger Bearing Bearing inserting - 22.268 Replace.

(4LF) housing area 1.0.
Piston ring - 22.5

inserting area 1.0.
Shaft and Piston ring - 1.68 Replace.

turbine wheel groove width
Bearing journal - 14.254

0.0.
Shaft concentricity - O.Q15
15-6
INTAKE AND EXHAUST - SERVICE STANDARDS,
SPECIAL TOOL
• Unit:mm
Oescript1on Nominal value Limit Correction and remarks

!Basic diameter!
Turbocharger Piston ring groove width of flinger sleeve - 3.3 Replace.

(4LFI
housing clearance
Shaft and turbine wheel end play 0.08 to 0. 152 - Replace.

in axial direction

Clearance between compressor cover and 0.15 - Replace.

compressor wheel in diametrical direction
Clearance between shaft and 0.15 - Replace.

turbine wheel and turbine housing
in diametrical direction
Piston ring end gap in insert 0.03 to 0.18 - Replace.
After cooler check pressure 6D22-TC 195 kPa - Replace.

(2 kgf/cm'I
Dust indicator operating resistance Standard 7.47 ± 0.57 kPa - Replace.

(762 .!: 58 mmH,Ol
Option 6.23 ± 0.57 kPa - Replace.

(635 ± 58 mmH,Ol

0.D. x Pitch Nm (kgfml
mm
Inlet manifold bolt <Except 6D22-TC> MlO x 1.5 35 (3.6)
Exhaust manifold nut M10 x 1.25 41 (4.21
Turbocharger Attaching nut MlO X 1.25 26 (2.7)

attaching nut
Lock nut MlO x 1.25 35 (3.61
Turbocharger Shaft and turbine wheel - 17 to 20

(3LMI attaching nut (1.73 to 2.071
Compressor cover attaching cap screw - 6.9 (0.71
Turbine housing attaching cap screw - 17 (1.7)
Turbocharger Coupling assembly - 5.9 (Q.6) Apply MOL YKOTE

(TD-OB) grease or equivalent
Shaft and turbine wheel lock nut - 20 (2) lo threads
Turbocharger V clamp attaching nut - 11 ( 1.1) Apply MOLYKOTE

(4LF) grease or equivalent
Shaft and turbine wheel lock nut - 27 (2.8) to threads
4. SPECIAL TOOL
Socket MH061242 Removal and installation of exhaust
'5)
manifold mounting nut
Width across
flats 14 85341A

• INTAKE AND EXHAUST - SERVICE PROCEDURES
5.1 REMOVAL AND INSTALLATION OF INTAKE SYSTEM
<6022>
Install the air heater with

the embossed arrow
directed to the inlet
manifold side.
35 Nm
(3.6 kgfm) 3
Earth plate
2 Inlet pipe
3 Air heater
4 Inlet manifold
NOTE:
1. Remove all harnesses before disassembly.
2. Pay attention to the air heater mounting direction.
3. For inspection of air heater, see "Group 16".
84556A
15-8
INTAKE AND EXHAUST - SERVICE PROCEDURES
<6D22-T>
5
�� .
35 Nm ��nstall
� the air heater with the
(3.6 kgfml embossed arrow directed to
downward.
1 Earth plate
2 Inlet pipe
3 Rubber hose
4 Air heater
5 Inlet manifold
NOTE:
2. Pay attention to air heater mounting direction.
3. For inspection of air heater, see "Groupe 16".
84557A
15-9
<6022-TC>
Install the air heater with

the embossed arrow directed
to the cylinder head side.
1 Inlet pipe
2 Air escape pipe
3 Water inlet pipe
4 Water return pipe
5 After cooler assembly
6 Earth plate
7 Air heater
8 Rubber hose
NOTE:
2. Pay attention to air heater mounting direction.
3. For inspection of air heater, see "Groupe 16".
84558A
15-10
Bl
5.2 REMOVAL AND INSTALLATION OF EXHAUST SYSTEM
<6D22>
Stamped mark "TOP"
To be installed with
stamped mark toward
manifold.
Seal ring
t
Ends
• Install the seal ring so that the ends of each ring are positioned
180° apart from those of the other.
• Install the expansion ring so that any one of its crests is not
positioned at the seal ring ends.
1 Heat insulator
2 Exhaust manifold
3 Seal ring
4 Expansion ring
5 Center exhaust manifold
B4560A
The exhaust manifold mounting nuts should be

tightened to the specified torque through use of
Socket (special tool: MH061242).
15-11
<6D22-T, TC>
4
35 Nm
(3.6 kgfml
�
26 Nm
----®L.
(2.1 kgfml
41 Nm
�
(4.2 kgfml ---......._
dt'
ic o_. (�1
--
[t]0�-- --- �',
J�� - �"-\1- � --r-\V tf}}
------ ------ �� Expansion ring
J\
Stamped mark "TOP" 0
Seal ring
To be installed with
stamped mark toward manifold. i E!ds
:;i • Install the seal ring so that the ends of each ring are positioned
\(
180° apart from those of the other.
• Install the expansion r.ing so that any one of its crests is not
positioned at the seal ring ends.
Heat insulator
2 Oil pipe
3 Oil return pipe
4 Turbocharger
5 Exhaust manifold
6 Seal ring
7 Expansion ring
8 Center exhaust manifold
84561A
The exhaust manifold mounting nuts should be

tightened to the specified torque through use of
Socket (special tool: MH061242l.
15-12
5.3
AIR CLEANER
m
5.3.1 Disassembly and Reassembly
<Single element type>

Assembling direction mark
Clarnp
Dust indicator
Baffle
nut
Air cleaner body Gasket Clip
Element
Wing nut
Cover
Air cleaner body
<Double element type> Dust cup
Outer
Air cleaner body
Dust
Assembling
nut Baffle direction mark
Wing
nut Clip
nut
Do not remove the inner element when cleaning the outer

Vacuator valve element.
E0158
15-13
•
5.3.2
Inspection and Cleaning (3) Inspection of Element

(1) When there is Dry Dust on the Element
C7209A
C7207A
After the element has been cleaned, put an electric
If there is dry dust on the element, clean the dust by lamp inside the element to check for damage and pin
blowing 685 kPa (7 kgf/cm 2 ) or lower compressed air holes. If there are thin portions in the filter paper,
against the element. replace the element. If the packing on the top surface
Blow the compressed air from inside the element up of the element is broken, replace the packing.
and down along the frills of the filter paper and clean (4) Cleaning of Air Cleaner Body
the whole element evenly. Clean the inside of the air cleaner body and discharge
NOTE: the deposited dust.
1. Do not strike the element or sirike it (5) Inspection of Dust Indicator
against a hard object to loosen the
dust.
2, Do not clean the inner element. Reset button
(2) When there is Moist Dust on the Ele·

ment
If the element is contaminated with moist soot,
'replace it regardless of the specified replacement
frequency. Operating resistance Window (red signal!
NV
7.47 ± 0.57 kPa
(762 ± 58 mmH,O)
NV... Nominal value
6.23 :!. 0.57 kPa
1635 ± 58 mmH,O)
C72108
Start the engine and close the inlet port of air cleaner
gradually to increase negative pressure. If the red
signal is displayed at the dust indicator, or warning
lamp lights for the electric type, the dust indicator is
normal.
NOTE:
Perform this inspection after cleaning or
replacement of the air cleaner element if
the element is heavily clogged.
15-14
5.4 TURBOCHARGER
5.4.1 TD08 Type Turbocharger
(1) Disassembly
'&.
Interference with
turbine wheel, cracks
due to overheat, pitching,
deformation
13
Blade bend and damage,
17 corrosion, marks of interference
15 on back surface
Interference with turbine
wheel, damage
18
Bearing hole surface roughness,
damage, gas corrosion, turbine
side flange deformation
1 Coupling assembly 10 Thrust sleeve
0 Turbine housing 11 Thrust bearing
3 Snap ring assembly 12 Thrust ring
© Compressor cover 13 Shaft and turbine wheel
5 Compressor wheel 14 Piston ring
6 Snap ring 15 Turbine back plate
(j) Insert 16 Bearing
8 Piston ring 17 Snap ring
9 Oil deflector 18 Bearing housing
For parts with an encircled number, refer to Disassembly

Procedure that follows.
C8965B
15-15
•
(c) Removal of compressor cover
Alignment mark
Turbine Compressor cover

housing
Bearing housing 828190 C8982C
(a) Befo�e disassembling the turbocharger, make Remove the compressor cover by tapping it with a
alignment marks on the compressor cover, bearing plastic hammer with the snap ring loosened.
housing, and turbine housing so that they can be NOTE:
properly reassembled. Use care not to damage the compressor
(b) Removal of turbine housing wheel during the removal procedure.
(d) Removal of compressor wheel
Coupling assembly
�
Bearing housing
Turbine housing
Turbine housing
839468
82820C
To remove the turbine housing, remove the coupling
assembly and tap the housing with a plastic hammer 1) Fit the bearing housing into the turbine housing
or similar tool to prevent damage to it. which is clamped in a vise.
NOTE:
The turbine wheel blades are easy to bend.
Use care not to damage them.
15-16
(e) Remove the insert.
C8983C
88978A
2) While holding the shaft and turbine wheel boss,
remove the lock nut that secures the compressor 1) Remove the snap ring.
wheel.
NOTE:
Retain the snap ring by hand to prevent it
from springing out when slipping off the
snap ring pliers.
C8984A
3) Remove the compressor wheel.
C8985B
2) Fit the tip of a screwdriver into the portion of the

insert shown and carefully remove it from the bearing
housing.
15-17
• INTAKE AND EXHAUST - SERVICE PROCEDURES
(2) Cleaning and Inspection
Piston ring end gap

NV 0.05 to 0.25
Clean Clean
0.0.
L 20.382
1.0.
L
Clean
Bearing journal 0.0.

L 11.996
Shaft concentricity
L 0.015
(total gauge reading)
Clean
Bearing inserting portion 1.0.

L 20.506
NV Nominal Value
L Limit
C8988B
15-18
(a) Cleaning
Turbocharger manufacturers use a blasting equip
ment for cleaning parts at their workshops. As an
alternative effective method for overhaul at the
dealer's workshop, use the following procedures.
When a commercially available neutral detergent is
used for cleaning, make sure that it does not contain
corrosive component.
1) Before cleaning, visually check the condition of
the parts. Check for burns, wear, etc. which could not
be identified after washing.
C8991A
4) Clean deposits, using a plastic scraper or bristle

brush.
NOTE:
Use care to prevent damage to parts.
C8989A
2) Immerse all the parts in a non-inflammable sol

vent (Daido kagaku Kogyo's Dai Cleaner T-30 or
equivalent) to clean oily contamination.
C8990A
5) Blow clean compressed air again against the

entire internal and external surfaces.
NOTE:
The bearing housing and turbine wheel
shaft should be re-immersed in a non
inflammable detergent after Step 4). After
deposits have been removed, blow com
pressed air.
C8990A
3) Blow clean compressed air against the entire

internal and external surfaces.
15-19
2) Measure I.D., O.D., and length of the bearing. If

the measured values exceed the service limit, replace
the bearing.
B9036A
6) To prevent rust, apply engine oil to the entire

internal and external surfaces of the bearing housing, C8913A
turbine housing and turbine backing plate and the
shaft portion of the shaft and turbine wheel. 3) Measure the shaft and turbine wheel journal
(b) Inspection diameter. If the measured diameter is less than the
limit, replace the shaft and turbine wheel.
C9034A
C8915A
1) If the bearing hole diameter and piston ring hole

diameter are beyond the limit, replace the bearing 4) Set a dial indicator beside the threaded portion of
housing. the shaft to measure the concentricity.
If the deflection of the dial indicator is beyond the
limit, replace the turbine wheel shaft.
Measuring Measuring
direction position NOTE:
Do not correct but replace a bent shaft.
C8971A
15-20
5) Insert
m
Insert a new piston ring securely in the bore in the
Insert
Ends
insert and measure the end gap of the piston ring.
ring If the end gap is out of specification, replace the
insert.
B0467A
(3) Reassembly
11 I Apply engine oil.

5.9 Nm
10.6 kgfm)
Apply MOL YKOTE grease or equivalent

to the seat and threads in lock nut.
15
J Apply engine oil.
20 Nm
(2 kgfm)
Shaft and turbine wheel to
Apply MOLYKOTE grease turbine back plate clearance
or equivalent to threads. NV 0.48 to 0.92
Apply engine oil.

I a
Compressor wheel to
compressor cover 4
clearance
NV 0.08 to 0.28
NV ... Nominal Value -o1f------+----1 Shaft and turbine wheel to

turbine housing clearance
NV 0.39 to 1.0
Assembly sequence
18->17->16->15 13
} 12 ->11
Shaft and turbine wheel
14->13
� axial play
_ (6)-->@->�)--->3->(2)->1 NV 0.075 to 0.155
9-> 10->(a_r-' 7
For parts with an encircled number, refer to Reassembly

Procedure that follows. C8974B
15-21
•
(b) Installation of snap ring

(a) Installation of piston ring
Thrust sleeve
Oil deflector C8978C
Piston ring
B0472C
Set the thrust sleeve into the oil deflector, and install
the piston ring.
NOTE:
1. When mounting piston ring to the thrust
sleeve, ensure that the ring is not ex•
panded and ring ends are not twisted.
2. If the piston ring is to be replaced with a
new one, be sure to replace also the
thrust sleeve and shaft and turbine Install the snap ring to the bearing housing with its
wheel with new ones. taper up.
After installation, using a screwdriver drive the snap
ring into the groove in the bearing housing by
hummering.
NOTE:
1. Retain the snap ring by hand to prevent
it from springing out when slipping off
the snap ring pliers.
2. Special care must be exercised, when
tapping the snap ring into position, to
prevent damage to the bearing housing
by the screwdriver.
15-22
(c) Measurement of clearance between

m
2) Coat threads in the shaft and turbine wheel with
shaft and turbine wheel and turbine molybdenum disulfide base grease (NLGI No.2) Li
housing soap and mount the compressor wheel onto the shaft.
3) Holding the boss on the turbine wheel side,
tighten the compressor wheel lock nut to the specified
torque.
NOTE:
t
Set the bearing housing carefully to pre•
Turbine wheel vent damage on the turbine wheel blades.
�shaft
Shaft and
turbine wheel
Set the dial gauge on the shaft and turbine wheel end.
Move the shaft and turbine wheel in the axial
C9001B
t
direction and measure the clearance between the
turbine wheel and turbine housing.
If the clearance is out of specification, disassemble C9003B
and isolate the cause.
(d) Installation of compressor wheel (e) Set a dial gauge on the shaft and turbine wheel
end.
With compressor wheel moved in the axial direction,
measure the end play. If the play is out of specifica
tion, disassemble and check to locate the cause.
Bearing housing
Turbine housing
B2820C
Lock nut
-----
'-@
C9004B
(f) With the turbine housing removed from the

bearing housing and compressor cover installed,
measure the following.
C9002C
1) Holding the turbine housing in a vice, set the

turbine wheel side of the bearing housing into the
turbine housing.
15-23
m INTAKE AND EXHAUST - SERVICE PROCEDURES
Using two thickness gauges, measure the clearance (h) Installation of turbine housing and com
between the turbine back plate and turbine wheel pressor cover
back surface. If the clearance is out of specification,
disassemble and check to locate the cause.
NOTE:
Be sure to use two thickness gauges and
take measurement at the tip of the blades. Alignment mark
(g) Shaft and turbine wheel to compressor

cover clearance
Compressor cover
Snap ring
Coupling assembly
B2819E
Make sure that the alignment marks are aligned and

secure the parts with the coupling assembly and snap
ring.
Install the coupling assembly by the following proce
dures.
B4468A
1) Tighten the coupling assembly to specified tor
que.
Check by the following procedures. 2) Hammer the coupling assembly all around.
3) Tighten again the coupling assembly to specified
1) Move up and down the compressor wheel to
torque.
measure runout (R)
4) After reassembly, turn the turbine wheel and
NOTE: compressor wheel by hand and check for smooth
Do not measure runout by turning the rotation.
compressor wheel. If the wheels turn heavily, or bind, disassemble, and
2) Measure compressor cover inside diameter (D) locate the cause of trouble.
'and compressor wheel outside diameter (d) at places
indicated in the illustration.
3) Calculate the clearance by the equation given
below.
If it is out of specification, disassemble and check
again.
Clearance 1/2(0 - d - R)
15-24
5.4.2
4LF Type Turbocharger

m
See pages describing the TD08 turbocharger for
disassembly, inspection, cleaning and reassembly
procedures.
(1) Disassembly
covering layer,
Interference with
turbine wheel, damage
24
\ 20 7
Interference with turbine

wheel, cracks due to
overheat, pitching,
6 deformation
Blade bend and damage,
corrosion, marks of
22 interference on back surface
Worn beyond covering layer,

deep scratch
Bearing hole surface

roughness, breakage, gas
25 corrosion, turbine-end
<Disassembly sequence> flange deformation
1 V-clamp 10 Piston ring 18 Bearing

2 Turbine housing 11 Flinger sleeve @ 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 @ Snap ring 25 Bearing housing
9 Insert
For parts with an encircled number, refer to Disassembly Procedure
that follows.
NOTE:
1. Make alignment marks to clarify the positional rela 2. The compressor wheel and turbine wheel blades are
tionships among the compressor cover, bearing hous• easily bent. Use care not to allow them to fall and not
ing and turbine housing before disassembly. to strike them.
3. Do not remove the two pins of the bearing housing.
84265A
Bl INTAKE AND EXHAUST - SERVICE PROCEDURES
Disassembly Procedure When the snap ring holding the bearing in position is
to be removed, use pliers (tip diameter 1 mm) to
prevent damage to the insid.e of the bearing housing.
Pliers
B4266A
Clean Piston ring end gap
,al��
(New piston ring to
j
be used for measurement!
!:>'
NV O o O
Clean
.... ·. �,£:t\
�
L 3.3
Clean
�
Bearing journal potion 0.0.
L 14.254
Piston ring groove width (clearance

when new piston ring is mounted)
L 1.68
Shaft runout
(total indicator reading)
0.015
Bearing inserting portion 1.0. NOTE:

L 22.268
t---- ---
- -----i-Before cleaning, visually check the parts for b urnt or
-
Piston ring inserting portion 1.0. rubbed marks which would be hard to find out after
L 22.5 cleaning.
B4267A
15-26
(a) Measurement
of piston ring groove (b) Measurement of flinger sleeve groove

m
width width
New
piston ring
C8914A C8916A
Install a new'piston ring in the piston ring groove and Measure the piston ring groove width of the flinger
measure the clearance. sleeve.
If the reading is more than the limit, replace the shaft If the reading is more than the limit, replace the
and turbine wheel. flinger sleeve.
15-27
•
(3) Reassembly
Clearance between compressor wheel 11 Nm

and compressor cover (1.1 kgfm)
in diametrical direction Clearance between shaft
NV 0.15 Molykote grease or equivalent
to be applied to screw and and turbine wheel and
Engine oil to be seating surface turbine housing
applied to thrust side NV 0.84 to 1.75
3 1
Flat side to be
directed toward
�
2 Grease to be applied
to flange surface
8
7
Engine oil
to be applied
27 Nm Shaft and turbine wheel

(2.8 kgfm) play in axial direction
NV 0.08 to 0.152
Molykote grea:se:T---+-�c=-a�;;f
or equivalent
to be applied to Clearance between shaft
screw and and turbine wheel and
seating surface turbine back plate
NV 0.43 to 1.05
10
Engine oil
to be applied
faced
13
Clearance between shaft and
4 turbine wheel and turbine
Grease to be applied housing in diametrical direction
to flange area NV 0.15
<Assembly sequence>
25--,24->�3)--22->21->®)-+@
-,18----, 17'
� 1 &-.15--,(11)
NOTE:
&-.7
1. The piston ring should always be replaced with a new
->13->12
one. J 9--> 8->5-> 4-, 3->2-> 1
Since it is easily broken, do not open it more than 11->10
necessary.
2. Apply engine oil to all sliding surfaces before installa· On parts marked o, refer to the assembly procedure described
below.
tion.
3. When the compressor cover and turbine housing are
installed, make sure that their alignment marks are in
alignment with the marks on the bearing housing.
84268A
15-28
Assembly Procedure
(c) Measuring clearances between shaft

m
(a) Installing snap rings and turbine wheel and turbine housing,
and compressor wheel and compressor
cover in diametrical direction
Turbine housing
Compressor
�Turbine wheel
wheel
84266A
C8925A
Use pliers (tip diameter 1 mm) in installing snap rings.
NOTE:
Measure each clearance with a thickness gauge to
Install each snap ring with its round side
check that it is within the nominal value.
toward the bearing.
NOTE:
(b) Installing thrust bearing
When a clearance is to be measured, press
the shaft in the axial direction to minimize
Locating pin
the clearance.
Locating hole
To install the thrust bearing, apply engine oil to the

thrust receiving side. Press it in with its locating hole
in alignment with the locating pin of the bearing
housing until it is in flat contact with the bearing
housing.
15-29
•
5.4.3
3LM Type Turbocharger

See pages describing the TD08 turbocharger for
disassembly, inspection, cleaning and reassembly
procedures.
(1) Disassembly
G) Turbine housing 6 Flinger sleeve 11 Bearing housing
0 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 with an encircled number, refer to Disassembly Procedure that

follows.
NOTE:
1. Before disassembly, make alignment marks to indi·
cate the positional relationships among the compress
or cover, bearing housing and turbine housing.
2. The compressor wheel and turbine wheel blades are
easily bent. Use care not to allow them to fall and not
to strike them.
3. Do not remove the two pins of the bearing housing.
B9029A
15-30
m
\"•·
89048A
89031A
(b) Remove the compressor cover.
(a) Remove the turbine housing.
NOTE:
Do not drop and strike the compressor
wheel and turbine wheel, as their blades
are readily bent.
15-31
m INTAKE AND EXHAUST - SERVICE PROCEDURES

L ... Limit
Clean
1.0. (to be measured in

terms of end gap of
new piston ring
NV 0.015 to 0.18
·clean
Clean
Clean
Clean
Bearing journal 0.0.
L 11.18
Shaft concentricity
L 0.015
(total gauge reading)
Clean
Bearing hole diameter
L 19.06
NOTE:
The parts may be cleaned by use of a blast
equipment or any other effective methods, but a non·
corrosive neutral detergent should be used.
890348
15-32
(3) Reassembly
m
Bend lock washer. Shaft and turbine wheel to
NV ... Nominal Value 17 Nm 11.7 kqfml turbine housing clearance
NV 0.53 to 1.04
12
Shaft and turbine wheel
Non-chamfered side axial play
toward insert NV 0.05 to 0.13
17 to 20 Nm 1
11.73 to 2.07 kgfml
Turbine backing plate to
shaft and turbine wheel clearance
/ I NV 0.74 to 1.55
/ I
/,t,, '"''"' "''
<Assembly sequence>
Gasket
11 - 14 - 13 - 12 - 15 - (H! - 9 - 8
15 5 - 7 - 6 ]-
Apply engine oil.

10 - 4 -+ 3 ____. \21 -+ (1 J
2 Bronze side toward
Apply grease or oil compressor wheel For parts with an encircled number,
to socket portion. refer to Reassembly Procedure that follows.
NOTE:
1. The piston ring should always be replaced with a new
one. Since it is easily broken, do not open it more than
necessary.
2. Apply engine oil to all sliding surfaces before installa•
lion.
3. When the compressor cover and turbine housing are
installed, make sure that their alignment marks are in
alignment with the marks on the bearing housing.
B9037A
15-33
m
Locating hole
17 Nm
(1.7 kgfm)
B9031A
B9041A
(c) Install the turbine housing tightening the bolts to
(al Apply engine oil to both sides of the thrust the specified torque.
bearing and thrust ring before assembling them on NOTE:
the turbine wheel shaft. Then install the oil deflector. Apply an anti-seizure agent to the cap
NOTE: screw.
Install the thrust bearing with the bronze
side up.
6.9 Nm
(0.7 kgfm)
B9048A
(bl Install the compressor cover by tightening the

bolts to the specified torque.
15-34
5.5 AFTER COOLER

5.5.1 Disassembly, Inspection and Reassembly
2
Connector
2 Cover
3 Plate
Damage, water leaks,
4 Core assembly fin contamination,
4 scale and rust
5 Inlet manifold
inside core
5
C9305B
5.5.2 Air-pressure Test

Conduct the air-pressure test to check for water leaks
due to damaged core. To check, apply an air pressure
of 195 kPa (2 kgf/cm2 ) to the core. Replace the core if it
is leaking air or otherwise defective.
NOTE:
Never apply pressure over specification.
15-35
•
6. TROUBLESHOOTING
INTAKE AND EXHAUST - TROUBLESHOOTING
Low output Jnsutticient intake air

• Loaded air cleaner element Clean
• Air suction (with dust and other foreign matted

from intake system Repair
• Defective turbocharger
• Turbocharger rotation failure
• Seized bearing Replace
• Carbon deposit on turbine wheel Clean
• Turbine wheel and turbine back plate interfering Check
• Turbine wheel and turbine housing interfering Check
• Bent shaft and turbine wheel Replace
• Compressor wheel and compressor cover interfering Check
• Seized thrust sleeve and/or thrust bearing Replace
• Incorrect sliding between inside parts Clean, check

due to clogged lubricating oil pipe
• Damaged compressor wheel Replace
• Damaged turbine wheel Replace
Low exhaust efficiency

• Deformed front pipe, muffler and/or tail pipe Replace
(large exhaust resistance)
• Defective turbocharger
• Turbocharger rotation failure (See above) Check
• Damaged turbine wheel Replace
Whitish and Incorrect injection timing Adjust Group 13

much exhaust
gas Low compression pressure Check Group 11
Low quality fuel Replace Group 13
Defective turbocharger
• Oil leaks due to worn piston ring, and/or insert Replace
• Damaged oil seal due to clogged oil return pipe Replace
Dark and much Loaded air cleaner element Clean

exhaust gas
Trouble in engine proper Check Group 11
Nonuniform fuel injection amount to cylinders Adjust Group 13
Abnormal noise Poor connection of intake and exhaust systems Correct

and/or vibra-
tion from Defromed front pipe, muffler or tail pipe !large exhaust resistance) Replace
intake and
exhaust system Defective turbocharger (See above) Check
15-36
•
ENGINE ELECTRICAL
CONTENTS
1. GENER.AL ...................................... 2 5.3 30A, 40A, 80A ALTERNATOR ..... 34

1.1 STARTER ...................... "............ 3 5.3.1 Removal and Installation ••..•.• 34
1.2 ALTERNATOR .....•..••.•••••••..•....... 5 5.3.2 Disassembly ........................... 35
1.3 SAFETY RELAY •••••••••.........••••..•. 8 5.3.3 Inspection •••....•........••.••••...•••• 38
1.4 REGULATOR .•.•••••••••••.•.•.•......•.•• 9 5.3.4 Reassembly ••••••.•.•....•.••••..•..•.. 44
1.5 INTAKE AIRHEATER ••.........•••••. 10 5.3.5 Inspection and Adjustment
1.6 AUTOMATIC STOP DEVICE 10 after Installation •.....•...•••••••••• 46
2. SPECIFICATIONS •••••••••••.•••......••.•• 13 5.4 60A ALTERNATOR ..................... 49
3. SERVICE STANDARDS .................. 14 5.4.1 Removal and Installation ••••••• 49
3.1 SERVICE STANDARD TABLE ..... 14 5.4.2 Disassembly •.•.••....•.••.••.••••••••• 49
3.2 TIGHTENING TORQUE TABLE ... 16 5.4.3 Inspection .............................. 50
4. SPECIAL TOOL .............................. 17 5.4.4 Reassembly •••••••••••..•.••••.•.•••••• 51
5. SERVICE PROCEDURES ................ 17 5.4.5 Inspection and Adjustment
5.1 STARTER ................................... 17 after Reassembly ••••.•.•..•.••••••• 52
5.1.1 Removal and Installation ••••••• 17 5.5 SAFETY RELAY
5.1.2 Disassembly •••••••••••.•...•.•.•.....• 18 [Model R8T30171] ...........•••••••••• 53
5.1.3 Inspection ...••...•.•.•.•••.•.•••••••••. 22 5.6 REGULATOR
5.1.4 Reassembly •••••••••.••.•.•.......••••• 28 [Model R7T01071] ••••••••••.••.•...••• 54
5.1.5 Inspection and Adjustment 5.7 PREHEATER .............................. 54
after Reassembly .•••••••..••••••••• 32 5.7.1 Intake AirHeater .....••••••••••••••• 54
5.2 STARTER RELAY ....................... 34 5.7 .2 Heater Relay .......................... 55
5.8 AUTOMATIC STOP DEVICE ....... 55
5.8.1 Energize.to-stop Type ...•.••••••• 55
5.8.2 Energize-to-run Type ••••••..•.•••• 59
16-1
ENGINE ELECTRICAL - GENERAL
1. GENERAL
Alternator Starter relay

60
Air heater
Heater relay indicator
<Except 6022-TC>
15
---,_,__
p
lO
Safety relay
(6022-TC)
Oil bypass Oil bypass

alarm alarm lamp
15
60
0.85
Fuse
''
5
,--1
Ammeter
·c&·
I • '
i Battery
switch
- +
0.85 -=... Battery
0.85 --�
Oil pressure Thermometer

gauge l
lO lO
LD LO�
�CX)
0 00
Oil pressure
unit
� _v Thermometer Code size
l 0.85
_5 _
0.85 mm2 or more
5 mm' or more
L_�_j
.1.§_ 15 mm2 or more
60 60 mm2 or more
B1646F
16-2
1.1 Starter (2) Overrunning Clutch
M;1�pH:{!i;
switch
Outer
race Roller Pinion
Field coil
Armature
Pole
Yoke
Pinion �ear B3711A B3703A
The starter is a reduction starter with a built-in

Magnetic
reduction gear. Its motor has been downsized with switch attraction
even higher speed capability.
Major components of the starter are: motor section
generating power; the overrunning clutch section
transmitting armature torque and preventing the
engine from overrunning after startup; the magnetic
switch section which puts the pinion in mesh with the
ring gear and feeds load current into the motor; and,
the reduction gear section reducing armature speeds
and transmitting torque to the pinion.
'Ring gear
(1) Reduction Gear Section B3712A
The overrunning clutch is of roller type.

Overrunning clutch
Each roller is set in the wedge-shaped groove pro
vided by the outer and inner races (pinion) and is
pressed by a spring.
The roller is pressed against the narrower side of the
groove by the spring transmitting outer race rotation
to the pinion by its wedge action. On the other hand,
no torque is transmitted from the pinion as the roller
moves to the wider side releasing the wedge action.
B3702A
The end of the armature shaft is shaped as a gear and

is in mesh with the internal gear. After reduction by
the internal gears, the torque is multiplied several
times and is transmitted to the pinion.
16-3
(3) Operation
Starter switch
Starter relay
Starter relay
Plunger
Plunger
Pinion
Pinion
Ring gear
Ring gear
837098
837088
When the pinion comes into complete mesh with the
While the starter switch is ON, current flows from the ring gear, the contact "P1" closes and the large
terminal "SW" of the starter relay to the terminal "L" current of the battery directly flows to the motor
and closes the contact "P2". section to turn the pinion powerfully.
When the contact "P2" closes, current from the In this condition, no current flows to the pull-in coil.
battery flows from the terminal "S" of the magnetic The plunger is retained by the holding coil alone.
switch to the pull-in coil "P" and holding coil " H".
Furthermore, the current that has decreased flows
from the terminal "M" to the motor section.
The plunger, attracted by the magnetic flux of the
pull-in coil and holding coil, closes the contact "P,"
and simultaneously pushes out the pinion turning
slowly on weak current.
16-4
� - ----·------�--
-- - - - - - - - -
� 1.2 ALTERNATOR
( 1 ) 30A, 40A, 80A Alternator
Starter switch
kaj
SW
.--<CS,r>--1� ;�
� -
I
�
- L
Starter relay
,,
82976A
The alternator is a brush type in which a current flows

from the brushes through the slip ring to the field coil
in the rotor.
Ring gear Major components include: the rotor (field coil) that
generates magnetic field; the sator that generates
electromotive force; the rectifier that rectifiers elec
83710A
tromotive force so generated; the regulator that
keeps generated voltage constant.
When the starter switch is set to OFF, the contact
point P2 opens. (a) Rotor
The moment the starter switch is opened, the P1 is
still in closed position and the battery current flows
from the B terminal to the pull-in coil (p) and holding
coil (H). Slip rings
Since the direction of current that flows is reverse, the
magnetic fluxes cancel each other, and the return
spring pushes the plunger back to its original posi
tion. At the same time, the contact point P1 opens, so
the current to the motor section is cut off.
Rotor core
B2702D
When the rotor is driven by the pulley rotation, a

current flows from the brushes, through the slip ring,
to the field coil. The rotor core tabs then become
magnetic poles.
16-5
•
(b) Stator
(d) Regulator
Stator core
Brush B2708A
B2703A
The regulator alters the strength of the field coil field
to stabilize output power which varies with engine
Togethe� with the rotor core, the stator core forms the
speed fluctuations.
magnetic flux path. The magnetic flux lines in the
The regulator is integral with the brush holder. The
stator core are affected by the passage of the rotor
assembly combines the IC regulator, the brushes and
core field and generate electricity.
the brush springs.
(c) Rectifier
(e) Charging circuit
1) Setting the starter switch to ON
Alternator
B2704A
The rectifier mainly consists of 3 diode trios, 6 diodes

and 2 heat sinks. It rectifiers the AC stator output to
DC power.
Safety relay or
Each heat sink has the(+) or(-) leads from 3 diodes Battery charge lamp
attached to it, performing full wave rectification for
BR
3-phase AC. OFF Q Q
On the 80A alternator, two of rectifiers of this type are
provided.
I Starter switch I Safety relay or charge lamp ION)
I
Alternator IR terminal) Alternator (L terminal)
I Ground
16-6
2) Starting the engine (2) GOA Alternator
Alternator
I
I
I
I
I
I
I
I
r
I
�-��--<E
l
Battery I
E I
I
Starter switch 82542H B4007C
When the engine is started and the alternator starts The 60A alternator is an open type three-phase
generation so that the voltage at the alternator "B" alternator. The three-phase AC generated in the stator
terminal becomes higher than the battery voltage, the coil is converted into DC by the silicon diodes.
current flows as shown below. A total of 12 diodes (6 on the positive side and 6 on
the negative side) are housed in 6 heat sinks, two in
Alternator each heat sink.
IB terminal!
The alternator generated voltage is controlled by the
regulator.
I Ground I
In this way, battery charge is started and at the same
time, the charge lamp (if provided) goes out.
16-7
1.3 SAFETY RELAY The alternator rpm is detected and when it exceeds
the reference level, the safety relay prevents the
starter from operating even if its switch is accidentally
turned on during engine revolution.
B1453A
Operat�on
Charge lamp Starter switch
Battery
switch
Safety l
relay
P, i Battery
-1..
�arter
+ �:lay
To starter 1
B1454A
(1) When the starter switch is set to ON, current flow (3) When the pulse frequency at terminal "P" ex
from the starter relay to terminal "S" and to terminal ceeds the specified value, continuity between termin
"E" of the safety relay, closing contact P1. The charge als "S" and "E" is lost. Then, the starter does not
lamp also illuminates if provided. operate even if the starter switch is set to ON while
(2) As the starter runs and the engine starts running, the engine is running.
pulses of frequency 1110th of the alternator speed
appear at terminal "P" of the alternator. The charge
lamp goes out.
16-8
1.4 REGULATOR (Model R7T01071)
Its functions include:

•
(1) Voltage regulator
Maintains voltage generated by the generator con
stant
(2) Safety relay
Keeps the starter circuit in OFF state even with the
starter switch turned on during operation of engine.
(3) Field relay
IG F L Minimizes discharge current to the alternator field coil
r/}:t:I �
i '
even when the battery switch is left closed.
Connections of the alternator to the regulator are
I
A N E B4401B shown below. Following description of operations is
keyed to this figure.
This regulator is combined with the 60A alternator.
Operation of Regulator
Safety relay T
ransistor
Alternator Regulator
I
I
l__
I
__ j
Pilot lamp
'-----+- ---'>----+-----"----'
-
B1891A
(1) The battery switch in ON position causes field power, causing a current to flow in the coil VC1 in the
current to flow in the circuit as follows: following sequence:
Battery - Battery switch - Regulator IG terminal - Resistor R, - Voltage Alternator N terminal -• Regulator N terminal - Coil VC, - Ground
regulator K terminal - Voltage regulator F terminal - Alternator F terminal
- Field coil - Ground
As the coil VC1 is energized, the contact P1 is opened.
(2) When the starter switch is set to ON, the starter In this state, setting the starter switch to ON with the
relay coil is energized with its contact closed. When engine in operation leaves the starter inoperative.
the starter cranks the engine, the alternator generates
16-9
• ENGINE ..ELECTRICAL - GENERAL
(3) While the engine is in operation, field current 1.5 INTAKE AIR HEATER
flows in the following circuits, with alternator output
voltage controlled by the voltage regulator.
Alternator A terminal - Regulator A terminal - Contact P2 -- Voltage Starter
regulator K terminal - Transistor - Regulator F terminal - Alternator F switch Air heater
terminal - Field coil -Ground
B R1 ACC R2 C
OFF
If the transistor remains off too long, the alternator N
terminal output is decreased and the coil VC1 loses its HEAT
magnetic force to such an extent that the contact P2 ON
may be opened or P1 closed. The circuit of coil VC2

and resistor R2 keeps P2 closed ·and P1 open in such a
r
case.
Air heat er
t
indicator
y
�!\ t��
_ �
� Io �11
�---o_, �I ____,!
Battery
D8803C
The intake air heater is an electric heater which heats

the intake air to facilitate engine starting.
Place the starter switch to HEAT position to operate
the heater. If current is supplied for about 40 to 60
seconds by keeping the starter switch at HEAT
position, the temperature of the intake air heater will
exceed 800°C.
The intake air heater circuit has an indicator to let the
driver recognize the heat condition. For safety's sake,
a fuse is provided in the heater relay.
1.6 AUTOMATIC STOP DEVICE

If the coolant temperature rises or the oil pressure
falls while the engine is running, this device operates
the stop lever of the injection pump governor to cut
fuel supply and automatically stops the engine.
16-10
(1) Energize-to-stop Type
•
,-·--·-·
-··------------- - - --------�
Solenoid relay
.
- ·-- -
- -
-
i
02
Do
RB
--- -- --. --- --- ·-. - ---·---

� Alternator
L
Thermo switch®-i
---<k-�,: �
Battery switch
B4926C
(a) Start circuit 4) In the condition of the above item 3), the oil
1) When the battery switch is placed at "ON", pressure rises as the engine speed increases, and the
current flows from the solenoid relay (B) to the RY coil contact of the oil pressure switch is opened and no
and applies the voltage to the collectors of TR4 and voltage applied from R4 to TR1. In this condition, the
TRs but RY does not operate, as there is no input to alternator voltage is applied up to the base of TR1
the base. while the engine is running.
2) Current also flows from the oil pressure switch to (b) Automatic sto·p circuit
the solenoid relay (W) to R4 to Rs and applies the When the thermo switch and oil pressure switch
voltage to the base of TR3. When the voltage is detect an abnormal condition, the circuit operates as
applied to the base of TR3, current flow from R6 to C follows:
and E of TR3 to the ground, and RY does not operate,
1) Solenoid relay @ -• D1 C2 - Ground
as there is no input to TR4 and TRs of the stop circuit. T
L------ VR1 - Base of TR• -
[R6
3) The engine starts, and a voltage of 24V or more is Base of TRs - Ra- Ground
applied from the terminal "L" of the alternator • R• C andEof TR, - Base of TR2 - Ground
r
through VR1 to ZD1 (Zener voltage 24V), and charge L---�• CandEofTR2 _j
begins with the time constant (Oil pressure timer)
determined by VR1 and C1. (At this point the engine 2) Solenoid relay® - RY coil - C and E of TR• and TRs - Ra - Ground
oil pressure increases beyond the specified value and

the engine enters the operating state.) The charge
voltage passes through R2. If it becomes higher than
the level of the emitter of TR1, current flows from R4
to C and E of TR1 and biases TR2. TR2 passes current
from R4 to C and E of TR2 and to the ground, and the
circuit from Rs to base of TR3 is caused to be OFF. (Oil
pressure switch circuit opened)
16-11
•
3)
Thus RY contacts close, the solenoid operates, (c) Pushbutton stop

and the engine stops. When the engine stops, the To stop the engine during operation, operate the stop
alternator voltage goes out. At the same time, the switch, and the stop operation is performed as at the
stop timer made up of C2 and VR7 holds the solenoid. time of an automatic stop. (The engine stops regard
less of whether the alternator voltage is available.)
(2) Energize-to-run Type
Solenoid relay
\....----�
RY
Oil pressure switch Thermo switch
Stop DJ
switch
01
Ro
VR1
Starter switch 849278
(a) Start circuit Starter switch ©� Solenoid relay ® Resistor Ro - Ground

_
Diode OJ - RY holding corl H
[ - Ground
1) When the battery switch is turned ON:
Diode 01 - Capacitor C
Solenoid relay @ - RY pull-in coil P t TR2
TR, collector
collector When the capacitor C is charged, voltage is applied
from VR1 to the base of TR1 actuating TR1.
RY contacts do not operate with no input to the base
As voltage is applied to TR1 collector, TR1 emitter, and
of TR1 and TR2.
to TR2 base, a current flows from TR2 collector to TR2
2) When the starter switch is placed in the START
emitter, resistor R2, and ground, causing the RY
position:
pull-in coil P to close the RY contacts.
16-12
ENGINE ELECTRICAL - GENERAL, SPECIFICATIONS
3) When the RY contacts turn ON: This causes the current to flow from the starter@
Current flows from solenoid relay@ to RY, solenoid switch to oil pressure switch, thermo switch, solenoid
relay©, and the solenoid, activating the solenoid and relay@, RY holding coil H, and to ground, keeping the
starting the engine. RY contacts in ON state.
4) As the engine starts and starter switch is placed in (b) Automatic stop circuit
the ON position, voltage to the solenoid relay® is cut
When the thermo switch and oil pressure switch
off; however, TR1 and TR2 stay ON for approximately
detect an abnormal condition, each switch turns OFF
another 30 seconds by the discharge current of the
and the RY contacts open, deactivating the solenoid
capacitor C. During capacitor C's discharging, the oil
and stopping the engine.
pressure builds up as the engine speed increases,
causing the oil pressure switch to turn ON. (c) Pushbutton stop
To stop the engine during operation, operate the stop
switch, and the stop operation is performed just as
when the automatic stop is performed.
2. SPECIFICATIONS
Item Specification
Voltage - Polarity 24V - (-) ground
Starter Type Front nose electromagnetic push-in type reduction starter
I l
(Mitsubishi Electric
Corp. products! Model M3T95082 M5T50276 M5T50277 M5T50279
Output 24V-5kW 24V-6kW
Reduction Single stage reduction by internal spur gear
I
mechanism
Starter relay Model !Standard) !Option) )Option I

U1T06074 U1T06071 U1T07076
Alternator Type Alternator with built-in Y-connection Alternator with

(Mitsubishi Electric IC regulator alternator with built-in IC
Corp. product! silicon diode regulator
I I I I I
rectifier
Model A2T A2T A2T A4T A4T A4T A4T A6T A6T
72987 72986 73387 57986 57987 65772 65773 75386 75387
Output 24V-30A 24V-40A 24V-60A 24V-80A
Regulator Model R7T01071

(Voltage regulator! - (RFT24HI -
(Safety relay) (RX-021
Safety relay Model R8T30171 - R8T30171
Electric heating type
l
Intake air Type
heater
Capacity x )6022, 22· Tl 16022-TCI
quantity 2 kW x 1 0.3 kW x 6
Heater relay Model U1T06671
Fuse capacity 91 A
16-13
ENGINE ELECTRICAL - SPECIFICATIONS,
SERVICE STANDARDS
Automatic Stop System [Option]
Item Specification
Stop solenoid Type Electro magnetic type

(Nippon Denso Co.,
Ltd. product)
I
Solenoid relay Model !Energize-lo-slop lypel !Energize-to-run typel
(Nikko Denki product) 0-25000-5592 0-25000-6720
Oil pressure switch Type Diaphragm, built-in electric contact
Thermo switch Type Wax type, built-in electric contact
Unit:mm

Starter Commutator 0.0. 38.7 38.1 Replace.

(M3T95082)
Commutator periphery runout 0 to 0.03 0.1 Replace or
correct.
Depth of groove between segments 0.7 to 0.9 0.3 Replace or

correct.
Brush length 17 11 Replace.
Brush spring tension 25 to 34 N 18 N Replace.

(2.5 to 3.5 kgfl (1.8 kgf)
Pinion gap 1 to 3 - Adjust washers.
Gear shah thrust gap 0.1 to 0.5 - Adjust washers.
No-load Voltage 23V - Check.

characteristics
Current 110A or less -
Rotating speed 3 100 rpm or more -
Magnet switch operating voltage 16V or less - Replace.
Starter Commutator 0.0. 43.2 42.2 Replace.

(M5T50276)
(M5T50277l Commutator periphery runout 0 to 0.03 0.1 Replace or
(M5T50279l correct.
Depth of groove between segments 0.7 to 0.9 0.3 Replace or

correct.
Brush spring tension 25 to 34 N 18 N Replace.

(2.5 to 3.5 kgfl (1.8 kgf)
Pinion gap M5T50279 1 to 3 - Adjust washers.
M5T50276 4 to 6
M5T50277
Gear shah thrust gap 0.1 to 0.5 - Adjust washers.
No-load Voltage 23.5V - Check.

characteristics
Current 110A or less -
Rotating speed 3 300 rpm or more -
Magnet switch operating voltage 16V or less - Replace.
16-14
ENGINE ELECTRICAL - SERVICE STANDARDS
Unit:mm
Dcscriplion Nominal vc1luc Limit Correction and

I Basic diameter! remarks
Starter relay Coil resistance 10.4 !! - Replace.
Alternator Slip ring O.D. 40.8 to 41.2 40.4 Replace.

(A2T729871
(A2T729861 Brush spring tension 3.1 to 4.3 N 2 N Replace.
(A2T73387) 10.32 to 0.44 kgfl 10.2 kgfl
30A
Field coil resistance (at 2o·cl Approx. 9 !l - Replace.
Load Terminal voltage 27V - Check.

characteristics
(When cold) Current 17A or more -
Rotating speed I 500 rpm -

characteristics
(When cold) Current 26A or more -
Rotating speed 2 500 rpm -
IC regulator regulated voltage range 28 to 29V - Replace.

(5 000 rpm, 5A or less)

(A4T57986)
(A4T57987) Brush spring tension 3.1 to 4.3 N 2 N Replace.
40A 10.32 to 0.44 kgfi 10.2 kgfl
Field coil resistance (at 2o·cl Approx. 9 0 - Replace.

characteristics
(when cold) Current 26A or more -
Load Terminal voltage 27V -

characteristics
!when cold) Current 37A or more -
IC regulator regulated voltage 28 to 29V - Replace.

(5 000 rpm, 5A or less!

(A6T75386)
(A6T753871 Brush spring tension 3.1 to 4.3 N 2 N Replace.
BOA 10.32 to 0.44 kgfl lo 2 kgfi
°
Field coil resistance (at 20 CI Approx. 7.2 !l - Replace.

characteristics

Load Terminal voltage 27V -
characteristics
(when coldl Current 71A or more -
IC regulator regulated voltage 28 to 29V - Replace.

(5 000 rpm, 5A or lessl
16-15
• ENGINE ELECTRICAL - SERVICE STANDARDS
Unit:mm

Alternator Slip ring 0.0. 4G 45.4 Replace.

(A4T65772)
(A4T65773) Brush spring tension 3.7 N _(0.38 kgfl 2 N Replace.
60A (0.2 kgf)
Field coil resistance !at w·cl Approx. 13 ll - Replace.

characteristics
Regulator Regulated voltage 28 to 29V - Replace.
(R7T01071) (Alternator: 4 000 rpm)
Safety relay Resistance between L and R terminals Aprrox. 200 ll - Replace.

(R8T30171)
Intake Time required for air heater indicator 40 to 60 secs. - Check.

air heater to become red hot
Auto- Energize Solenoid Pointer clearance 1.5 to 2.0 - Replace.

matic -to-stop
stop type Clearance between stop lever and 0.4 to 0.5 -
device external stopper
Holding coil current 5A or less -

Solenoid relay Delay time at starting 13 to 23 - Replace.
(after 28.5V applied to terminal seconds
"B" and "W" and 28.5 V
to terminal "A")
Delay time at stopping 25 to 35 -

(after 24V applied to terminal "B" seconds
and "W" and no voltage to
terminal "A")
Thermo switch actuating temperature 93 to 97°C - Replace.
Oil pressure switch actuating pressure 69 to 98 kPa - Replace.

(O.7 to 1.0 kgf/cm 2l or less
Oil pressure switch Coil resistance 190 to 280 ll - Replace.

relay (24 V)
Min. operating voltage 16V or less -
Energize Solenoid Pointer clearance 1.5 to 2.0 - Replace.
-to-run
type Clearance i:Jetwecn 0.4 to 0.5 -
stop lever and
external stopper
Holding coil current 1A or less -

Solenoid relay delay time 26 to 34 seconds - Replace.
Thermo switch actuating temperature 93 to 97 C

° - Replace.
Oil pressure switch actuating pressure 79 to 118 kPa - Replace.

(0.8 to 1.2 kgf/cm2 ) or less

0.0. X pitch Nm (kgfm)
Imm!
Alternator pulley nut M17 x 1.5 83 to 105 (8.5 to 11)
M20 x 1.5 135 to 160 (13.5 to 16.5)
Alternator shaft nut - 345 to 360 (35 to 37)
16-16
4. SPECIAL TOOL
ENGINE ELECTRICAL - SPECIAL TOOL,
SERVICE PROCEDURES •
Unit:mm
Socket 31191-06100 Removal and installation of starter
Width across flats 17
85021A
5. SERVICE PROCEDURES 5.1 STARTER

NOTE: 5.1.1 Removal and Installation
Whenever removing electrical parts from
the vehicle, be sure to place the battery
switch in OFF position, disconnect the
negative battery cable, and wind the cable
end with vinyl insulation tape.
"-.--@
Starter
C0118A
The starter mounting bolt on the inner side (crankcase

side) can be easily mounted or removed by use of the
special tool, Socket.
16-17
ENGINE ELECTRICAL - SERVICE PROCEDURES
5.1.2 Disassembly
<M3T>
10
9
b.. Gear shaft thrust gap

NV 0.1 to 0.5
8 Rotating
condition
6
Roughened commutator surface,
seizure, ridge wear, worn damaged
gear
I 11
13
Worn arid
damaged gear
0
22
23

0 5 3
4
Deposited brush powder,
uneven wear, movement
1 of brush in holder
Mounted condition of
pole and field coil
CD Yoke assembly @ Overrunning clutch
2 Rear bracket 14 Packing
3 Brush holder 15 Plate
0 Brush spring 16 Spacer
® Brush 17 Lever
6 Armature 18 Collar
*7 Front bearing *19 Gear shaft bearing
*8 Rear bearing @ Ring
® Magnetic switch @ Pinion stopper
10 Center bracket 22 Front bracket
@ Gear bracket * 23 Sleeve bearing
@ Gear shaft
Part marked with * should not be removed unless defects are

evident.
that follows.
B1104B
16-18
<M5T>
,---------- -- --- - - -
--------------- ----------------- -----,
Roughened commutator surface,

Gear shaft thrust
seizure, ridge wear,
gap worn damaged gear
-�-�
NV 0.1 to 0.5 Rotating
condition 6
Rotating
Rotating condition
condition
14
15
2
Worn and
19 damaged gear 3
Deposited brush power,
uneven wear, movement
1 of brush in holder
Mounted condition of
ball and field coil
(i) Yoke assembly (il) Gear bracket

2 Rear bracket @ Gear shaft
3 Brush holder @ Overrunning clutch
© Brush spring 14 Packing
® Brush 15 Lever
6 Armature *16Gear shaft bearing
*7 Front bearing @ Ring
*8 Rear bearing @ Pinion stopper
® Magnetic switch 19 Front bracket
10 Center bracket *20Sleeve bearing
The parts marked • should not be removed unless there is anything

wrong with them.
On parts marked o, refer to the disassembly procedure described
below.
B9071C
16-19
Disassembly Procedure (3) Removal of Overrunning Clutch

The disassembly procedure for the M3T95082 is
described.
The procedure for the other starters is the same.
(1) Removal of Yoke Assembly
Front bracket
assembly
Gear bracket
mounting bolt
829548
Front bracket
Gear bracket
829518
Remove the magnetic switch and separate the front

bracket assembly and yoke assembly.
NOTE:
Do not drop the armature. 829550
Especially when disassembling with the
armature staying in the yoke, do not tilt (al Remove the gear bracket mounting bolt and
the yoke assembly. remove the overrunning clutch, to which the gear
(2) Inspection of Gear Shaft Thrust Gap shaft and gear bracket remain installed, from the front
bracket.
Ring
Ring groove-� ....

...--�
Pinion stopper�
829638
82957A
Before disassembly, set the dial indicator as shown to

measure the thrust gap in the gear shaft. If the (b) Apply a tool pipe to the pinion stopper and
measurement is out of specification, use adjusting hammer the pinion stopper out toward the pinion
washers to obtain correct gap. [For adjustment proce side. Then remove the ring and remove the overrun
dure, refer to Section 5.1.3 (8).) ning clutch.
16-20
NOTE:
Overrunning clutch
t Gear bracket
Gear shaft
Gear shaft
82959A
84141A
(d) Remove the overrunning clutch and gear bracket
When the ring is removed, keep the gear from the gear shaft.
shaft in overhanging condition. (4) Removal of Brush Spring
Ring
�
u-
Brush spring
�'---- Pinion stopper
82958A 82549A
(c) Remove the ring from the ring groove of the gear To remove the brush spring, first release the brush
sh9ft. Remove the pinion stopper from the gear shaft. spring and remove the brush.
16-21
•
5.1.3 Inspection
Item NV L
Commutator M3T 38.7 38.1
outside diameter
M5T 43.2 42.2
Commutator outside 0 to 0.03 0.1

circumference runout
Depth of groove 0.7 to 0.9 0.3

between segments
Short circuit test,

coil ground test,
open circuit test
Coil open circuit test
Melted contacts
Loose contact
0 0
Coil earth test
Open circuit test
Item NV
NV Nominal Value
Limit 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
Inspection Procedure (c) Inspection of commutator

The inspection procedure for the M3T95082 starter is
described. On the other starters, only the differences
are jointly described.
(1) Armature Inspection
(a) Coil short circuit test
07507A
Measure the runout of commutator using a dial gauge

and turning the armature by hand.
If the runout exceeds the limit, correct, ensuring that
the 0.0. limit is not exceeded.
07505A If the commutator surface is rough developing ridge
wear, correct with sandpaper (No. 300 to 500).
Place the armature on a growler tester. Hold a piece of After correction, make sure to check the runout again.
iron in parallel with the armature and slowly turn
(d) Commutator O.D.
armature by hand. If the iron piece is attracted or
vibrates, it means there is a short circuit. Replace the
armature.
(b) Coil ground test
07508A
Measure the commutator 0.0. If the measurement

exceeds the limit, replace the armature.
07506A
Check for continuity across the commutator and shaft

(or core). If there is a continuity, indicating that the
coil is grounded, replace the armature.
16-23
(e) Mica depth between groove lead and brush (+).

If there is no continuity, indicating an open circuit,
replace the yoke assembly.
Mica depth
�
(b) Coil ground test
�
82563A
Measure. the Mica depth of groove between seg

ments. If it does not reach the limit, correct. D75118
Check that there is no continuity between the yoke

and brush (+).
If there is continuity indicating that the coil is
�Segment grounded, check for poor insulation.
� If repair is impossible, replace the yoke assembly.
(3) Inspection of Brush
��F-1&� �\3,qzy�
Good Bad
075098
If the segment indicates the faulty condition as shown

' in the illustration, replace the armature.
(2) Inspection of Field Coil
(a) Coil open circuit test
D7512C
(a) Measure the brush length and, if the measure

ment is less than the limit, replace the brush as an
assembly [(-) side: yoke assembly; (+) side: brush
holder assembly).
(b) If the brush is unevenly worn or develops rough
surfaces, correct with sandpaper (No. 300 to 500).
NOTE:
Correct the brush contact surface to a
075108 curve of the commutator.
Check that there is continuity between the terminal
16-24
(4) Inspection of Brush Spring (6) Inspection of Magnetic Switch
u
(a) Coil open circuit test
<MST>
M terminal
M terminal 8 terminal
/
D7513A S terminal
82586K
Measure the installed load of the brush spring. Using
a new brusli read the load at the moment the spring Check that there is a continuity across "S" and "M"
leaves the brush. terminals.
If the spring tension is below the limit, replace the If there isn't, replace the magnetic switch.
spring.
(5) Brush Holder Insulation Test
82586J
D7514A Check to ensure that there is a continuity across "S"

and ground terminals.
Check to ensure that there is no continuity between If there isn't, replace the magnetic switch.
the ( +) brush holder and (-) holder plate.
If there is continuity, replace the brush holder.
16-25
• ENGINE ELECTRICAL - SERVICE PROCEDURES
(b) Fused contact check (7) Inspection of Overrunning Clutch
M terminal
(or B terminal)
829608
Check th.at there is no continuity across "B" and "M" Install the gear shaft to the overrunning clutch and
terminals. If there is, replace the magnetic switch. check to see if the gear shaft turns smoothly when
(c) Loose contact test turned clockwise (in the drive direction) and locks
when turned counterclockwise.
If any unusual condition is noted, replace the overrun
ning clutch.
(8) Adjustment of Gear Shaft Thrust Gap
825878
Close the contact of the magnetic switch as shown.
829648
If the thrust gap is out of specification, insert the

adjusting washer into the position shown.
[For adjusting procedures, refer to Section 5.1.2 (2).)
M terminal (Adjusting washer: 0.25, 0.5 mm)
(or B terminal)
In this condition, check that there is a continuity

across "B" and "M" terminals. If there isn't, replace
the magnetic switch.
16-26
(9) Replacement of Bearings (b) Replacement of front and rear bearings

(a) Replacement of gear bearing (Removal)
(Removal)
Press down with a press.

Bearing puller
Rear bearing
Armature
Cylindrical
block
B2576B
Bearing 07503A
Using the bearing puller, remove the bearings from
If the bearing of the gear shaft is defective, put a pin the armature.
or bolt in each of the four holes (6 mm in diameter) in (Installation)
the internal gear and press down the bearing out of
position with a press.
(Installation)
Inner ra
�
,'\
,
. .
- .
Install the rear bearing by striking its inner race
B2962A
uniformly with a soft hammer.
Apply a tool pipe to the bearing inner race and

hammer it into position.
/� '"""' rnce
mt��
Pipe
B2578A
Install the front bearing applying a pipe of same

diameter as its inner race and striking it into position.
16-27
•
5.1.4 Reassembly
<M3T>
Apply grease *1.
14
16
18
Apply grease *2.
21 20
8 4 5
2 J Apply grease •2. j
Apply grease *3.

6 1 12 13 22
Apply grease *2. Apply grease *1.
Apply grease *4.

Gear shaft thrust gap
NV 0.1 to 0.5
Assembly sequence
(Recommended greases)
*1: Mystik JT-6 (Kyodo Yushi) '.2�23
or equivalent ([� 19----,@-,(1}-,@-+ _,
*2: MULTEMP MS-2 (Kyodo Yushi)
fT>--->(ll\
or equivalent
*3: MULTEMP HD-2 (Kyodo Yushi)
or equivalent
-16� ,� 1: '�®['
*4: MOLYCOAT AS-19 (Dow Coning) 6---> 7---,8
or equivalent
3___, 5---> 4---> i
For parts with an encircled number, refer to Reassembly

D7548C
16-28
<M5T>
•1 grease to
be applied
9
I
•2 grease to
be applied
17
A thin coat of •3 grease

to be applied to outside
circumference
2
•2 grease to
3 5 6 7 19 13 be applied
•4 grease to Pinion gap

be applied
Model NV
M5T50279 1 to 3
•2 grease to
be applied M5T50276 4 to 6
M5T50277
NV... Nominal Value Gear shaft thrust gap
NV 0.1 to 0.5
(Recommended grea.ses)
*1: Mystik JT-6 (Kyodo Yushi)
or equivalent
*2: MULTEMP MS-2 (Kyodo Yushil
or equivalent <Assembly sequence>
*3: MULTEMP HD-2 (Kyodo Yushi)
or equivalent 11 i._.16-,(i 1,-.:1 J'->lla-1.1 )'->(is
*4: MOLYCOAT AS-19 (Dow Coning) 19-,20�
l____,_
or equivalent
-,1�1�9·· ·
6--, 7-,3 5
2
3-,��11:
For parts with an encircled number, refer to Reassembly Procedure

that follows.
890738
16-29
The reassembly procedure for the M3T95082 starter is
described. On the other starters, only the differences Ring
�
are described.
(1) Reassembly the Gear Shaft, Overrun t--��Gear shaft
Ring groove
ning Clutch, and Gear Bracket in the
Following Way
Overrunning clutch
82968A
Gear bracket
Gear shaft
(c) Fit the ring into the ring groove in the gear shaft.
Grease
(MULTEMP MS-2
or equivalent)
829598
(a) Coat the portions in gear shaft shown with the

specified greases and install the gear bracket and
overrunning clutch over the gear shaft.
82969A
Pinion stopper
(d) Pull hard the pinion gear toward the ring and
IEjJ �....--1��
J> secure it by fitting the ring into the ring groove in
Gear shaft pinion stopper.
(2) Installation of Lever
(a) Collar fixed type <M3T>
Front bracket
82967A
(b) Install the pinion stopper to the gear shaft in the

direction shown.
82956C
Install the lever in the direction shown, together with

the collar, into the front bracket.
16-30
(b) Pin fixed type <MST> (4) Installation of Magnetic Switch

•
Screw
Pin
Grease
B terminal Magnetic switch (Mystik JT-6
or equivalent)
B2956D
B2952C
Insert the lever in the direction shown and mount it
B terminal S terminal
with the pin· from outside the front bracket.
(3) Installation of Overrunning Clutch and
Gear Shaft
Overrunning
clutch
Front bracket
<M3T> <M5T>
B4538B
Coat the portion indicated with the specified grease

and install the magnetic switch to the lever, ensuring
that B terminal faces up for the M3T starter and S
terminal faces up for the M5T starter.
Grease
(Mystik JT-6
or equivalent) B2955E
Overrunning clutch B2970B
Before installing the overrunning clutch and gear

shaft to the front bracket, be sure to apply the
specified greases to the portions indicated.
Upon installation, make sure that the lever is wedged
into the overrunning clutch.
16-31
(5) Installation of Yoke Assembly (a) Wire the reassembled starter as shown above.
(b) Turn ON switches K 1 and K 2 to project the pinion.
(c) Turn OFF switch K 2 to stop pinion from rotating.
Pinion
_ ;,,.:
'r-+'l
':
I I- I
I:
�J - ,l---j ��I
I ::
1
:: :1
I' 11
I J , I I 11
rI I I , ,,
r--
82697A
Apply gr�ase to the splines of the armature before

mounting the yoke assembly to the center bracket. Pinion gap
NOTE:
When the yoke assembly and center brack·
Model Nominal Value
et are mounted, the locating notch should
M3T95082 1 to 3
be aligned with the projection. M5T50279
M5T50276 4 to 6
5.1.5 Inspection and Adjustment after M5T50277
Reassembly
(1) Inspection of Pinion Gap 800540
(d) Measure the axial movement (pinion gap) when

the pinion is pushed lightly toward the armature side.
Switch K2
Battery
Switch K1
S terminal M terminal
16-32
NOTE:
m
1. Use a wire as thick as possible and
Washer secure each connection firmly.
Magnetic switch 2. Apply voltage gradually from OV up to
24V.
(b) Measure the current and rotating speed when the
specified voltage is applied. If the measurement is out
of specification, replace the starter.
Measure the rotating speed by illuminating the pinion
with strobe light.
Nominal values (No-load characteristics)

B2975B
Model Voltage Current Rotating speed

(e) If the measurement is out of specification, in
M3T 23 V 110A or less 3 100 rpm or more
crease or decrease the number of washers used at the
M5T 23.5 V 110A or less 3 300 rpm or more
portion to which magnetic switch is mounted.
Washers
0.25, 0.5, 1.0 mm (c) Gradually increase the voltage from OV and
measure the voltage when the pinion springs out and
(2) Inspection of No-load Characteristics
turns.
and Magnetic Switch Operating Vol·
If the voltage exceeds the specification, replace the
tage
starter.
<M3T>
Ammeter Voltmeter Battery Nominal value 16V or less
(magnetic switch opera! ng voltage)
<MST> 836218
Ammeter Voltmeter Battery
B3621E
(a) Set up a circuit as shown including the ammeter,

voltmeter and battery.
16-33
5.2 STARTER RELAY
�--11
S B
L terminal . mal
l ,.,m
�
"
� :: SW
terminal
U1T07076
L
D8002A
B terminal Coil resistance
S terminal NV 10.4 n (24V, 20° c)
(1) Check for continuity between the SW and L
D8003H
terminals and check to ensure that the coil resistance
<Model \J1T06071>
is up to specification.
(2) Check to ensure that when the battery voltage
(24V) is applied across the SW and L terminals, there
is continuity between the 8 and S terminals.
5.3 JOA, 40A, 80A ALTERNATOR

D8003D
V-belt
B0104H
16-34
5.3.2
Disassembly
•
�--------------·--·- ------------··----- ----------------�
-
2
(1) Rear bracket assembly 11 Spacer
(2_i Stator 12 Rotor assembly
(31 Rectifier 13 Spring
@ Rectifier <80A only> *14 Rear bearing
({l Regulator assembly @ Rotor
® Brush (16) Front bracket assembly
(fl Brush spring 17 Cover
7 Rear bracket 18 Cover
8 Pully and fan *19 Front bearing
@ Pulley (2g Front bracket
@ Fan
Parts marked with • should not be removed unless defects are
evident.
that follows. B3907E
16-35
(1) Separation of Front Bracket Assembly
from Rear Bracket Assembly
D8107H
2. At time of separation, use care not to

lose the spring fitted to the outside of
819490
the rear bearing.
Remove the through bolt and, using a screwdriver, (2) Removal of Pulley
pry off the front bracket assembly from the rear
bracket assembly.
NOTE:
Fan
Bearing box
Front bracket
Rotor
B1029Z
Hold the rotor in a vice, etc. and remove the pulley,

fan and front bracket.
81949P
NOTE:
1. The rear bearing is tightly fitted. Before
separation, therefore, preheat the bear
ing box of the rear bracket by an air
dryer to facilitate separation.
Rotor 810290
When holding the rotor in a vice, be sure to

hold at illustrated portion.
16-36
ENGINE ELECTRICAL SERVICE PROCEDURES
(3) Removal of Stator Coil (4) Separation of Rectifier <80A>
Rectifier
Stator
B3909A
Separate the rectifier by unsoldering the area shown.

NOTE:
When unsoldering, finish it in a short time
(less than 5 seconds) with a soldering iron.
To remove the stator coil, unsolder the stator coil

leads soldered to the rectifier.
NOTE:
When unsoldering, finish it in a short time
(less than 5 seconds) with a soldering iron.
16-37
•
5.3.3 Inspection
Description NV L
Field coil 30A, 40A Approx. 9 n

resistance
80A Approx. 7.2 n
Slip ring 0.0. 40.8 to 41.2 40.4
Ground test
Brush spring pressure
NV 0.32 to 0.44 kg
L 0.2 kg
Open circuit test
Ground test

L ... Limit
83907F
16-38
Inspection Procedure (2) Inspection of Rotor

(1) Inspection of Stator (a) Continuity between slip ring and core
(a) Continuity across leads
081300
08058A
Check that there is no continuity between the slip ring
Check that there is continuity across stator leads. If and core.
there is no continuity indicating a broken wire, If there is, replace the rotor as it is grounded.
replace the stator. (b) Field coil resistance
(b) Continuity across stator leads and core
081310
080588
Measure the resistance across slip rings. Replace the
Check that there is continuity across the stator leads rotor if the resistance is not within the specification.
and core.
If there is, replace the stator as it is grounded.
16-39
(c) Slip ring O.D. (b) Inspection of brush spring
D8132C
Measure �he slip ring O.D. If the slip ring has rough
surface or is unevenly worn, correct with sandpaper
or lathe.
Correction must be made within the limit of slip ring
O.D.
(3) Inspection of Brush and Brush Spring
(a) Inspection of brush
82718A
If the spring pressure is lower than the limit, replace.

(c) Replacement of brush and brush spring
f
C:
E
C: .c
Q) Cl
.c C:
3 Q)
Cl
C:
.c
V) Wear limit line
08062A
Replace the brush if it is worn beyond the limit.
82716A
1) Unsolder the pos1t1on shown in the illustration

and remove the brush and brush spring.
'•, I
16-40
(a) Measurement of diode mounted to heat

sink (6 places)
Stator coil lead
-:::==1
.-
L:c:: g I
827378
Heat sink
2) When soldering the brush, insert a pin into the
brush hole and fix to the regulator assembly. B2720A
NOTE:
1�=
�I
When soldering or unsoldering, work

I
�
quickly (within about 5 seconds) with a
g -
soldering iron.
(4) Inspection of Rectifier
Measure resistance of each diode. Measure both
when with the circuit tester (+) probe applied to
the diode and when with the (-) probe applied to 82721A
the diode.
• If resistance is infinite in both cases, the diode Measure between the heat sink and stator coil lead
is open. connections.
• If resistance is close to zero in both cases, the
(b) Measurement of diode trio (3 places)
diode is shorted.
In the case of open or shorted diode, replace the
rectifier.
Measure according to the following procedures.
82722A
Measure between the plate connecting to the regula

tor and the stator coil lead connections.
16-41
• ENGINE ELECTRICAL
(5) Inspection of Bearings

SERVICE PROCEDURES
{Installation)
Replace the bearing if defect is evident.
(a) Replacement of front bearing
Apply engine oil.
{Removal)
82728A
Front bearing
Cover
Front bracket
82724A Front bracket
1) Remove the bearing cover. -.l...,.---,.-�---=-1-----1-

83109A
' Rod 1) Apply a light coat of engine oil to the outside of

the bearing and install to the inside of the front
bracket using a press.
Front bracket
Install flush with the cover mounting portion.
Front bearing
Front bracket
82725A
2) Apply a rod to the spacer on the front side of the

front bracket and strike out the bearing.
Spacer
Front bracket \ Front bearing
82730A
2) Install the cover and strike the spacer with a soft

hammer, etc. to make sure that the bearing and cover
are in contact with each other. If not, strike the spacer
to bring them into contact.
16-42
(b) Replacement of rear bearings (Installation)

(Removal)
Rear bearing
Apply grease.
Spring
fitting groove
827320
82731 D
Apply a light coat of engine oil to the inside of the
NOTE: bearing and using a press, install with the spring
Use care not to cause damage to the slip fitting groove of the bearing facing the rotor field coil
ring by the bearing puller. side.
16-43
•
5.3.4 Reassembly
<30A, 40A alternator>

Engine oil to be applied
to outside circumference
14 13 of rotor shaft
3
I
9
135 to 160 Nm
(13.5 to 16.5 kgfm)
19
4
6
B2990L
<80A alternator>
135 to 160 Nm
(13.5 to 16.5 kgfm)
Engine oil to be applied

to outside circumference
of rotor shaft
5 19
Components
1: 3, 3A <80A only>, 4, 5, 6, 7
12: 13, 14, 15
16: 17, 18, 19, 20
<Assembly sequence>
16 (20--, 19--, 18--, 17)--,@ (15-, 14-, (jj)) __, 8
(11 -> 10-> 9) --, 2-, 1 (7 _:. © --, 6 --, 5-, (:i) __, (:l)A <80A only>)
On components marked o, refer to the following reassembly

procedure. B2990M
16-44
Reassembly Procedure Installation of Front Bracket Assembly and

(1) Installation of Rectifier (80A Alterna Rear Bracket Assembly
tor)
B2745A
(a) Push in the brush by hand and insert the pin into
When the rectifiers are to be connected together by the brush hole from the rear of the rear bracket to fix
soldering, do the soldering with the regulator as well the brush.
as the rectifiers mounted to the rear bracket. (b) Noting the spring position of the rotor bearing
mounted to the front bracket side, install the rear
NOTE:
bracket assembly.
When soldering, finish it in a short time
(less than 5 seconds). NOTE:
After completion of reassembly, be sure to
(2) Installation of Spring
remove the pin and close the hole.
Minimize spring
projection
D8099E
Install the spring with its highest point seated in the

deepest of the spring fitting groove of the bearing.
16-45
ction and Adjustment after ln-

tion
Precautions
the alternator, observe the following
08074A
(c) Do not use a megger or other high-voltage

multi-meter, or damaged diode and regulator will
resu It.
D80728
�ct the battery reversely.

of the battery is reversed when
made, a large current flows from the
nator, damaging the diode and IC
(d) Do not expose the alternator to the water. If the

alternator is exposed to water, short-circuit may
result, causing damaged alternator.
D80738
:rnnect the battery terminal connec

mgine is running, or a surge voltage
)rating the diode and regulator.
D80768
(e) Operating the alternator with its "B" and "L"

terminals shorted results in the damaged diode trio.
2) While gradually increasing the alternator speed

•
and reducing the load resistance, measure the current
value with the specified terminal voltage and speed.
If the measurement is below the specification, check
I /
alternator parts.
/'
Nominal value (when alternator is cold)
<30A alternator>
Terminal voltage 27V 27V
Current 17A or more 26A or more
Rotating speed 1 500 rpm 2 500 rpm

D80778
<40A alternator>
(f) When quick-charging the battery with a quick
charger, be sure to disconnect terminal connections Terminal voltage 27V 27V
in advance. Otherwise, a damaged diode and regula Current 26A or more 37A or more
tor will result. Rotating speed 1 600 rpm 2 500 rpm
(2) Performance Test

(a) Test bench inspection <80A alternator>
Terminal voltage 27V 27V
Current 39A or more 71A or more

Ammeter Voltmeter
Rotating speed 1 500 rpm 2 500 rpm
(b) On-vehicle inspection
Voltmeter
B terminal Switch K1
Alter
nator �-----1o----o1�
Variable resistor
'------. Alternator
drive motor B terminal
836238
R terminal 1) Provide a switch between the battery and alterna

tor "B" terminal. With the switch turned off, connect
B3622C an ammeter (with 60A full-scale to the 30A or 40A
alternator and 100A full-scale to the 80A alternator)
Perform the test using the circuit shown above. and voltmeter.
1) With the load resistance set at maximum (mean 2) Turn on the switch and make sure that the
ing that there is almost no load current flowing), close voltmeter indicates the battery voltage.
switches K, and K2. 3) Start up the engine and immediately turn on all
lamp switches. Then, increase the engine speed and
read the maximum current value when the alternator
speed reaches 5 000 rpm.
16-47
• ENGINE ELECTRICAL - SERVICE PROCEDURES
4) If the current reading is 70% or more of the (b) On-vehicle inspection

nominal output, the alternator may be regarded as in
good condition. Voltmeter
NOTE:
The on-vehicle test is an easier way of
inspection; the test bench inspection is
Ammeter
necessary for more accurate results.
(3) Inspection of Regulator
(a) Test bench inspection
Ammeter Voltmeter Battery L terminal B3625E
1) Connect a voltmeter and ammeter and provide a

switch as shown.
2) The regulator is in good condition if the voltmeter
registers O when the switch turns ON. If the voltmeter
Switch pointer deflects, the alternator or wiring is defective.
3) With the ammeter terminal shorted to prevent
B terminal flow of the starter current through it, start the engine.
R terminal /' Alternator
'- 4) Increase the engine speed to around 2 000 rpm
and read the regulated voltage value if the charge
current is 5A or less.
L terminal If the charge current is 5A or more, continue charging
for a while or replace the battery with a fully-charged
one.
Or, a 1/4 n (25W) resistor may be connected in series
to the battery to _limit the charge current.
L terminal
5) If the measurement is out of specification, replace
the regulator assembly.
B3624C
Inspect the regulator regulated voltage as follows

using the circuit shown above.
1) Use a fully-charged battery. Turn on the switch.

2) Gradually increase the alternator speed up to
5 000 rpm. Check that the current value at this speed
is 5A or less.
3) The regulator is in good condition if the regulated
voltage under this condition is within specification.
If not, replace the regulator assembly.
Nominal value 28 to 29V
16-48
5.4
GOA AL TERNATOR
•
[Refer to 5.3.1.I
5.4.2 Disassembly
1
,
i 14
�&-
�
. t
Cover 10 Stator *19 Pulley
2 Brush holder assembly 11 Plate *20 Fan
3 Brush holder 12 Lead wire assembly 21 Rotor assembly
4 Brush 13 Terminal set @ Rotor
5 Brush spring 14 Connector *23 Rear bearing
6 End cover 15 Condenser Ct}! Front bracket assembly
7 Cover 16 Heat sink set 25 Cover
8 Bolt set 17 Rear bracket *26 Front bearing
9 Rear bracket @ Pulley assembly @ Front 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 Inspection
Description NV L
Field coil Approx. 13 !!
resistance
Open circuit test
Slip ring 0.0. 46 45.4
Ground test
Ground test
Brush spring pressure
NV 3.7 N (0.38 kgf)

L 2 N (0.2 kgf)
3
�
B
;
Short test
Open test

L ... Limit
For the inspection procedure, refer to 5.3.3.

To check the heat sink for a short circuit, no disassembly is
required.
The short-circuit can be identified by checking for continuity
between the individual connector terminals. [Refer to 5.4.5.J
845398
16-50
5.4.4 Reassembly
16
8
11 7
83 to 105 Nm
(8.5 to 11 kgfm)
6 345 to 360 Nm
(35 to 37 kgfm)
27
Components
2: 3, 4, 5
9: 11, 12, 13, 15, 16, 17
21: 22, 23
24: 25, 26, 27
<Assembly sequence>
24 (27 _, 26-, 25) _, 21 (23 _, 22) -• 18 (20-• 19) _, 10 _, 9 ( 17 _, 16
_, 15 _, 13 _, 12 _, 11) _, 14 _, 8 _, 7 _, 6 _, 2 (5 _, 4 _, 3)-, 1
B4543A
16-51
•
5.4.5
Inspection and Adjustment after

Reassembly
( 1) Simple Procedures for Checking Alter
nator from Outside Inspection by Con
tinuity Tester
Measuring Good Defective

points
F - E Tester shows continuity. No continuity (Brush in poor contact or field coil open-circuited)
Resistance O (Field coil short-circuited)
N - A Tester shows continuity when If tester shows no continuity when (black) is connected to N and
(black) is connec1ed to N and !red) connected to A, all of three ( +) diodes are open-circuited
(red) connected to A. or stator coil open-circuited.
If tester shows continuity when (black) is connected to A and
(red) connected to N, ( >) diodes are short-circuited.
N - E Tester shows continuity when If tester shows no continuity when (black) is connected to E and
(black) is connected to E and (red) connected to N, all three (-) diodes are open-circuited.
(red) connected to N. If tester shows continuity when (black) is connected to N and
(red) connected to E, (-) diodes are short-circuited.
NOTE: Load test

The colors in parentheses show the colors Increase the load resistance R to a maximum and
of tester lead rods. All three diodes are close the switches K1 and K2. Measure the current
rarely open-circuited. value when the alternator reaches the specified
Each diode should be tested to determine speed.
whether it is good or defective.
Nominal value
(when alternator is cold)
Terminal voltage 28 V
Current 60 A or more
Rotating speed 2 200 rpm
Connector
A�F
N�E
08078A
(2) Performance Test
�-..----..---1 A 1----1-----,
A mmeter Switch
(dual Kt
.
deflection){
T
I
Boltmeter,
_l. Battery
24V
08080A
16-52
5.5 SAFETY RELAY [Model R8T301 71]

Inspection
------------------;==-=-====-
' ====-==--··'
Res1stanc1: between L and R
1
1
!
�V Approx 200 \! ___ J
S terminal
NV. No,rnnal Vah,e
814538
Measure voltage at each terminal in the sequence

shown below to identify faulty parts.
(1) On-vehicle Test
Sequence Engine Voltage al Voltage at Voltage at terminal

" .. s ..
.
00
operation terminal P
00
terminal R" or L"
00
1 Starter switch ON 1 V or less - Terminal

"R'"
• (+ I diode shorted if close • Approx. 24 V
to battery voltage • If O V, wiring is faulty
Terminal "L" (with charge lamp)
• Approx. 24 V
00
Terminal "L (without charge lamp)
• Approx. 3 V or less
• If close to battery voltage, wiring
or alternator is faulty
2 During cranking - • Approx. 1 V or less -

• If close to battery voltage,
safety relay is faulty
!cranking impossible)
3 Idling (600 rpm or • Approx. 13 to 16 V • A bulb connected between -

higher! battery and terminal "S"
does not come on
• If bulb comes on despite
00
normal terminal "P voltage
(shown to left), replace
safety relay and test again
(2) Off-vehicle Test

The resistance valve between terminals "R" and "L"
shall be within specified range.
16-53
5.6 REGULATOR [Model R7T01071] 5.7 PREHEATER

Inspection 5. 7 .1 Intake Air Heater
( 1) Removal and Installation
[Refer to Group 15 Intake and Exhaust]
(2) Inspection
Air heater
#�
IG F L
Starter switch (6D22, 6D22-TI

OFF
A N E HEAT
844018 0 N
START
(1) Regulated Voltage of Voltage Regulator Heater relay
Nominal value (between A and E terminals) ... 28 to

29V with alternator at 4 000 rpm
Battery overcharged ... Voltage too high Air heater
indicator
Battery discharged ... Voltage too low y
f �!\_��
�
NOTE:
This regulator uses a transistor type volt·
age regulator, so the regulated voltage
� � ��p
cannot be changed. If the regulated volt· �--� 1�--v-;--,�I
Battery
age is out of the nominal value, replace the
regulator.
D8803C
(2) Voltage Regulator Regulated Voltage

Measuring Procedure Perform the following inspection and check the
function of each part or the wiring if necessary.
(a) Increase the engine speed until the alternator
(a) Time required before indicator becomes red-hot:
reaches the specified speed.
(b) Continue charging until the charging current to Standard time
the battery falls to less than 10 A (the battery fully 40 to 60 seconds
charged). (b) Check each terminal of the air heater for loose
(c) Measure the voltage across the A and E terminals. ness and the heater element for damage and contact
(d) Measure the voltage across the A terminal and the with other parts.
negative terminal of the battery and check to ensure
that there is no difference between the value and the
value measured under Item (c).
16-54
5. 7 .2 Heater Relay 5.8 AUTOMATIC STOP DEVICE

Inspection 5.8.1 Energize,to,stop Type
( 1 ) Stop Solenoid
Clearance
NV 0.4 to 0.5 Pointer clearance
NV 1.5 to 2.0
Stop ' :
lever .. ! Extern�l stopper
\ 'I '
Amperage
SW terminal ' r- I ':
08901A
�-1 Lock nut
marked ', -1
!(! Lock Rod
�?df-
'
-�l�\
i n_ u \
Ct�-
/
(1) Check to ensure that there is continuity between
the terminals "B" and "S" when 2.3 A exciting current Operating Stop side
is applied between terminal SW in the figure and side I
I
Before Stroke 27 to 29 mm Cover Battery
body earth. attraction (24V)
Aftere attraction
·cv:{j])·
(2) Check also the heater relay fuse and replace with P.C P.C
new one if it has been burnt out. II· Ammeter
NV 5A or less
When replacing fuses, be sure to use a fuse of H.C H.C
specified capacity.
�
B4121B
(a) Connect the stop lever and solenoid using the rod
and remove the solenoid cover.
(b) Push manually the stop lever to the stop position
and adjust the rod so that the solenoid pointer gap
becomes as specified.
(c) Check that the stop lever to external stopper
clearance is as specified when the stop lever is on the
operation side.
(d) In the state of (c) above, apply specified voltage to
solenoid "B" terminal and check that the pointer gap
and ammeter reading are as specified. (Stop lever
stop side)
(e) Tighten the lock nut of the rod.
(f) Check that the solenoid pointer color has not
changed and then install the cover.
16-55
•
(2) Solenoid Relay
After the tests of the above items 1) and 2), allow 5

(a) Unit test minutes before making retests. It takes 5 minutes
before the capacitor C 1 which is an element of the
time constant of the oil pressure timer finishes
Terminal voltage
Oil pressure Limcr
Solenoid relay discharging.
measurement
DC 28.5V
E
t
Stop timer measurement
DC 24 V B C ST W A
SW@
Terminal voltage
SW©
DC 28.5 V
Solenoic1 or
coil load
30A -, 3A
SW@
SW@
ON
18 l 5"
Oil pressure
timer
SW@
30 l 5"
Stop timer
Test schedule
Description of symbols
SW@ : Snap switch A
SW@ : Snap switch B
SW© : Push switch C D9558A
Make connections as shown above and perform the

following checks.
1 J Oil pressure timer
Set the snap switch A to ON. Operate a stop watch as
,soon as the snap switch Bis set to ON, and measure
the time required before the solenoid is operated.
2) Stop timer
Set the snap switch B to OFF 5 seconds after the
solenoid has been operated. At the same time, using
a stop watch, measure the time required before the
solenoid is reset.
The snap switch B is set to OFF 5 seconds after
operation of the solenoid because if the solenoid is
operated, it takes 5 seconds before the alternator
voltage disappears.
3) Manual stop timer
When the push switch C (stop switch) is set to ON, the
solenoid will be operated. Operate a stop watch as
soon as the stop switch C is set to OFF, and measure
the time required before the solenoid is reset.
16-56
•
Check the solenoid relay according to the following
flowcharts and determine whether it is good or not on
the basis of the terminal voltage, etc. measured in the
individual states.
• The terminal symbols denote those of the sole
noid relay.
• The voltage 24V means the battery voltage.
Turning the battery switch Is voltage No Measure ov Solenoid relay

from OFF to ON actuates 1-----sK 24 available at voltage at ST >- -------------a>1 defective
the solenoid. A terminal/ terminal.
I Yes
Alternator defective I , 24V
Stop switch defective
Engine cannot 24V OV Solenoid relay

be stopped by >- - - - --- ---- defective
stop switch.
I Stop switch defective I Solenoid defective
Perform measurements with engine running.
Engine does not stop with ov

water temperature high >----;"' Solenoid relay
and oil pressure low. defective
Thermo switch or Alternator

oil pressure switch defective
defective
Solenoid is not forced Solenoid relay

to OFF state after engine defective
has stopped.
Solenoid Stop switch Alternator

defective defective defective
Solenoid operates Solenoid relay

while engine >---s� defective
is running.
Solenoid Stop switch Thermo switch or Normal In normal operation,

defective defective oil pressure switch responding to abnormal
defective water temperature or
oil pressure.
16-57
•
(3) Thermo Switch
Connect the pipes as shown above, close the cocks A

and B, and start the engine. After the oil pressure has
risen, fully open the cock A to lead the oil pressure to
the oil pressure switch. Then close the cock A to shut
Item NV
off the oil passage to the engine and hold the oil
Operating 93 to 97"C
temperature pressure directly in the oil reservoir.
° Slowly open the cock B to lower the oil pressure and
ON-OFF 7 C
difference check the oil pressure switch operating oil pressure
with the test oil pressure gauge.
(5) Oil Pressure Switch Relay

NV .. Nominal Value
Tepmerature
sensing
portion D9559A
When voltage is 24V

The ther�o switch won't operate if the temperature
Item NV
sensing portion is not in contact with coolant. If the
Coil resistance 190 to 280 n
coolant level is low or if there is only steam, the
Minimum operating 16 V
thermo switch won't operate completely. voltage
Immerse the temperature-sensing portion in water,
heat the water, and check the thermo switch operat
0
ing temperature with a mercury thermometer.
Heat the water gradually when the temperature NV... Nominal Value
approaches near the operating temperature.

(4) Oil Pressure Switch
Engine oil
Testing oil pressure gauge
pressure gauge
Cock A ll) 5, t
"' "' 0
Oil "' "' Q.
u "'
reservoir J----"<�------t---! � "- .;
ro :=; 09562A
.... :-= ::,
UC O
Oil pressure
switch Cock B
(a) Check to ensure that there is continuity between
D9560A
the terminals (i) and @.
(b) Check to ensure that there is no continuity
between the terminals (i) and 0).
(c) Check to ensure that there is continuity between
the terminals© and® and that the coil resistance has
a nominal value.
Operating pressure
NV 69 to 98 kPa (d) Check to ensure that when the battery voltage is
(0.7 to 1.0 kgf cm') or less
applied across the terminals © and ®, there is
continuity between the terminals (i) and 0 and no
continuity between the terminals 0 and @.
NV... Nominal Value
09561A
16-58
5.8.2 Energize-to-run Type (2) Solenoid Relay

( 1) Stop Solenoid (a) Unit test
Eh--�
Clearance Pointer clearance 8 C H S
NV 0.4 to 0.5 NV 1.5 to 2.0
SWl SW3 SW2

�--------,·-�--
External Terminal voltage
Solenoid 24V
stopper Solenoid or coil load
Stop lever 30A ± 3A
i Lock nut '. B terminal
. Rod . Delay time
Lock nut NV ... Nominal Value
NV 26 to 34 sec.
Operating
side ---,-------
L. 09564A
Stop side
·''
Stroke 27 to 29 mm .--1 Cover Wire as shown and check the following.
Battery
Before attraction After attraction
(24V) 1) Relay operation and delay time
P.C P.C
�11·
0
�II· Ammeter
a) Check if the solenoid is energized when switches
H.C H.C NV 1A or less SW1 and SW2 are turned ON.
b) Using a stop watch, measure the time required for
the solenoid to return after switch SW2 is turned OFF.
2) Relay holding
84121C a) Turn ON switch SW1 and SW2 and, after the
solenoid is activated, turn ON the switch SW3.
(a) Connect the stop lever and solenoid using the rod b) Turn OFF the switch SW2 and make sure that the
and remove the solenoid cover. solenoid remains activated for more than 34 seconds.
(b) Push manually the stop lever to the operation c) After verifying 2) above, turn OFF the switch SW3
position and adjust the rod so that the solenoid to ensure that the solenoid returns.
pointer gap becomes as specified. In this state, also
ch�ck that the stop lever to external stopper clearance
is as specified.
(c) In the state of (b) above, apply specified voltage to
solenoid "B" terminal and check that the pointer gap
and ammeter reading are as specified. (Stop lever
operation side).
(d) Tighten the lock nut of the rod.
(e) Check that the solenoid pointer color has not
changed and then install the cover.
16-59
m
Check the solenoid relay according to the following

flowchart and determine whether it is good or not on
the basis of the terminal voltage, etc. measured in the
individual states.
• Terminal symbols denote those of the solenoid
relay.
• Voltage 24V means the battery voltage.
Turning the battery OV Solenoid relay

switch (or key switch) '>--- - - - -
-- --- -- --
- - --------! defective
from OFF to ON
actuates solenoid.
Battery switch (or key

switch) defective or
miswired
Is vol-
Solenoid does not tage 18V or No
operate when key Check battery. more available at Battery defective
switch is set from s terminal with key
ON to START. switch at START
No
ov Solenoid relay
defective
Solenoid defective or
Is there miswired
continuity No
>------------
between emergency --.! Emergency switch
switch termi defective
nals?
I Yes
Wiring defective
Is voltage
Solenoid operates 18V or more
when key switch is available at S Y�e=s�----
>---------- - - ----� Solenoid relay
- -
changed back from defective
START to ON.
I Battery defective
No
16-60

•
/�
Engine does not stop Measure OV /Measure' ov Solenoid relay
with water temperature voltage H ;'� �..,.- voltage at S defective
�: / -
./
high and oil pressure terminal.

low.
-��
I 24V
Thermo switch or
oil pressure switch
24V
Key switch defective I Solenoid defective
defective
Engine does not stop

with emergency switch
at OFF.
Measure
voltage at B
termma1.
24V
-�- - - - - - - - - - - -- - - - - �
Solenoid relay
- �� defective
I
ov
I Solenoid defective
While engine is running,

solenoid is forced to Solenoid relay
OFF state and defective
engine stops.
Solenoid defective Emergency switch Thermo switch or Normal In normal operation,

defective oil pressure responding to abnormal
switch defective water temperature or
oil pressure.
16-61
(3) Thermo Switch (4) Oil Pressure Switch
Engine oil
Testing oil pressure gauge
pressure gauge
Item NV
Operating 93 to 97°C
temperature
ON-OFF 7°C Cock A

difference
Oil
reservoir
Oil pressure
NV ... Nominal Value switch Cock B
Temperature- �
sensing
portion D9560A
D95598
The therr,no switch won't operate if the temperature

sensing portion is not in contact with coolant. If the
coolant level is low or if there is only steam, the
thermo switch won't operate completely.
Immerse the temperature-sensing portion in water, Operating pressure
heat the water, and check the thermo switch operat NV 79 to 115 kPa
(0.8 to 1.2 kgf/cm') or less
ing temperature with a mercury thermometer.
Heat the water gradually when the temperature
approaches near the operating temperature. D9565A
Connect the pipes as shown above, close the cocks

"A" and "B", and start the engine. After the oil
pressure has risen, fully open the cock "A" to lead the
oil pressure to the oil pressure switch." Then close the
cock "A" to shut off the oil passage to the engine and
hold the oil pressure directly in the oil reservoir.
Slowly open the cock "B" to lower the oil pressure
and check the oil pressure switch operating oil
pressure with the test oil pressure gauge.
16-62
ENGINE ELECTRICAL - TROUBLESHOOTING
6. TROUBLESHOOTING
Symptom Probable r.aus1� Remerly Ref. group

·-
Starter will l Defective ballery or lnw capacily Replace or charge
not start.
.
l Defective wiring
Defective starter wiring Correct
I • Defective starter relay wiring
. Defective magnetic switch wiring
. Defective heater relay wiring
! • Defective starter switch wiring
• Defective baltery or battery switch wiring
Defective magnetic switch Replace

I
Defective stortcr relay

I
Worn. damaged. binding brush
I Defective motor Replace armature or yoke
Defective overrunning clutch Replace
Defective heater relay
Defective starter switch
Starter starts but Pinion not meshing with ring gear

engine does not. • Incorrect voltage at magnetic switch S terminal Replace starter relay
or starter switch
• Incorrect voltage at starter relay SW terminal
• Worn or damaged pinion Replace
• Worn or damaged ring gear Replace Group 11
Pinion meshes with ring gear but does not rotate

• Defective battery or low capacity Charge or replace
. Poor brush contact Replace brush or

brush spring
• Defective overrunning clutch Replace
Alternator is Low V-belt tension Adjust Group 14

funetioning
normally but Damaged V-belt Replace
battery is
overdischarged. Defective wiring
• Defective alternator wiring Correct
Defective battery Replace
Battery is normal Defective alternator

but is over-
discharged.
• Open circuit in stator coil Replace
• Stator coil and core grounded
• Slip ring and rotor core grounded
• Defective field coil
• Worn slip ring
• Worn brush
• Defective brush spring
• Defective rectifier
• Defective regulator
16-63
ENGINE ELECTRICAL - TROUBLESHOOTING
Charger lamp does Defective regulator Replace

not come on when
engine is stopped
(starter switch ONl.
Premature loss of Defective alternator (see "Battery is normal but is Replace

battery electroyte. overdischarged" .)
High battery electro-
lyte temperature. Defective regulator
Engine is hard to Defective wiring

start. • Defective air heater wiring Correct
• Defective heater relay wiring
• Defective water temperature sensor wiring
Defective heater relay or blown fuse Replace
16-64
CLUTCH
CONTENTS
1. GENERAL ...................................... 2 5.2 CLUTCH PROPER ....................... 7

2. SPECIFICATIONS •••.•••.•••••••••••.•••••• 3 5.2.1 Disassembly and Inspec-
3. SERVICE STANDARDS .••...••.•........ 3 tion ......................................... 7
3.1 SERVICE STANDARD TABLE ••••. 3 5.2.2 Reassembly and Adjust-
3.2 TIGHTENING TORQUE TABLE •.• 3 ment ....................................... 11
4. SPECIAL TOOL •••.•••.•.••..•..••.•••••••••. 4 5.3 BEARING CASE .......................... 12
5. SERVICE PROCEDURES •••••.•.....••.• 5 5.3.1 Disassembly and Inspec-
5.1 REMOVAL AND INSTALLA· tion ............ 11............................ 12
TION ........................................... 5 5.3.2 Reassembly ............................ 13
CAUTION:
When servicing clutch assemblies or components, do NOT create dust by
sanding or by cleaning clutch parts with a dry brush or with compressed
air. (A water dampened cloth should be used).
The clutch disc contains "Asbestos Fibers" which can become airborne if
dust is created during service operations. Breathing dust containing
"Asbestos Fibers" may cause serious bodily harm.
21-1
fD CLUTCH - GENERAL
1. GENERAL
Strap plate
Release lever
support
Clutch disc Pressure plate E0754A
The clutch is a dry single disc type which transmits is performed, the pressure spring force causes the
and disconnects engine power through the clutch pressure plate to press the clutch disc against the
shift shaft. engine flywheel to transmit power.
When the operation for clutch disengagement is The clutch consists of a clutch disc, pressure plate and
performed, the clutch release lever is pushed. Since release lever assembly. The clutch disc has a woven
the clutch release lever pivots round the release lever facing.
pin in the release lever support provided in the clutch The drive system is the strap drive type which uses a
.cover, the pressure spring is compressed, causing the strap plate between the clutch cover and pressure
clutch disc clamped between the engine flywheel and plate to couple them. This system insures smooth
pressure plate to become free and cuts transmission engagement and disengagement of the clutch.
of power. When the operation for clutch engagement
21-2
2. SPECIFICATIONS
CLUTCH - SPECIFICATIONS, SERVICE STANDARDS
m
Clutch [Option]
Item Specification
·------+-- --------- ---�--- - -
--- -
--- -
Clutch 160221 16022-T, TCI
Type Dry single disc coil spring type Dry single disc coil spring type
Model C10W41 or C12W43 C12W43
Facing Material Woven Woven
0.0. x 1.0. mrn 410 x 250 or 430 x 250 430 X 250
Bearing case Type Direct-coupled type
Model PC12
3.1 SERVICE STANDARD TABLE Unit: mm

Clutch Depth from facing surface to rivet head 2.2 to 2.8 0.2 Replace.
disc
Flatness 0.6 or less - Replace.
Lateral runout 1.2 or less - Replace.
Vertical runout C10W41 1.0 or less

1.5
C12W43 1.2 or less
Play in turning direction 0.06 to 0 195 0.42 Replace.
Pressure Free C10W41 99.5 - Replace.

spring length
Cl 2W43 92.1 -
Installed load C10W41 1 205 to 1 325 N 1 070 N Replace.

(Installed length: 63) (122.6 to 135.4 kgfl (109 kgfl
C12W43 1 425 to 1 570 N 1 270 N

(145 to 160.2 kgfl (129 kgtl
Spring squareness C10W41 3.5 or less 5.2 Replace.

lln free length state)
C12W43 3.2 or less 4.8
Pressure Flatness of friction surface 0.05 or less 0.2 Correct or replace.

plat'e
Thickness 59.7 to 59.9 56.8 Replace.
Strap bolt fitting hole 12.21 to 12.22 12.5 Replace.
Clearance between release lever pin and bushing 112.71 0.3 Replace.
0.06 to 0.15
Clearance between strap plate and strap bolt 112.21 0.3 Replace.
0.01 to 0.11
Release lever height 36.5 to 37.5 - Adjust.

(Dimension from clutch cover top surface) !Difference among four levers:
0.7 or less)
Clearance between release fork shaft and 1301 0.2 Replace.

needle roller bearing 0.03 to 0.08

Description Thread size Tightening torque
0.0. x Pitch mm Nm (kgfm)
Strap bolt M12 x 1.5 39 to 49 (4 to 51
Lock plate mounting bolt MB x 1.25 9.8 to 15 (1 to 1.51
Pressure plate and lever assembly mounting bolt M10 x 1.5 32 to 49 (3.3 to 5.0)
Bearing case mounting bolt M16 x 2.0 140 (14.21
21-3
fD CLUTCH - SPECIAL TOOL
4. SPECIAL TOOL
Unit:mm
Clutch alignment arbor 03726-21000 Alignment of clutch disc

at installation
E0012B
Clutch installer MH061331 Removal and installation

of clutch cover
E0007A
Clutch lever aligner MH061330 Adjustment of release

lever height
37 ±
Plain washer 43502-39200 Removal and installation

of clutch proper
55
Stopper bolt 43502-39100
M10 x 1.25
30
�
E0005B
Needle roller bearing installer 44590-12600 Installation of needle roller

bearing of bearing case
21-4
CLUTCH - SERVICE PROCEDURES
fD
5. SERVICE PROCEDURES NOTE:
5.1 REMOVAL AND INSTALLATION 1. Before removing the clutch, be sure to
install the stopper bolt and plain
(1) Removal
washer to prevent the strap plate from
�--- - ---- ---- - -----
- - --
· being damaged.
2. Use the stopper bolt (M10 x 1.25 - 85
with effective length 30 mm or morel
and plain washer (for M12 threads)
commercially available.
(2) Installation
,------------ l� -- Part number

stamped here
Pilot Clutch disc
3 1
Flywheel -- -�
Clutch Alignment
Arbor 03726-21000
E0187A
1. Bearing case assembly
2. Pressure plate & lever assembly
(a) Install the clutch disc using the special tool, Clutch
3. Clutch disc assembly
E0755A Alignment Arbor.
NOTE:
When installing the clutch disc, make sure
that it is installed in the correct direction:
install it so that· its side with the part
number stamped is visible.
Clutch Alignment Arbor

03726-21000
Plain washer (4 places) E0119B
When removing the pressure plate and lever assem

bly, secure the pressure plate with the special tools, Knock pin
Stopper boll
Stopper Bolt and Plain Washer. (4 places: M10 x 1.25) EOB59B
Before removing the pressure plate and lever assem
bly, install the special tool, Clutch Alignment Arbor, to (b) Secure the pressure plate of the pressure plate
prevent the clutch disc from dropping. and lever assembly with the stopper bolts, then install
the clutch, aligning it with the knock pins in the
flywheel.
21-5
fD CLUTCH - SERVICE PROCEDURES
NOTE: (d) Adjustment after installation of clutch

1. Before installing the clutch, check and and bearing case
clean the flywheel and repair or replace
as necessary.
2. Tighten bolts evenly, in the diagonal
order.
3. After installation, be sure to remove the
set bolt.
(c) Inspection of release lever height
Clutch Lever Aligner

MH061330
E0756A
The clutch should be set in the most worn position as

wear of the clutch disc during service causes the
clutch to slip.
1) Move the lever in the direction that the clutch
engages. At a position where a click is heard in the
clutch, turn the adjusting bolt A until it is blocked by
the stopper, and lock it by turning down the bolt
another two or three threads.
2) From the position where the release bearing has
touched the release lever, turn the adjusting bolt Bin
Release lever the direction that the clutch disengages, check to see
that the clutch is in disengaged position, and then
lock the bolt.
Support nut
\
Clutch cover E0421A
Using Clutch Lever Aligner (special tool), check the

heights of the clutch cover and release lever.
Use the support nut for adjustment.
21-6
fD
5.2 CLUTCH PROPER
Depth to rivet head

r--------1
Clcarc1nce of hub spl111e
NV 2.2 to 2.8 I 111rn11H1 d1rcct1on
L 0.2 I NV O 06 to O 195
� L 0 47
-
I
Flatness 0.6 or less
j- ---------
Lateral runout 1.2 or less J
Vertical runout r···------------

NV 1.0 or less (C10W41 l
�
f ti,,p IJoll litt111g hole
�ess
1.2 or less (Cl 2W43) NV 12.21 lo 12.22 NV 0.05 or less
L 1.5 I L 12 5 L 0.2
�-----�-- --'-------�- -
---'
1 Thickness
NV 59.7 to 59.9
L 56.8 IC10W411 (C12W431
Installed load Installed load
(Installed length 631 (Installed length 63)
NV 1 205 to 1 325 N NV 1 425 to 1 570 N
(122.6 to 135.4 kgfl (145 lo 160.2 kgfl
L 1 070 N (109 kgfl L 1 270 N (1 29 kgfl
Free length 99.5 Free length 92.1
Squareness Squareness
NV 3.5 or less NV 3.2 or less
L 5.2 L 4.8
Clearance from strap plate

BO 12.2
VN 0.01 lo 0.11
Clearance between pin L 0.3
and bushing
BO 12.7
NV 0.06 to 0.15 13
L 0.3
6 5 4 3 BO . Basic Diameter
NV . Nominal Value
·L Limit
(1) Clutch disc assembly 9 Release lever pin
(2) Strap bolt 10 Return spring
°
!J l Lock bolt 11 Release lever support
(4) Lock plate 12 Release lever pin
(SJ Support nut 13 Release lever subassembly
(6) Clutch cover (with strap plate) 14 Bushing
(]) Pressure spring (15) Pressure plate
8 Spring seat
For parts with an encircled number, refer to Disassembly and Inspection

NOTE:
1. Since the clutch cover and pressure plate are ba
lanced, make alignment marks before disassembly.
2. Do not remove the strap plate.
E0757A
21-7
Disassembly and Inspection Procedure (2) Inspection of Clutch Disc

(1) Removal of Clutch Cover (a) Facing wear
----�
Strap bolt
Depth to rivet head

or cup head
Stopper bolt
1rn
Assembled
rd:
(4 places) thickness
E0860A E0694A
(a) Compress the pressure spring with the stopper Measure the assembly thickness of facing and the
bolts and, at the same time, remove the strap bolts, depth from facing surface to rivet head or cup head. If
support nuts, and other parts. the measurement is below the limit, replace the clutch
disc assembly.
Clutch Installer
MH061331
(b) Flatness of clutch disc
Dial gauge
Clutch disc
Align stopper bolts

with plate holes.
Surface plate
E0443A
(bl Put alignment marks on the clutch cover and E0695A

pressure plate. Compress the pressure spring using
the special tool, Clutch Installer, and at the same time Measure the flatness of facing surface. If it is beyond
remove the stopper bolt. the limit, correct or replace.
(c) Gradually loosen the handle of Clutch Installer to
remove the clutch cover.
21-8
fD
(c) Clutch disc runout (3) Inspection of Pressure Plate
(a) Measurement of thickness
E0696A
Pressure plate
E0438A
Using the runout tester, measure the clutch disc
runout. If tlie measurement exceeds specification, Measure the pressure plate thickness and, if it is
correct or replace the clutch disc. below the limit, replace.
(d) Spline play in turning direction (b) Measurement of flatness
E0697B E0439A
Using a piano wire, measure the play in the turning Measure the flatness of the pressure plate friction
direction of the clutch disc hub splines and bearing surface. Regrind or replace if the limit is exceeded.
case clutch shaft. If the limit is exceeded, replace the
clutch disc.
21-9
(c) Strap bolt fitting hole I.D. (5) Inspection of Pressure Spring
Strap bolt hole Squareness
Pressure spring
E0440A E0487A
Measure. the 1.0. or strap bolt fitting hole in the Measure the free length, squareness, and installed
pressure plate and, if the limit is exceeded, replace. load of the pressure spring. If the measurement is
below the limit, replace the spring.
(4) Inspection of Release Lever
Release lever Release lever pin
E0441A
Measure the release lever pin 0.0. and bushing 1.0 ..

Replace if clearance exceeds specification.
21-10
5.2.2
Reassembly and Adjustment

m
<Assembly sequence>
IJY12]
14
--,11-9-10- a.�7-6-,5-4-,3-2--·1
15-
that follows. E0754B
(2) To install the clutch cover, align the alignment

(1) Whenever the pressure plate friction surface is marks and, using the special tool, Clutch Installer,
corrected, insert adjusting washers of thickness temporarily tighten the stopper bolts.
equivalent to correction amount.
Friction surface Adjusting washer

correction amount thickness
Less than 1 None required
1 or more and less than 2 One 1.2
2 or more and less than 3 Two 1.2 or one 2.3
21-11
Clutch Lever Aligner

MH061330
Stopper bolt
E0860A
(3) With the pressure spring compressed by the (4) After installing the clutch, check the clutch cover
stopper bolts, install the strap bolt, support nut, and and release lever for height using the special tool,
other parts. Clutch Lever Aligner.
5.3 BEARING CASE

BD ... Basic Diameter

NV... Nominal Value
L ... Limit
Clearance
BO 30 mm
NV 0.03 to 0.08 mm
Rotating condition, L 0.2 mm
<Disassembly sequence> wear, damage, seizure
Clutch shifter 6 Clutch release 9 Oil seal 14 Oil seal

*2 Clutch release fork shaft 10 Clutch shaft *15 Needle roller
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:
Parts marked * should not be removed unless they are to
be replaced.
E0760A
21-12
5.3.2 Reassembly
CLUTCH - SERVICE PROCEDURES m
Apply sealant
THREE BOND 1102C or equivalent
� -
--- -
-- --·
- -- - -
-' < Assembly sequence>

that follows.
E0761A
Installation of Needle Roller Bearing Using special tool, the Needle Roller Bearing Installer,
install the needle roller bearing in the housing.
The needle roller bearing should be pressed in up to
the specified dimension with the oil seal side inward
and the inscribed side outward.
NOTE:
When installing the needle roller bearing,
direct the lip in the correct direction.
Needle roller bearing
Inscribed side
(dust seal side)
Needle Roller Bearing Installer
44590-12600
Needle roller bearing
Installing -
direction
Dust seal -
�/L\i;;;;;;;;;;;;�;;;;;�lj_J
3 to 5
E0762A
21-13
fD CLUTCH - TROUBLESHOOTING
6. TROUBLESHOOTING
Clutch drags Defective clutch proper

when
.
(Disassemble and check clutch assembly)
.
disengaged
Damaged or poorly lubricated pilot bearing Replace or lubricate
Damaged release bearing Replace
• Uneven height of release lever or its damage Adjust height or

replace
• Defective clutch disc Replace
• Damaged or deformed clutch disc
• Worn or rusty splines and clutch disc hub Replace or repair

defective parts
• Distorted or damaged pressure plate Grind or replace
Distorted or damaged flywheel Group 11
Clutch slips Defective clutch proper

(Disassemble and check clutch assembly.I
• Uneven height of release lever Adjust
• Pressure spring losing proper tension Replace
• Defective clutch disc Replace
• Worn facing
• Deformed clutch disc
• Hardened facing Remove hardened

surface or replace
• Oil on facing Remove oil or replace
Clutch is not Defective clutch proper

smoothly engaged (Disassemble and check clutch assembly)
• Defective clutch disc Replce
• Distorted facing Replce
• Hardened facing Remove hardened

surface or replace
• Loose rivet Replace
• Oil on facing Remove oil or replace
• Binding clutch disc splines Correct or lubricate

splines
• Clutch disc torsion spring losing proper Replace

tension or broken
• Uneven height of release lever Adjust
• Pressure spring losing proper tension Replace
21-14
CLUTCH - TROUBLESHOOTING
m
Clutch is Worn. damaged, or poorly lubricated pilot heari119 Replace or lubricate

noisy when
disengaged Worn, damaged, or poorly lubricated release bearing
Defective clutch disc

•
.
Worn clutch disc splines Replace
Clutch disc torsion spring losing prorer

tension or broken
Bent strap rlate Replace clutch cover
Clutch is Defective clutch disc

noisy when
engaging
• Clutch disc torsion spring losing proper Replace
tension or broken
• Worn clutch disc hub splines
Worn splines of clutch shah Replace
Pressure spring losing proper tension Replace
Low idle speed Adjust Group 11
21-15
m
SPECIAL EQUIPMENT
CONTENTS
1. GENERAL •••.••••••••••..••.••••••.••••••••.••• 2 5. SERVICE PROCEDURES ................ 8

2 SPECIFICATIONS •••••.•••••••.••••••.•.•.• 4 5.1 AIR COMPRESSOR ..................... 8
3. SERVICE STANDARDS •••••••••••••....• 5 5.1.1 Removal and Installation •••••.• 8
3.1 SERVICE STANDARD TABLE ••..• 5 5.1.2 Disassembly ••••••••..••••••••••.•..... 11
3.2 TIGHTENING TORQUE TABLE ... 6 5.1.3 Inspection and Correction ..••. 14
4. SPECIAL TOOL ••.•.••••.•••••••••.••.•••••.. 7 5.1.4 Reassembly ••••••.••.••••••..•••••..•.. 19
5.2 PRESSURE GOVERNOR ............. 22
5.2.1 Disassembly and lnspec-
tion ......................................... 22
5.2.2 Reassembly and Adjust·
ment ....................................... 23
61-1
•
1. GENERAL
SPECIAL EQUIPMENT - GENERAL
( 1) Air Compressor
[1-cylinder Air Compressor) [2-cylinder Air Compressor]
To air tank To air tank
From oil
cooler
,�
84809A 84810A
� - - -- - ---- - - -
----
- - - -
- -
- - - -
- -
- - - - -- - - - - - - - - '
- -
I
The air compressor, installed at the flywheel housing
on the left side of engine, is driven at one-half the
engine speed by the timing gear train (injection pump From oil cooler
gears) of the engine. A coupling is mounted at the Suction

valve
rear end of the air compressor crankshaft to drive the
Delivery valve
injection pump.
, Lubrication is accomplished by the engine oil led
through the oil pipe from the engine oil cooler. The
engine oil passes through the oil hole in the crank
shaft to lubricate bearings. The cylinder liner and
connection rod small end are splash-lubricated using
crank rotation. Excess oil returns to the oil pan from 84811A
the hole at the bottom of crankcase through timing
gear train. The cylinder head is water-cooled to prevent over
heating by the compression heat of the air compres
sor. Coolant led from the oil cooler cools each valve of
the cylinder head, then returns to the water outlet
pipe.
61-2
SPECIAL EQUIPMENT - GENERAL m
From
jHPss11re Snap rmq
Cylinder head
quidc
Delivery valve
Unloader volve To air tank
holder ------ sprinn
0-ring
Suction valve
spring
Delivery valve spring
Delivery valve
seat
B4812A
A suction valve, delivery valve, and unloader valve

are provided in the cylinder head of the air compres
sor.
B4814A
The compressed air overcomes the force applied by

the delivery valve spring to open the delivery valve,
being sent under pressure to the air tank.
B4813A
Valves operate as follows:
The suction valve is opened by the negative pressure

generated during downward stroke of the piston,
which introduces air into the cylinder. When the
piston goes upward, the valve is closed by the suction
valve spring to compress air.
61-3
m SPECIAL EQUIPMENT - GENERAL, SPECIFICATIONS
(2)Pressure Governor
Cornpressed air Adjusting spring

from pressure
To air compressor
unloader Low pressure
..
valve
Valve body·
Diaphragm
Filter From air tank B4080A
The pressure governor controls compressor opera

tion to keep the air tank pressure within specified
limits.
To the high pressure valve of the diaphragm, the
same air pressure as in the air tank acts always
through the filter, thereby balancing with the adjust
ing spring force. When the pressure in the air tank
B4815A
increases to exceed that opening pressure of the high
pressure valve, the air forces up the high pressure
The unloader valve, operating with the pressure
valve seat of the diaphragm. This causes increase of
governor, controls pressure in the air tank. When the
acting area so that the diaphragm moves up quickly
air pressure in the air tank exceeds the specified
to close the seat of the low pressure valve.
pressure (pressure governor operating pressure), the
When the low pressure valve is closed, air now flows
pressure governor opens to send the compressed air
through the valve body to force down the unloader
to the unloader valve. The compressed air not only
valve of the air compressor, thereby stopping air
depresses the unloader valve, but keeps the suction
supply to the air tank.
valve open, causing the air compressor to operate
As the air pressure in the air tank gradually drops, the
under no load.
diaphragm is forced down by the adjusting spring
When the air pressure in the air tank falls below
and the low pressure valve opens and the high
specification, the pressure governor resumes opera
pressure one closes. As a result, the air on the
tion, discharging compressed air present at top of the
unloader side is exhausted through the exhaust hole
unloader. Then the unloader valve spring puts the
and air supply to the air tank is resumed.
unloader valve back to its original position, causing
the suction valve to begin operation.
2. SPECIFICATIONS
Item Specification
Air Compressor
Type Water-cooled 1-cylinder type Water-cooled 2-cylinder type
Cylinder diameter x stroke mm 85 X 50 80 X 50
Cylinder capacity cc 284 502
Turning direction Clockwise Clockwise
(as viewed from drive side)
Pressure governor
Type Diaphragm type
61-4
SPECIAL EQUIPMENT - SERVICE STANDARS
m
3.1 SERVICE STAN DARO TABLE
(1) 1-cylinder Air Compressor
Unit:m m
Descriptmn Nominal value Limit Correction and

Suction valve spring Installed load/ 4.4 N (0.45 kgfl/5 3.5 N (0.36 kgtl/5 Replace.
installed length
Delivery valve spring 4.5 N (0.46 kgfl/9.5 3.6 N (0.37 kgfl/9.5
Cylinder liner to piston Top portion 1 85) 0.27 Replace piston or

clearance cylinder liner.
Skirt portion 1851 0.18
Piston ring groove to compression ring clearance - 0.08 Replace. (Replace piston
rings as a set.I
Piston ring open end clearance - 1.0 Replace. (Replace piston

rings as a set.I
Fit between piston pin hole and piston pin 1181 0.08 Replace.
Piston pin to connecting rod small end clearance J18J 0.07 Replace piston pin or
connecting rod.
End play of crankshaft - 1.0 Replace.
Crankshaft journal to bearing clearance 1421 0.1 Replace crankshaft or

crankcase.
Crankshaft to connecting rod bearing clearance J34J 0.1 Replace. (Replace bearing
for worn plating.I
End play of connecting rod - 0.5 Replace crankshaft or

connecting rod.
Connecting rod bearing - When internal plating Replace bearing.

is worn to expose
copper color.
(2) 2-cylinder Air Compressor

Unit:mm

Suction valve spring Installed load/ 4.4 N (0.45 kgfl/5 3.5 N (0.36 kgfil Replace.
installed length
Delivery valve spring 4.5 N (O 46 kgtl/9.5 3.6 N (0.37 kgfl/9.5
Cylinder liner to piston Top portion 1801 0.29 Replace piston or

clearance cylinder liner.
Skirt portion J80J 0.17
Piston ring groove to piston ring clearance - 0.08 Replace. (Replace piston
rings as a set.I
Piston ring open end clearance - 1.0 Replace. (Replace piston

rings as a set.I
Fit between piston pin hole and piston pin 1161 0.08 Replace.
Piston pin to connecting rod small end clearance 1161 0.07 Replace piston pin or
connecting rod.
End play of crankshaft - 1.0 Replace.
Crankshaft journal to bearing clearance 14 21 0.1 Replace crankshaft or

crankcase.
Crankshaft to connecting rod bearing clearance 134) 0.1 Replace. (Replace bearing
for worn plating.)
End play of connecting rod - 0.5 Replace crankshaft or

connecting rod.
Connecting rod bearing - When internal plating Replace bearing.

is worn to expose
copper color.
61-5
ID SPECIAL EQUIPMENT - SERVICE STANDARDS
(3) Pressure Governor

Unit: kPa (kg!/cm2)

High pressure valve opening pressure MC802148 +3.4 (+0.35) - Adjust or replace
72 (7.3)
-0.5 (-0.05)
MC802150 3.4 ( 0.35)

78 (8.0) + +
--0.5 (-0.05)
Low pressure valve opening pressure MC802148 +0.5 ( +0.05)

63 (6 4)
. -3.4 (-0.35)
MC802150 +0.5 (+0.05)

70 (7.1)
-3.4 (-0.35)

( 1 ) Air Compressor
Location tightened Thread size Tightening torque Remarks

0.0. x Pitch mm Nm (kgfml
Cylinder head nut 1 cylinder M10 x 1.25 23 to 27

(2.3 to 2.8)
Cylinder head bolt 2 cylinders MlO x 1.5 39 to 49

(4 to 5)
Cylinder liner mounting bolt 2 cylinders MlO x 1.5 25 to 29

(2.5 to 3)
Bearing holder bolt 1 cylinder MB x 1.25 14 to 18

(1.4 to 1.8)
Bearing holder nut 2 cylinders MB x 1.25 14 to 18

(1.4 to 1.8)
Connecting rod cap nut MB x 1.25 23 to 25

(2.3 to 2.6)
Unloader valve guide M28 x 1.5 98 to 115

(10 to 12)
Delivery valve holder M36 x 1.5 98 to 115 Apply 0.2 to

(10 to 12) 0.3 cc of
THREEBOND NEJI
LOCK 13238 to
three threads
Suction valve holder M45 X 1.5 98 to 115

(10 to 12)
Injection pump gear mounting nut M24 x 1.5 215 (22)
Joint PT 1/8 15 to 20
(1.5 to 2.0)
Tachometer sensor M16 x 1.5 24 to 35

(2.4 to 3.6)
(2) Pressure Governor
Location tightened Thread size Tightening torque Remarks

0.0. x Pitch mm Nm (kgfml
Sleeve lock nut - 15 to 20 (1.5 to 2)
Adjusting screw lock nut - 9.8 to 15 ·(1 to 1.5)
61-6
4. SPECIAL TOOL
SPECIAL EQUIPMENT - SPECIAL TOOL
m
Air Compressor
Unit: mm
.-W��, -
Suction valve tool MH0612G3 Removal and installation
of suction valve holder
V .:, )
13
B5241A
Piston ring tool MH060014 Removal and installation of air

compressor piston ring
for 60 to 120
d1rirneter
B5231A
61-7
ID SPECIAL EQUIPMENT - SERVICE PROCEDURES
5.1 AIR COMPRESSOR
[1-cylinder type) [2-cylinder type)
8
Water outlet pipe
2 Air outlet pipe
3 Unloader pipe A
4 Unloader pipe B (2-cylinder type only)
5 Water inlet pipe
6 Air suction hose (1-cylinder type)
Air suction pipe (2-cylinder type)
7 Oil pipe
8 Air compressor 890508 890518
NOTE:
1. To remove the air compressor, remove
the injection pump beforehand.
2. At installation, the injection pump gear
installed on the air compressor should
be in mesh as specified.
61-8
SPECIAL EQUIPMENT - SERVICE PROCEDURES
Installation of Air Compressor (2) Insert the bolt (M10 x 1.5 about 100 mm long)
from the rear end of the flywheel housing to support
the air compressor. Using the bolt as a guide, insert
the air compressor into the mounting hole of the
flywheel housing. At the position where both ends of
the injection pump gear and idler gear C have
touched each other, align the inscribed line on the
----
rear plate with that on the injection pump gear tooth
-- _,/
surface, and then push the air compressor in.
C0767A
Tachometer sensor or
plug mounting position
(1) Crank the engine to align the stamped mark "1, 6"
on the periphery of the flywheel with the pointer of
the inspection window in the flywheel housing and
put the piston in the No. 1 cylinder of the engine at top
dead center on the compression stroke.
Flywheel housing
If the piston in the No. 1 cylinder is at top dead center
on the compression stroke, the No. 1 cylinder will
have a valve clearance. If both inlet and exhaust Sensor plate projection
valves have no valve clearance, the piston in the No. 6
cylinder will be at top dead center on the compression
stroke. So let the engine rotate 360° .
NOTE:
When the engine is to be cranked, make
Threaded hole
sure that it is cranked manually more than
180° in the normal direction.
C0769A
(3) Remove the tachometer sensor or plug. Look

through the threaded hole to confirm that the projec
Air
compressor
tion on the sensor plate is positioned at the center of
the threaded hole, and then secure the air compress
or. If the projection on the sensor plate is not
positioned at the center of the threaded hole, remove
the air compressor and perform Item (3) again.
After the air compressor has been installed, install the
plug.
Injection pump gear C0768A
NOTE:
If the injection pump gear and idler gear C
are misaligned a tooth, about half of the
projection on the sensor plate will be
hidden from the plug hole.
61-9
m SPECIAL EQUIPMENT - SERVICE PROCEDURES
(4) Installation of Tachometer Sensor (b) Adjusting type

(a) Non-adjustable type
Clearance Flywheel housing
0.5 to 1.5 mm
Sealant to be applied
to threaded portion
(THREEBOND 1211) Hexagonal portion
Sensor plate
24 to 35 Nm
(2.4 to 3.6 kgfm)
Tachometer sensor
Lock nut 24 to 35 Nm
(2.4 to 3.6 kgfm)
N2825A
C0762A
To mount the tachometer sensor, apply sealant to the
To install the tachometer sensor, apply sealant to the threaded portion of the sensor and screw it in until it
threaded portion of the sensor and screw the sensor seats on the sensor plate. Thereafter, back it off
in until the hexagonal portion of the sensor seats. two-thirds of a turn (240° ) (to make 1.0 mm clearance).
Tighten the lock nut to the specified torque.
61-10
5.1.2 Disassembly
•
[1-cylinder Type)
Settling
L Limit
wear
2 Cracks,
3 wear
Wear,
Cracks
��11;f� ,: 0
damage
2
Scratch. clogged oil hole
J� ��
Crankshaft end play
L 1.0
25
Sensor plate 11 Spring holder '2f1 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 !15i 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 1201 Compression ring 30 Crankshaft
31 Crankcase

follows.
D9252A
NOTE:
Do not remove the stud bolt unless trouble is evident.
61-11
m
(2-cylinder Type I
4
Cracks. 23
scratch
Cracks. wear of
bushing, clogged
oil hole
26
Damage of
circle, wear
1
Cracks,
wear
I 30
:�28 Damage of circle. wear
�_
�27
!
29
Wear. damage Crankshaft end play
L 1.0
L Limit
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 (1_41 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 (i_o; Oil ring 30 Crankcase

follows.
09253A
The procedures for disassembly of the 1- and 2- procedures for disassembly of the 1-cylinder type are
cylinder types are much the same. So only the described below.
61-12
•
D9259A
D9257A
(2) Using Piston Ring Tool (special tool), remove the
(1) Using Suction Valve Tool (special tool), remove compression ring and oil ring from the piston.
the suction valve holder from the bottom surface of NOTE:

the cylinder head and remove the suction valve When a piston ring is removed, do not
spring, suction valve and suction valve seat. widen the open ends of the piston ring
NOTE: more than 28 mm for 1-cylinder type and
Since the suction valve holder is staked by more than 26 mm for 2-cylinder type.
punching, do not attempt disassembly un
less trouble is evident.
61-13
m
5.1.3
Inspection and Correction

(1-cylinder Type]
Tension
NV 4.5 N (0.46 kgfl/9.5
L 3.6 N (0.37 kgfl/9.5
Tension
NV 4.4 N (0.45 kgf)/5
L 3.5 N (0.36 kgtl/5
Piston ring groove to Clearance

compression ring clearance BO 85
L 0.08 L Top 0.27
Skirt 0.18
Piston ring open
end clearance
L 1.0
Clearance
BD 18
L 0.08
Clearance
BO 18
L 0.07
Connecting rod end play

L 0.5
Clearance
BO 34
L 0.1
Clearance
BD 42
L 0.1
Crankshaft end play

L 1.0
BD .. Basic Diameter
NV.. Nominal Value
L Limit
D9252B
61-14
(2-cylinder Type]
SPECIAL EQUIPMENT - SERVICE PROCEDURES •
Tension Load/installed length
NV 4.5 N 10.46 kgfi/9.5
L 3.6 N 10.37 kgfi/9.5
Tension Load/installed length

NV 4.4 N I0.45 kgfi/5
L 3.5 N 10.36 kgfi/5
Clearance
BO 80
L Top 0.27
Skirt 0.18
Clearance
BO 16
L 0.08
Connecting rod end play

L 0.5
Clearance between piston ring and

piston ring groove
L 0.08
Piston ring open end clearance

L 1.0
BD . Basic Diameter
NV.. Nominal Value
L Limit
D9253B
61-15
(1) Piston and Cylinder Liner (a) Measure the clearance between the piston ring
groove and compression ring. If the clearance is over
the limit, replace the compression ring or piston.
NOTE:
Measure the clearance all around the pis
ton.
Cylinder liner
Piston measuring direction
measuring direction
Measuring position Measuring position
D9266A
(b) Fit the piston ring over a standard gauge or new

cylinder liner and measure the open end clearance. If
the clearance is over the limit, replace the piston ring.
D9264A
NOTE:
Push the piston in and measure the clear
Measure the cylinder liner inside diameter and piston
ance with the piston ring in horizontal
top and skirt outside diameter and calculate the
position.
clearance.
If the clearance is over the limit, replace the piston or
(3) Connecting Rod and Crankshaft
cylinder liner .
. (2) Piston Ring
Measuring position Measuring direction
EB
D9267A
(a) Calculate the clearance from the piston pin out

D9265A
side diameter and connecting rod small end inside
diameter. If the clearance is over the limit, replace the
piston pin or connecting rod.
61-16
m
(c) Measure the crankshaft journal outside diameter
[Crankshah[
Mr.asuring
and bearing inside diameter and calculate the clear
Measuring position direction ance. If the clearance is over the limit, replace parts.
End play
!Connecting rod bearing! 09268A

Measuring
Measuring direction position
09270A
(d) Measure the end play in the connecting rod and

crankshaft and, if the play exceeds the limit, replace
the connecting rod.
(4) Piston Pin

84134A
(b) Measure the diameter of connecting rod bearing

sliding section. If the diameter is smaller than the
Measuring position
limit, replace the crankshaft.
Replace the connecting rod bearing if the plating layer
Measuring direction
on its inner surface is worn out and copper color
metal appears.
EB
Measuring position 09271A
Measure the piston pin outside diameter and the pin

fitting hole inside diameter of the piston and calculate
the clearance. If the limit is exceeded, replace the
piston pin or piston.
09269A
61-17
m SPECIAL EQUIPMENT
(5) Unloader Valve Assembly

SERVICE PROCEDURES
If the unloader valve in unloader valve assembly is

badly worn, replace the unloader valve assembly.
Snap ring
�
Unloader valve-----1
tr
Valve spring ------�
Valve guide
D9272A
61-18
5.1.4 Reassembly
•
(1-cylinder Type]
98 to 115 Nm
(10 to 12 kgfm)
98 to 115 Nm
98 to 115 Nm 1
( 0 to 12 kgfm)
9 (10 to 12 kgfm)
� 10 4
15
6 � 11
"--
/
� Apply 0.2 to 0.3 cc of
THREEBOND Neji Lock
TB13238 or equivalent to
three threads
5
15 to20Nm
(1.5 to2.0 kgfm)
1 23 to25 Nm
(2.3 to2.6 kgfm)
Apply engine oil 215 Nm
to lips (22 kgfml
14 to 18 Nm
/'
(1.4 to1.8 kgfm)
31 30 29 28
<Assembly sequence>
31->30->2 9->ti&'>--.@--,25---,26->24->23->22->@--,@---,1 9_, 5--->4->
3->@--,(i) J
14->13->12->11--,10->18---,17->16->��
8---, 7-->6->9---------��
For reassembly of parts with an encircled number, see procedure

given in the following
.
B3256C
61-19
m
[2-cylinder Type]
Apply 0.2 to 0.3 cc

THREEBOND Lock Paint
13238 to three threads
98 to 115 Nm
(10 to 12 kgfm)
98 to 115 Nm
8 (10 to 12 kgfm)
4 9
5
6
:tT��19 12
20 13
15 to 20 Nm 15
(1.5 to 2.0 kgfm)
0
Apply engine oil to lips

215 Nm
(22 kgfm)
Locating pin
Bend lock washer

14 to 18 Nm
(1.4 to 1.8 kgfm)
26 27 28 29 30 3 2 1
23 to 25 Nm
(2.3 to 2.6 kgfm)
<Assembly sequence>
30-+29-->24-->25-->28----,(27)-,�i\1---->23---,22---,21 -,120)----,(19,-.18-,4--,3--,•:i ._., 1)
13_, 12-, i 1-,10-+9_, 17_, 16-> 15-->114f--, J
8---, 7---,&-,5
For reassembly of parts with an encircled number, see procedure given in the
following.
N27538
61-20
m
( 1) Assembly of Connecting Rod Face side with letters
stamped lip
1_st com pression

rtng
'<.):r. --��
•.
-
2nd, 3rd compression
ring
LC�
Connecting <2- Oil ring
Nut
rod 23 to 25 Nm cylinder>
(2 3 to 2.6 kgfm)
Bend lock washer <1-

id_e ring
COil ring
-h/
cylinder> Side ring
( /jk
2nd compression
Alignment marks .,,,.-----t_:::;,< ring ends
Approx. /
/ Jr
_,.,...-----1 Approx.
Position notch in holt head 0 1 120 120"
the connecting rod cap end �
83259A
Make sure th'at the alignment mark on the connecting

·/:��) ��0\,
rod is aligned with that on the connecting rod cap.
3rd comprssion ring \';:r;-;;;,\�rox 1_st compression
ends \ Oil rinlg ends nng ends
(2) Installation of Piston Rings
Side ring Side ring
ends ends
<1-cylinder> <1-cylinder>
N2044D
Make sure that the right piston rings are installed at

the right positions and their sides with letters
stamped face up. Keep the compression ring ends
120° apart from one another; place the oil ring ends at
the center between the ends of compression rings;
place the side ring ends 45° further away to the right
and left from the oil. ring ends.
�-'��
\\ �09259A (3) Installation of Suction Valve Holder
61-21
(4) Installation of Injection Pump Gear
Punch at three places. "U" mark,

except the head gasket
surface
83251A
83262A
Stake the cylinder head at three places shown over
the suction valve holder. Install the injection pump gear, sensor plate, and nut
as instructed in the figure.
5.2 PRESSURE GOVERNOR
Damage, corrosion
Settling, damage
Damage, corrosion <Disassembly sequence>

Cover 6 Filter
Damage, deterioration
2 Adjusting screw 7 Screen
3 Spring 8 Cap
8 4 Sleeve 9 Diaphragm
7--o 5 Snap ring 10 Body
6---8 i Repair Kit:
Pressure Governor Kit
5 ,..------@
84081A
61-22
5.2.2
Reassembly and Adjustment

m
Unit: kPa (kgf/cm')
Part no. Nominal value
High pressure valve Low pressure valve

opening pressure opening pressure
MC802148 t-3.4 ( 10.351 +0.5 (-t-0.051

72 (7_3) 63 (6 41
-0.5 (-0 05) -3.4 (-0.35)
MC802150 f 3.4 ( +0.35) I 0.5 ( + 0.05)

78 (8.0l 70 (7.11
-0.5 (-0.051 -3.4 (-0 35)
pressure valve <Assembly sequence>

10-9-8--7--,6-----5-4----3-2-1
5 840808
Testing (3) Slowly decrease the air tank pressure and check
that the air gauge reading starts to increase when the
Pressure governor Air gauge nominal pressure (low pressure valve opening pres
sure) is reached.
For adjustment, use the adjusting screw. After adjust
ment, tighten firmly with the lock nut.
(4) After tightening the lock nut, check again the high
and low pressure valve opening pressures. If they are
out of specification, adjust again.
(5) Install and seal the cover.
Air compressor Air tank

84082A
(1) Connect an air gauge between the pressure

governor and air tank.
(2) Start the engine and increase air pressure slowly
while observing the air gauge. Check that the reading
of the gauge when it has stabilized is as specified
(high pressure valve opening pressure).
If not, adjust by adjusting tightening amount of the
sleeve. After adjustment, tighten firmly with the lock
nut.
61-23
Notes: for 6D22 parts call: Phone: 269 673 1638
or email: EngineParts2@gmail.com
Mitsubishi 6D22 Gasket and Seal Reference Page 1 of 28 Valve Stem Seals, Rocker Shaft Bracket Orings,
e
e
e
0 .e
I
Oring under
rC-t
Rocker Shaft Bracket @
� MH096246
I
QValve Stem Seal
CJ M E092685
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 2 of 28 - 6D22 Head Gasket , Cylinder Head Soft Plugs, Injector Tube,
M E998000 Kit
6022 Cylinder Head
Soft Plug Kit
( all soft plugs for 6
cylinder heads )
� Injector Tube
v-ME998605
c= _oring ME998607
( for injector tube )
Sealing Cap
Soft Plug ME99809 �----
g. Sealing Cap
Soft Plug ME99809
Head Gasket
ME998722
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 3 of 28 Injector Gaskets and Seals
Sealing Washer
ME997905
� Injector-Tube
v--ME998605
0.: _ Oring ME998607

( for injector tube )
i
Sealing Washer
ME916490 -===:::::
� //!;'E916402
SealRing
ff
I
r L
�
sealRlog
ME916414
0
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 4 of 28 6D22 Valve Cover Gasket, Seal Grommet,
�::�:;�;,m et, Valve Cove c
� Valve Cover Gasket

�ME962499
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 5 of 28 6D22 Exhaust Manifold Gaskets, Seal Rings,
www.6D22.com
Mitsubish i 6D22 Gasket and Seal Reference Page 6 of 28 6D22 Turbo Mounting Gasket, Air Intake Plug Sealing Washer
Gasket,
Turbocharger to
Exhaust Manifold
ME980061
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 7 of 28 6D22 Turbo Lines Gaskets and Sealing Washers
�
Gasket, Turbo Oil
Return Line to
Block
ME977030
�
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 8 of 28 6D22 Intake Manifold Gaskets
Intake Manifold Gasket ME099644
Intake Elbow Gasket

ME098201
Intake Elbow Gasket with

Screen ME099649
-www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Pag_e 9 of 28 6D22 Intake Heater Gaskets
ME999602 Intake Heater

ME999612 Element
0
Intake Manifold �
Gasket, for-�/
u
engines with
O �
intake heaters.
ME999612 Intake Manifold

--Gasket, for engines with intake
heaters.
ME999603 Gaskets for

�
\�
Intake Manifold Spacers
ME099640 Intake
Manifold Gasket ME999601 Gaskets for
��---, Intake Manifold Spacers
I
P
o _ rHO �-,
·,' ,· 0
--ME099632 Intake
Manifold Gasket
'J
( for engines with intake
manifold heaters )
ME099608 Intake
Heater Element
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 10 of 28 6D22 Rear Crankshaft Seal, Three Types Rear Crankshaft Seal.
Mitsubishi 6D22 Rear Crankshaft Seal Reference Page, Three Types Rear Crankshaft Seal.
1. Rear Crnnkshaft Seal Combined with Four Bolt Retainer Assembly
2. Rear Crankshaft Seal - Two Seal Type
3. Rear Crankshaft Seal - One Seal Type
Gasket ME150048
-- - - --·
r-- --
l. -aI\"\,JJ
I
ME963604 Rear Crankshaft Seal with

'°"' Bolt Reta;M, As<emb.
3092020100 Slinger
Two Seal Type
ME151333 Sleeve ME058232 Retainer

Assembly for Two Oil Seals
One Seal Type
ME058232 Retainer
Slinger Assembly for One Oil Seal
ME15 909 Rear

Crankshaft Oil Sea I.
for One Seal Type
www.6D22.com
Mitsubishi 6022 Gasket and Seal Reference Page 11 of 28 6022 Rear Flywheel Housing Gaskets
MF931522 Oring
ME963801 Gasket
ME963782 Gasket,
Plate to block
ME963789 Gasket,
Flywheel housing to plate
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 12 of 28 6D22 Front Crankshaft Seal, Gasket, Side Cover Gaskets.
Front Crankshaft Seal �

ME979033'
Slinger ME971034 \
Gasket ME942608
Side Cover Gaskets (3)
ME940057
www.6D22.com
Upper Cylinder L"iner Seals
ME963597
Middle Cylinder Liner
. Seal
ME963608
Lower Cylinder Liner
. Seals
ME963610
Soft Plug
MF998847
A' Sealing Washer

MH942197
Sealing Washer/�
MH946199
www.6D22 .com
Mitsubishi 6D22 Gasket and Seal Reference Page 14 of 28 6D22 Oil Cooler Gaskets and Seals
ME969501 Gasket, Oil Cooler Housing to Block
MF969623 Orings, Oil Cooler Housing to Block
MF969311 Oring
�
0/
MF969313 Oring
()
'c:JJ ME998629 Sealing Washers
@ ·,
"'5
ti
l@--
� ME998633 Sealing Washer
MF969311 Oring ------i
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 15 of 28 6D22 lntercooler Gaskets and Seals
,�
ME969904 Gasket
ME969849 Gaskets
for Inter Cooler
__,,--�·,
MF969773 Orings
MF969773 Orings
ME969904 Gasket� • .
�
� MF969704 Sealing Washers
L--1
��
�J'\.
� ME969982 Gasket
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 16 of 28 6D22 Injection Pump Oil Line Seals
AD Type Injection Pump P Type Injection Pump
Oring, ME997625 Oring, ME997625

for pressure regulator for pressure
regulator
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 17 of 28 6D22 Oil Pump Gaskets
Gasket, oil pump to

oil outlet tube
ME998607
Mitsubishi 6022 Gasket and Seal Reference Page 18 of 28 6022 Oil Pan Gasket and Sealing Washers
Oil Pan Gasket

ME998508
Sealing Washer
( for oil pan plug )
ME998622 ----
o -sealing Washer
� ( for oil pan plug )
ME998629
www.6D22.com
Mitsubishi 6022 Gasket and Seal Reference Page 19 of 28 6022 Injection Pump Drive Gaskets and Seals
MF969591 Oring ME970401 Gasket
ME924665 Oil Seal
MF969800 Oring
www.6D22.com
Mitsubishi 6022 Gasket and Sea I Reference Page 20 of 28 6022 PTO Orive
. Gaskets and Seals
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 21 of 28 6D22 Water Pump Seals, Thermostat Gasket.
ME979604 Oring
MF906631 Sealing Washer
ME930669 Gasket
for thermostat
MH964114
Water Pump Seal Assy
MH661202 Sealing
Washer
www.6D22.com
Mitsubishi 6D22 Gas ket and Seal Reference Page 22 of 28 6D22 Timmg Gear Orings
MF961701 Oring
MF961694 Oring
www.6D22.com
Dip stick and Block
6D22 Gaskets and O<in gs lo<
Mitsubishi 6D22
Gasket and seal
Referenc e Page 23 of 28 @
ck
Oring, for dipsti
MF9300 06
881
Gasket ME942
g
MF921 633 Orin
m
www .6022.co
Mitsubishi 6D22 Gasket and Seal Reference Page 24 of 28 6D22 Water Manifold Gaskets and Seals.
--
Water Manifold
Oring
ME979604 Sealing Washer
I on water manifold olua \
ME979803
www.6D22.com
Mit,ubi<hl6D22Gasle!andSealRe!erenceP,>ge2�of286D220ilLineSeal,withlntercooler
Mitsubishi 6D22 Gasket and Seal Reference Page 26 of 28 6D22 Parts - Notes
www.6D22.com
www.6D22.com
www.6D22.com
Mitsubishi 6D22 Parts Description -
( Partial List ) Reference: www.HeavyEquipmentRestorationParts.com
ME052488 6D22 Bearing Set
MF140258 6D22 Bolt
MH000707 6D22 Bolt
MH000714 6D22 Bolt
ME151450 6D22 Bushing, Connecting Rod
ME051187 6D22 Cam Bushing
ME052330 6D22 Connecting Rod
ME999365 6D22 Cylinder Head
ME050502 6D22 Cylinder Liner
855315 6D22 Cylinder Liner Cat Excavator
30922200102 6D22 Damper
ME052337 6D22 Damper
ME068269 6D22 Damper
ME051697 6D22 Exhaust Valve
3110401103 6D22 Exhaust Valve
ME979033 6D22 Front Crankshaft Seal
ME051575 6D22 Head Gasket
ME059751 6D22 Injection Pump Body
ME050825K 6D22 Injection Pump Rebuild Kit
ME050883 6D22 Injector
3090400302 6D22 Intake Valve
3090400401 6D22 Intake Valve
ME051063 6D22 Intake Valve
ME963597 6D22 Liner Seal
ME052038 6D22 Main Bearing
ME150453 6D22 Oil Cooler
ME051615 6D22 Oil Jet
ME051709 6D22 Oil Jet
3090711400 6D22 Oil Jet
ME998508 6D22 Oil Pan Gasket
ME120351 6D22 Oil Pump
ME054373 6D22 Oil Pump Cover
ME052597 6D22 Piston
861395 6D22 Piston Cat Excavator
1R5828 6D22 Piston Cat Excavator
3091737100 6D22 Piston Ring
ME052029 6D22 Piston Ring
ME052124 6D22 Piston Ring Set
3091720010 6D22 Piston Ring Set
861396 6D22 Piston Ring Set Cat Excavator
1R5909 6D22 Piston Ring Set Cat Excavator
ME150909 6D22 Rear Crankshaft Seal
ME058006 6D22 Ring Set
ME051051 6D22 Rocker Arm
ME940057 6D22 Side Cover Gaskets
3092020100 6D22 Slinger
ME930669 6D22 Thermostat Gasket
31109-07109 6D22 Thrust Washer
ME051120 6D22 Valve Guide
MH964114 6D22 Water Pump Seal Assembly, Internal
MH037087 Banjo Bolt 6D22
ME705400 Banjo Bolt 6D22 Injector
3092503800 Bearing 6D22
ME719820 Bearing 6D22 Turbocharger
ME052054 Bearing Set
MH052053 Bearing Set
MH040026 Bearing,
ME704268 Bearing, 6D22 Injection Pump
ME719030 Bearing, 6D22 Turbocharger
MS556005 Bearing, 6D22 Water Pump
MS556125 Bearing, 6D22 Water Pump
ME152008 Bolt
MF241222 Bolt
MH000714 Bolt
MH000733 Bolt
ME061330 Bolt
MF140260 Bolt
MH000706 Bolt 6D22 Oil Line
MF300843 Bolt, 6D22
MF303367 Bolt, 6D22
MF303374 Bolt, 6D22
3091900400 Bolt, 6D22 Connecting Rod
ME052765 Bolt, 6D22 Connecting Rod
MF300843 Bolt, 6D22 Cylinder Block
MH000706 Bolt, 6D22 Cylinder Block
MF300896 Bolt, 6D22 Engine Mount
MH000727 Bolt, 6D22 Engine Mount
MH000392 Bolt, 6D22 Exhaust
MH000679 Bolt, 6D22 Exhaust
ME052691 Bolt, 6D22 Flywheel
ME052693 Bolt, 6D22 Flywheel
MF100031 Bolt, 6D22 Flywheel Housing
MH000924 Bolt, 6D22 Flywheel Housing
MF243649 Bolt, 6D22 Flywheel Housing,
MH000925 Bolt, 6D22 Flywheel Housing,
ME704150 Bolt, 6D22 Injection Pump
MH000714 Bolt, 6D22 Intake
MF140020 Bolt, 6D22 Intake Heater
MS146006 Bolt, 6D22 Oil Cooler
MF140011 Bolt, 6D22 Oil Line
MF140013 Bolt, 6D22 Oil Line
MF140002 Bolt, 6D22 Oil Pan
MH000707 Bolt, 6D22 Oil Pan
MH000830 Bolt, 6D22 Oil Pan
MH001103 Bolt, 6D22 Rocker Cover
MH000377 Bolt, Crankshaft Pully
MH000922 Bolt, Damper
MF000729 Bolt, Exhaust
MH000679 Bolt, Exhaust
ME051712 Bolt, for oil jet
ME061330 Bolt, Main Cap
ME150511 Bracket, 6D22 Rocker Shaft
3090402200 Bushing, 6D22
3092502901 Bushing, 6D22
ME034549 Bushing, 6D22
ME704596 Bushing, 6D22 Governor
ME704055 Bushing, 6D22 Injection Pump
ME704057 Bushing, 6D22 Injection Pump
ME051209 Camshaft,
ME151299 Camshaft,
ME704094 Camshaft, 6D22 Injection Pump
ME704147 Camshaft, 6D22 Injection Pump
3000424302 Cap
ME031518 Check Valve, Oil Jet Bolt,
ME062573 Collar
3092504400 Collar
3097521400 Compressor Piston
ME052330 Connecting Rod
3091902102 Connecting Rod Bearing, Lower
ME052334 Connecting Rod Bearing, Upper
ME056100 Coupling, 6D22 Injection Pump
ME056242 Coupling, 6D22 Injection Pump
ME058609 Coupling, Exhaust Pipe
ME150441 Cover, 6D22 Oil Cooler
ME996339 Crankshaft 6D22
ME998340 Crankshaft 6D22
ME719270 Deflector, 6D22 Turbocharger
ME062523 Director, Cylinder Head Water 6D22
MF472407 Dowel Pin, 6D22 Crankshaft
MF472405 Dowl Pin 6D22 Flywheel
ME153170 Element, 6D22 Oil Cooler
ME153172 Element, 6D22 Oil Cooler
ME964223 Exhaust Manifold Gaskets 6D22
ME964643 Exhaust Seal Rings 6D22
ME150048 Flywheel Housing Gasket
ME062828 Flywheel Ring Gear
ME942608 Gasket
ME969980 Gasket
ME977030 Gasket
ME0988209 Gasket
ME942663 Gasket
ME942881 Gasket
ME942906 Gasket
ME942907 Gasket
ME963782 Gasket
ME963789 Gasket
ME963801 Gasket
ME969303 Gasket
ME969982 Gasket
MH033077 Gasket
ME942881 Gasket, 6D22 Block
ME997610 Gasket, 6D22 Engine Oil Pump
ME998633 Gasket, 6D22 Engine Oil Pump
ME969312 Gasket, 6D22 Gear Housing
ME704586 Gasket, 6D22 Governor
375117000 Gasket, 6D22 Injection Pump
ME704044 Gasket, 6D22 Injection Pump
ME970401 Gasket, 6D22 Injection Pump Drive
ME969962 Gasket, 6D22 Intake Heater
ME969849 Gasket, 6D22 Intercooler
ME969904 Gasket, 6D22 Intercooler
ME969501 Gasket, 6D22 Oil Cooler
ME998604 Gasket, 6D22 Oil Pump
ME969310 Gasket, 6D22 PTO Drive
ME977028 Gasket, 6D22 Turbo Oil Return Line
ME980061 Gasket, 6D22 Turbocharger to Manifold
ME977602 Gasket, 6D22 Water Manifold to Head
3003232100 Gasket, Exhaust Pipe
ME063680 Gasket, Exhaust Pipe
ME120385 Gear and Case 6D22 Oil Pump
3123500044 Gear, 6D22 Oil Pump
ME054703 Gear, 6D22 Oil Pump
ME150506 Gear, Cam Idler
ME151298 Gear, camshaft
ME091034 Gear, Crankshaft
ME052996 Gear, Inj Pump Drive
ME150689 Gear, Inj Pump Idler
ME051515 Head Bolt 6D22
ME704011 Holder, 6D22 Injection Pump
ME704041 Holder, 6D22 Injection Pump
ME705431 Holder, 6D22 Injector
ME055398 Impeller, 6D22 Water Pump
ME157062 Impeller, 6D22 Water Pump
ME059655 Injection Pump Body
ME059669 Injection Pump Body
ME998605 Injector Tube, 6D22
ME098201 Intake Elbow Gasket 6D22
ME099649 Intake Elbow Gasket with screen 6D22
ME999603 Intake Gasket
ME999601 Intake Gasket 6D22
ME099608 Intake Heater Element 6D22
ME999602 Intake Heater Elemment 6D22
ME999612 Intake Manifold Gasket
ME099644 Intake Manifold Gasket 6D22
ME099632 Intake Manifold Gasket for 6D22 Intake Heater
ME099649 Intake Manifold Gasket with screen
ME099640 Intake Manifold Gasket with screen 6D22
ME099640 Intake Manifold Gasket with screen 6D22
MS476135 Key,
ME996464 Kit
ME997089 Kit
ME997284 Kit
ME997802 Kit
ME998000 Kit, 6D22 Cylinder Head Soft Plug Kit
ME997018 Liner & Piston Kit
3120434200 Lock , valve keeper 6D22
ME051705 Mitsubishi 6D22 Washer
ME705429 Nozzle, 6D22 Injector
ME032042 Nut
MF430122 Nut
MF430007 Nut, 6D22 Exhaust
MF434105 Nut, 6D22 Exhaust
MH004054 Nut, 6D22 Exhaust
MS430007 Nut, 6D22 Exhaust
MS446185 Nut, 6D22 Exhaust
ME051197 Oil Jet 6D22
MC850069 Oil Pressure Gauge
ME924665 Oil Seal, 6D22 Injection Pump Drive
ME972338 Oil Seal, 6D22 PTO
MF969804 Oring
MD000523 Oring
MF921633 Oring
MF930006 Oring
MF931522 Oring
MF969640 Oring
MH096246 Oring
ME979604 Oring 6D22 Thermostat Housing
ME701153 Oring, 6D22 Injection Pump
MF969591 Oring, 6D22 Injection Pump Drive
MF969800 Oring, 6D22 Injection Pump Drive
MF969773 Oring, 6D22 Intercooler
3110702401 Oring, 6D22 Liner
ME051375 Oring, 6D22 Liner
MF969623 Oring, 6D22 Oil Cooler
MF969628 Oring, 6D22 Oil Cooler Element
MF969630 Oring, 6D22 Oil Cooler Element
ME997625 Oring, 6D22 pressure regulator
ME150992 Oring, 6D22 Rear Crankshaft Seal
MF961694 Oring, 6D22 Timing Gear Shaft
MF961701 Oring, 6D22 Timing Gear Shaft
ME979604 Oring, 6D22 Water Pump
MF969305 Oring, 6D22 Water Pump
MF969332 Oring, 6D22 Water Pump
ME998607 Oring, for Injector Tube
ME061399 Outer Valve Spring 6D22
ME051094 Packing
3090722300 Packing, 6D22 Liner
MH012026 Pin, Crankshaft
MF472405 Pin, cylinder block 6D22
MH007011 Pin, cylinder block 6D22
3003233030 Pipe, Exhaust
3003233040 Pipe, Exhaust
ME157305 Pipe, Exhaust
32261002 Piston Connecting Rod Assembly 6D22
ME052149 Piston Pin
ME052149 Piston Pin 6D22
3031900600 Piston Pin Bushing 6D22
3031900690 Piston Pin Bushing 6D22
ME052158 Piston Pin Bushing 6D22
3121733100 Piston Pin Retainer
ME062326 Plate
ME062660 Plate
MH037725 Plug
MH037137 Plug
ME031088 Plug, threaded
ME704144 Plunger, 6D22 Injection Pump
ME051180 Push Rod, 6D22
ME051199 Push Rod, 6D22
ME705406 Push Rod, 6D22 Injector
3093194010K Rebuild Kit for 6D22 Turbocharger
ME050738K Rebuild Kit for 6D22 Turbocharger
ME995231K Rebuild Kit for 6D22 Water Pump
ME995234K Rebuild Kit for 6D22 Water Pump
MEO95645 Retainer
3121733100 Retainer Ring, 6D22 Piston
ME058232 Retainer, 6D22 Rear Crankshaft Seal, specify one or two seal type
3112100201 Ring Gear
4480102200 Ring Gear
ME062696 Ring Gear
ME053951 Ring Seal
ME719056 Ring, 6D22 Turbocharger
3097502050 Rings, Compressor Piston
ME051584 Screw,
ME041001 Screw, Valve Adjust
MF669804 Seal
MF669805 Seal
MF669902 Seal
MF669909 Seal
MF669912 Seal
MF669913 Seal
MF669914 Seal
MF669916 Seal
MF669919 Seal
ME962485 Seal Grommet, 6D22 Valve Cover
ME916402 Seal Ring, 6D22 Injector
ME916414 Seal Ring, 6D22 Injector
ME063946 Seal Ring, 6D22 Turbocharger
ME034997 Seal Ring, Exhaust Pipe
ME705228 Seal, 6D22 Governor
ME705333 Seal, 6D22 Governor
ME705210 Seal, 6D22 Injection Pump
ME998801 Seal, 6D22 pressure regulator
MF969311 Sealing Ring
MF969313 Sealing Ring
MH946199 Sealing Washer
MF906631 Sealing Washer 6D22 Thermostat Housing
MH661202 Sealing Washer 6D22 Water Pump
ME051374 Sealing Washer,
ME051705 Sealing Washer,
ME998629 Sealing Washer, 6D22 Air Compressor
ME998551 Sealing Washer, 6D22 Injection Pump
ME998601 Sealing Washer, 6D22 Injection Pump
ME916490 Sealing Washer, 6D22 Injector
ME997905 Sealing Washer, 6D22 Injector
MH942197 Sealing Washer, 6D22 Oil Jet
ME977020 Sealing Washer, 6D22 Turbo Oil Line
ME051353 Seat Exhaust
ME051354 Seat Exhaust
ME051214 Seat Intake
3093615300 Seat, 6D22 Oil Pump
ME051034 Seat, Exhaust
ME051354 Seat, Exhaust
ME051300 Seat, Intake
ME051083 Seat, Valve Spring
ME719350 Shaft & Turbine, 6D22 Turbocharger
ME719756 Shaft & Turbine, 6D22 Turbocharger
3123500501 Shaft, 6D22 Oil Pump
ME054372 Shaft, 6D22 Oil Pump
3092504100 Shaft, Cam Idler
ME150519 Shaft, Cam Idler
ME150520 Shaft, Cam Idler
ME151333 Sleeve
ME704024 Sleeve, 6D22 Injection Pump
ME060125 Slinger
ME971034 Slinger
ME999101 Slinger
MF522236 Snap Ring
ME704404 Snap Ring, 6D22 Injection Pump
MF998840 Soft Plug
MF998847 Soft Plug
ME998007 Soft Plug Kit, 6D22 Block
ME99809 Soft Plug, Sealing Cap
MH012037 Spring pin
ME704668 Spring, 6D22 Governor
ME705405 Spring, 6D22 Injector
3093615200 Spring, 6D22 Oil Pump
ME054393 Strainer
ME054526 Strainer
ME157586 Strainer
ME157587 Strainer
MF407035 Stud, 6D22 Exhaust
MF407728 Stud, 6D22 Exhaust
MF401931 Stud, 6D22 Flywheel Housing
MF402541 Stud, 6D22 Flywheel Housing
MH002113 Stud, 6D22 Flywheel Housing
MF406288 Stud, cylinder block 6D22
MH002131 Stud, cylinder head 6D22
MC840219 Switch 6D22 Oil Pressure
ME049107 Switch 6D22 Oil Pressure
ME061021 Tappet
ME704062 Tappet, 6D22 Injection Pump
ME722244 Tappet, 6D22 Injection Pump
ME151300 Thrust Plate
3090401600 Thrust Plate, 6D22 Rocker Shaft
3120978101 Thrust Washer Set 6D22
ME056097 Timer, 6D22 Injection Pump
3003291300 Turbine Seal
ME051410 Upper Valve Spring Retainer 6D22
ME061746 Upper Valve Spring Retainer 6D22
ME051694 Valve Cover
ME051372 Valve Cover
ME051373 Valve Cover Gasket 6D22
ME962499 Valve Cover Gasket 6D22
ME051208 Valve Spring
ME061398 Valve Spring
ME092685 Valve Stem Seal 6D22
ME704008 Valve, 6D22 Injection Pump
ME084527 Valve, Oil Cooler Bypass
ME074455 Valve, Oil Pressure Regulator
ME719360 Wheel Compressor 6D22
ME719843 Wheel Compressor 6D22
MB110315
MC000039
MC000241
MC000325
MC010080
MC010186
MC011294
MC011362
MC012759
MC041272
MC251843
MC420083
MC429036
MC513075
MC521036
MC840100
MC840110
MC840182
MC840219
ME052868
ME052886
ME052887
ME052888
602
ENGINE
Shop Manual
364 MAR. 1989
200 IHI

Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II

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Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II

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Shop Manual

Pub. No. 97841-02003

This shop manual contains the specification, con­ LUBRICATION ..............................

Applicable Engine Models

EngineParts2@gmail.com Parts phone: 269 673 1638

No. Group name Description

2. TERMS AND UNITS

(1) Front and Rear

(2) Right and Left

(4) Tightening Torque

3. TABLE OF CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS

Unit Sign of SI unit Sign of foot-pound unit Conversion rate

Mass quantity of matter kg lb 1 kg = 2.2046 lb

Dimension m ft. 1 m = 3.2808 ft.

Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)

Force N (Newton) lbf 1 N = 0.2248 lbf

Pressure kPa (kilopascal) lbf/in. 2

Stress N/cm2 lbf/in.2 1 N/cm2 = 1.45 lbf/in.2

Moment of force N m lbf. ft 1 N m = 0.7375 lbf. ft

Output kW (kilowatt) HP 1 kW= 1.34 HP

Te mperature "C "F t° C = ( 1.8t°C + 32) ° F

4. READING THE ILLUSTRATION

NV ... Nominal Value

0--6 Indicates the

Scratches on outer periphery,

Inner or outer periphery damaged,

Indicates visual checks.

Inner or outer periphery damaged,

Numbers assigned indicate a typical disassembly sequence.

NV ... Nominal Value

Specifies the lightening torque;

Indicates a typical assembly sequence - <Assembling sequence>

identical among various types of available systems

1. EXTERNAL VIEW •..••••••••••••.•.•••••.••.•. 2 3. ENGINE NUMBERS AND

EngineParts2@gmail.com Parts phone: 269 673 1638

Engine model 6022-TC (Turbocharged, with

Type Diesel. 4-cycle. Diesel, 4-cycle, Diesel, 4-cycle,

Combustion method Direct injection Direct injection Direct injection

No. and arrangement of cylinder 6 in-line 6 in-line 6 in-line

Cylinder bore x stroke mm 130 X 140 130 X 140 130 X 140

Total displacement cc 11 149 11 149 11 149

• Empty weight as measured according to Mitsubishi Motors Corporation standard.

2.2 ENGINE OUTPUTS CLASSIFIED BY APPLICATION

NUMBERS AND CAUTION

The engine number is stamped on the position as

Ex: 6022 -012345

�--- Engine model

The engine number is important in knowing the

(2) Caution Plate

The caution plate is located as illustrated. The caution

4. GENERAL PRECAUTIONS FOR SER·

(7) The oil seals, packings, 0-rings, and other rubber

(1) Before performing the service procedures given

(4) Carefully check parts for oil leaks before cleaning.

5. GENERAL BOLTS AND NUTS TIGHT·

Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or 8) BT (Head mark 8 or <Bl

Flange bolts and nuts

Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or 8) BT (Head mark 8 or <Bl

Identification mark of nut

1. GENER·AL ...................................... 2 5.3 FLYWHEEL, TIMING GEAR AND

(1) Combustion Chamber

the nozzle sheathed by it from coolant. Since the

The valve mechanism is of overhead valve type and is

(a) Both inlet and exhaust valves are made of

This shop manual contains the specification, con LUBRICATION ..............................

(a) The crankshaft is a high-rigidity die forging integ · Crankshaft