Servic d r Motor Nissan Fe6 Fe6t Fe6ta

ENGINE FE series FE6,FE6T & FE6TA

Pub.No. SMEFES2E01

ENGINE SERVICE MANUAL MODEL FE6 series

QUICK REFERENCE INDEX

GENERAL

GE

MAINTENANCE

MA

TROUBLE DIAGNOSIS

TD

ENGINE DISASSEMBLY AND REASSEMBLY DR Applicable Engine Numbers FE6-200001 —

ENGINE PROPER

EP

CYLINDER HEAD AND VALVE MECHANISM HV

FOREWORD This manual describes the service, by system, of the engine of FE6A, FE6B, FE6T and FE6TA models. In order for a vehicle to perform at its best, and to extend vehicle life, maintenance should be performed properly. Also, overhaul and repair should be effected in accordance with prescribed service standards. This manual should be kept readily available in the workshop as a helpful reference for those engaged in servicing vehicles. Nissan Diesel Motor Co., Ltd. reserves the right to make changes for improvement at any time without notice. This manual is based on vehicles that were manufactured on or before April.1, 1998. Revisions, if any, will be introduced in the Technical Bulletin.

© 1999 NISSAN DIESEL MOTOR CO., LTD.

LUBRICATION SYSTEM

LB

COOLING SYSTEM

EC

FUEL SYSTEM

EF

AIR INTAKE AND EXHAUST SYSTEM

IE

ELECTRICAL SYSTEM

EE

AUXILIARY EQUIPMENT

EA

FM edition: Mar. 2005 1st edition: Jun. 1998 9904K30-14203-100-SZ1(M)

HOW TO USE THIS MANUAL X

A quick reference index, a black tab is provided on the first page, so you can quickly find the first page of each chapter by mating it to the chapter’s black tab.

X

The contents are listed on the first page of each chapter.

Construction illustration: The assembled unit is indicated. The construction illustration includes the names of the major components, items requiring adjustment after reassembling and their maintenance standards. [EXAMPLE]

X

-1-

X

Exploded illustration: The number given to each part in the illustration corresponds to the number attached to each part name, and the number is determined according to the operation sequence. No. 1, 2, 3 Disassembly sequence Reassembly sequence is in the reverse order of disassembly. The marks “+” and “,” affixed to the part name number indicate that the key points of operation (precautions, technique, use of special tools, and other maintenance information) are explained in the text. +: Key points of disassembly

,: Key points of reassembly The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the illustration. NOTE z

Disassembly and reassembly sequences show general examples and in some operations it may be possible to change sequences.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Plug , 2. Gasket , 3. Spring

4. Ball 5. Cover 6. Gasket

7. Driven gear assembly ,+ 8. Pump gear assembly

Marks “,” and “+” indicate that the key points of operation are explained in the text.

-2-

Removal and installation, disassembly and reassembly: Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated by the star marks “+” and “,” affixed to the sequence number in the exploded illustration. NOTE

X

If there are no “+” and “,” marks affixed to the parts, general explanation is given for those parts. X The following marks and abbreviations are used in this manual. Marks: : Tightening torque : Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. : Should be lubricated with oil. : Sealing point : Always replace after every disassembly. z

Abbreviations T.D.C.:

Top dead center

I.D.:

Inside diameter

B.T.D.C.:

Before top dead center

Dia.:

Diameter

A.T.D.C.:

After top dead center

S.T.D.:

Standard

B.B.D.C.:

Before bottom dead center

O.S.:

Oversize

A.B.D.C.:

After bottom dead center

U.S.:

Undersize

O.D.:

Outside diameter

Ass’y:

Assembly

X

Engine position:

X

Unit: This manual uses mainly SI units with metric and yard/pound system equivalents in braces.

X

Specific terms related to the maintenance standard z Maintenance standard “Maintenance standard” indicates the standard clearance when parts are assembled or the standard performances of assembly parts. zService limit “Service limit” indicates the limit value where adjustment, correction or parts replacement must be done.

X

The captions WARNING and CAUTION warn you about procedures that must be followed to prevent personal injury and/or damage to some parts of the vehicle.

-3-

X

Engine model: Engine model

Max. gross output (JIS) kW {PS}/rpm

For general markets

For TAIWAN

118 {160}/3,000

FE6A

—

119 {162}/3,000

FE6B

FE6

132 {180}/3,000

FE6B

—

135 {183}/3,000

FE6T

FE6T

151 {205}/2,800

FE6T

FE6T-Z

162 {220}/2,800

FE6T

—

157 {213}/2,800

FE6TA

—

173 {235}/2,800

FE6TA

FE6TA

Engine models specified for TAIWAN are different from those for general markets. Hereinafter, engine models will be described by specifications for general markets. For TAIWAN specifications, use the above table to identify the engine model specification for TAIWAN when reading this service manual. NOTE z

Only maintenance interval information includes information for TAIWAN engine models.

-4-

- MEMO -

-5-

GE

GENERAL

CONTENTS SPECIFICATIONS .................................. GE-1-1 ENGINE SPECIFICATIONS ............................. GE-1-1 ENGINE NUMBERS ......................................... GE-1-9 LUBRICATION ........................................ GE-2-1 PRECAUTIONS ...................................... GE-3-1

PREPARATION ................................................ GE-3-1 GENERAL REMARKS REGARDING IN DISASSEMBLY OPERATIONS ................... GE-3-1 CLEANING AND INSPECTION ........................ GE-3-2 STANDARD TIGHTENING TORQUE ..... GE-4-1

SPECIFICATIONS

SPECIFICATIONS ENGINE SPECIFICATIONS Engine models FE6A and FE6B Engine model Item Max. gross output (JIS)

kW {PS}/rpm

FE6A

FE6B

118 {160}/3,000

Type

Water cooled

Number of cylinders and cylinder arrangement

6, in-line

Stroke cycle

4

Combustion chamber

Direct fuel injection

Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

108 x 126 (4.25 x 4.96)

Compression ratio

18.0 kPa {kgf/cm2, psi}/rpm

Cylinder compression

2,942 {30, 427}/200

Idling speed

600 Intake

Valve timing Exhaust Valve clearance mm (in)

Open (B.T.D.C.)

15º

Closed (A.B.D.C.)

40º

Open (B.B.D.C.)

53º

Closed (A.T.D.C.)

9º

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system Lubrication system

132 {180}/3,000

Diesel

Cooling method

Forced-circulation type

Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler

Water cooled flat tube type

Regulator valve opening pressure

2

kPa {kgf/cm , psi}

Cooling system Cooling system

119 {162}/3,000

422 - 461 {4.3 - 4.7, 61 - 67} Forced-circulation type

Radiator type Cooling fan

Corrugated fin Outside diameter - Number of fins mm (in)

480 (18.90) - 6 485 (19.09) - 8

510 (20.08) - 6 485 (19.09) - 8

530 (20.87) - 6

510 (20.08) - 7 530 (20.87) - 6

Water pump

Centrifugal, belt-driven type

Thermostat

Wax pellet type

GE-1-1

SPECIFICATIONS

Engine model Item

FE6A

FE6B

Ignition system

Compression ignition

Fuel injection timing (B.T.D.C.)

14º

15º

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter Type

Bosch

Plunger diameter

mm (in)

9.5 (0.374)

9.0 (0.354)

Fuel system

Plunger lead Fuel injection pump

Cam lift

mm (in)

Governor

8.0 (0.315)

6.0 (0.236)

Type

Centrifugal

Type name

RAD/RLD/RFD

RLD

Type name

Conventional type Flange type

Nozzle

Multi-jet

Identification mark

Z

D2

Z

5

kPa {kgf/cm2, psi}

Overflow valve Injection pump outlet opening pressure kPa {kgf/cm2, psi} Fuel filter

19,614 {200, 2,844} 157 {1.6, 23} 108 - 147 {1.1 - 1.5, 16 - 21}

Air cleaner

Paper element (Dry: Single or dual type) Model External dimensions (Length x Width x Height)

— —

mm (in)

Maximum permissible continuous speed

—

Direction of rotation

—

Air volume

kg (lb)/min

—

Compression ratio Exhaust brake

SA (RAD, RLD) /SAG (RFD)

SA

Number of nozzle holes

Turbocharger

RAD/RLD/RFD

Centrifugal

Nozzle holder

Air intake and exhaust system

9.0 (0.354)

Feed pump

Type

Injection pressure

9.5 (0.374)

Right lead Injection pump

Type Timer

Fuel injection nozzle

12º

—

Type

Chamber type

Cylinder type

Operating method

Vacuum type

Air type

GE-1-2

SPECIFICATIONS

Engine model Item

Electrical system

Starting motor

FE6A

Type

Shift type

Model

0350 502 0310/0350 502 0321

Output

V-kW

24-4.5

Type Alternator

AC, diode-rectified 0202 152 0310

Model

0202 152 0311

Output

V-A

IC-transistor type

Type

Ribbon

Voltage x Current - Number

V-A

22 x 85 - 1

Type Air compressor

Engine rear PTO

Reciprocating type

Bore x stroke - Number of cylinders mm (in)

85 x 40 - 1 (3.35 x 1.57 - 1)

Cooling system

Water cooled

Allowable maximum torque N·m {kgf·m, ft·lbf}

343 {35, 253}


Clockwise (as viewed from the rear)

Gear ratio (PTO gear : crankshaft gear) Vacuum pump

0201 152 0420/0201 152 0421 24-50

Regulator Air heater

Auxiliary equipment

FE6B

1.264 (67 : 53)

Type

Vane

—

Model

VD-120

—

GE-1-3

SPECIFICATIONS

Engine model FE6T Engine model

FE6T

Item Max. gross output (JIS)

kW {PS}/rpm 135 {183/3,000}

Type

Water cooled


6, in-line

Stroke cycle

4

Combustion chamber


Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

Compression ratio

108 x 126 (4.25 x 4.96) 18.0


kPa

{kgf/cm2,

17.5 2,942 {30, 427}/200

psi}/rpm

Idling speed

600 Intake


Open (B.T.D.C.)

15º

Closed (A.B.D.C.)

30º

Open (B.B.D.C.)

53º

Closed (A.T.D.C.)

9º

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system Lubrication system

162 {220/2,800}

Diesel

Cooling method


Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler



kPa

{kgf/cm2,

psi}


151 {205/2,800}

422 - 461 {4.3 - 4.7, 61 - 67} Forced-circulation type


Corrugated fin Outside diameter - Number of fins mm (in)

510 (20.08) - 7 510 (20.08) - 7

580 (22.83) - 6

580 (22.83) - 7

580 (22.83) - 7

Water pump


Thermostat

Wax pellet type

GE-1-4

SPECIFICATIONS

Engine model

FE6T

Item Ignition system



12º

10º

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter Type

Bosch

Plunger diameter

mm (in)

9.0 (0.354)

Fuel system


Cam lift

mm (in)

Governor Timer


9.0 (0.354)

6.0 (0.236)

Type

Centrifugal

Type name

RLD

Type

Centrifugal

Type name

SA

SAG Conventional type

Nozzle holder

Flange type

Nozzle

Multi-jet

Identification mark

D3

A5

Number of nozzle holes Injection pressure

kPa {kgf/cm2, psi}

19,614 {200, 2,844}

19,614 {200, 2,844}

108 - 147 {1.1 - 1.5, 16 - 21} Paper element (Dry: Single or dual type)

Model Air intake and exhaust system

21,575 {220, 3,128} 157 {1.6, 23}

Air cleaner

External dimensions (Length x Width x Height)

mm (in)


Air volume

T04B

RHC62E

220 x 190 x 160 (8.66 x 7.48 x 6.30)

218 x 238 x 145 (8.58 x 9.37 x 5.71)

138,000

150,000

Counterclockwise as viewed from the exhaust turbine side

Direction of rotation kg (lb)/min


A6

5


Turbocharger

10.0 (0.394)

Feed pump

Type


9º

21 (46)

18.8 (41.5) 3.2

Type

Cylinder type

Operating method

Air type

GE-1-5

SPECIFICATIONS

Engine model

FE6T

Item Type Starting motor

Shift type

Model

0350 502 0310/0350 502 0321

Electrical system

Output

V-kW

24-4.5

Type

AC, diode-rectified

Model

0201 152 0420/0201 152 0421

Alternator Output

V-A

0201 152 0420 0201 152 0421 —

Regulator

Auxiliary equipment

Engine rear PTO

24-80 Ribbon


V-A

22 x 85 - 1

Type

Air compressor

0201 222 0273

IC-transistor type

Type

Bore x stroke Number of cylinders mm (in)

0201 152 0421

24-50

0201 222 0273

Air heater

0350 502 0321

Reciprocating type 408738-5600 408738-5601

85 x 40 - 1 (3.35 x 1.57 - 1)

408738-5611

—

408738-5741

—

—

85 x 40 - 1 (3.35 x 1.57 - 1)

85 x 60 - 1 (3.35 x 2.36 - 1)

Cooling system

Water cooled


343 {35, 253}


—


Gear ratio (PTO gear : crankshaft gear)

GE-1-6

1.264 (67 : 53)

SPECIFICATIONS

Engine model FE6TA Engine model

FE6TA

Item Max. gross output (JIS)

kW {PS}/rpm

157 {213}/2,800

Type

Diesel

Cooling method

Water cooled


6, in-line

Stroke cycle

4

Combustion chamber


Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

108 x 126 (4.25 x 4.96)

Compression ratio

17.5


kPa

{kgf/cm2,

2,942 {30, 427}/200

psi}/rpm

Idling speed

600 Intake


Open (B.T.D.C.) Closed (A.B.D.C.)

Lubrication system

15º 30º

40º

Open (B.B.D.C.)

53º

Closed (A.T.D.C.)

9º

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system


Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler



kPa

{kgf/cm2,

psi}


173 {235}/2,800



422 - 461 {4.3 - 4.7, 61 - 67} Corrugated fin

Outside diameter - Number of fins mm (in)

510 (20.08) - 7

580 (22.83) - 6

580 (22.83) - 7

580 (22.83) - 7

Water pump


Thermostat

Wax pellet type

GE-1-7

SPECIFICATIONS

Engine model

FE6TA

Item Ignition system



3º

12º

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter Type Plunger diameter

mm (in)

TC-MD

Bosch

11.0 (0.433)

9.0 (0.354)

Fuel system


Cam lift

mm (in)

Governor Timer


10.0 (0.394)

Feed pump

6.0 (0.236)

Type

Centrifugal

Type name

RLD

Type

—

Centrifugal

Type name

—

SAG

Electronic (MD-TICS)

—

Injection timing control Type

Conventional type

Nozzle holder Fuel injection nozzle

Flange type

Nozzle

Multi-jet

Identification mark

F4 or C1


5

Injection pressure

19,614 {200, 2,844}

1st: 16,672 {170, 2,417} 2nd: 21,575 {220, 3,128}


255 {2.6, 37}

157 {1.6, 23}

Air cleaner

Paper element (Dry: Single or dual type)

kPa {kgf/cm2, psi}


A3

108 - 147 {1.1 - 1.5, 16 - 21}

Model External dimensions (Length x Width x Height) Turbocharger

mm (in)


kg (lb)/min


RHC6V

230 x 195 x 265 (9.06 x 7.68 x 10.43)

246 x 214 x 196 (9.69 x 8.43 x 7.72)

125,000

150,000

Counterclockwise as viewed from the exhaust turbine side

Direction of rotation Air volume

T04E

20 (44)

19.4 (42.8) 3.2

Type

Cylinder type

Operating method

Air type

GE-1-8

SPECIFICATIONS

Engine model

FE6TA

Item Type

Electrical system

Starting motor

Shift type

Model Output

V-kW

24-4.5

Type Alternator

AC, diode-rectified

Model V-A

24-50

Regulator

IC-transistor type

Type

Ribbon


V-A

22 x 85 - 1

Type

Reciprocating type

Auxiliary equipment

408738-5610 408738-5611

Air compressor

Engine rear PTO

Bore x stroke Number of cylin408738-5780 ders mm (in) F8040

—

85 x 40 - 1 (3.35 x 1.57 - 1)

85 x 40 - 1 (3.35 x 1.57 - 1)

—

80 x 40 - 1 (3.15 x 1.57 - 1)

—

Cooling system

Water cooled


343 {35, 253}



Gear ratio (PTO gear : crankshaft gear) Vacuum pump

0202 152 0220/ 0202 152 0221

0201 152 0421

Output

Air heater

0350 502 0310/ 0350 502 0321

0350 502 0321

1.264 (67 : 53)

Type

Vane

—

Model

VD-30

—

ENGINE NUMBERS The engine serial number is stamped on the right side of the cylinder block. FE6-XXXXXXC* Engine serial number Engine model *Engine specification A: Natural aspirated engine B: Natural aspirated engine C: Turbocharged engine D: Turbocharged engine with intercooler

GE-1-9

LUBRICATION

LUBRICATION RECOMMENDED FUEL AND LUBRICANTS Lubricant

Specifications

Remarks

Engine oil

API CC or CD

For further details, refer to the recommended SAE viscosity chart.

Power steering fluid

DEXRON® or DEXRON® II

GM ATF type

Bearing grease

NLGI No. 2

Lithium soap base

Antifreeze Fuel

—

Ethylene glycol base

Above –7ºC (20ºF) 2-D Diesel fuel or equivalent blended diesel fuel Check with the service establishment to Below –7ºC (20ºF) 1-D Diesel fuel or equivalent blended diesel fuel be sure you get the properly blended fuel.

NOTE z

It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged engines.

RECOMMENDED SAE VISCOSITY NUMBER Use oil having the proper viscosity beforehand which meets temperatures forecast for areas where you are planning to drive.

CAPACITIES (APPROXIMATELY) Item Engine oil pan (H-level) Engine oil Total Power steering system

Liter (Imp measure) FE6A, FE6B, FE6T, FE6TA

12 (2-5/8 gal)

FE6TA*

14 (3-1/8 gal)

FE6A, FE6B, FE6T, FE6TA

15 (3-1/4 gal)

FE6TA*

17 (3-3/4 gal)

MK and LK series PK series

3 (2-5/8 qt) 5.5 (4-7/8 qt)

Cooling system

22 (4-7/8 gal) Square type

100 (22 gal) 130 (28-5/8 gal) 200 (44 gal) 100 + 100 (22 gal + 22 gal)

Round type

109 (24 gal) 150 (33 gal) 227 (50 gal)

Fuel tank

NOTE

Capacities shown are for reference only. When filling, observe the specified level. z * Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only). z

GE-2-1

PRECAUTIONS

PRECAUTIONS PREPARATION Observe the following when servicing the vehicle. z Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle may move abruptly. z Engage the parking brake and chock the wheels securely. z If the engine is hot, wait until it cools off. z Set the transmission gear shift lever to “NEUTRAL”. z Turn the key switch to “OFF”. Disconnect the ground cable when servicing the electrical system. z Do not touch rotating parts of the engine if servicing requires engine operation. Always operate the engine in a well-ventilated area. z

When tilting the cab indoors, make sure that there is a clearance of at least 4 m (13.1 ft) in H and a clearance of 1 m (3.3 ft) in F.

GENERAL REMARKS REGARDING IN DISASSEMBLY OPERATIONS Checks before disassembly Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For instance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil leakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engine needs to be disassembled and which part does not. It will also save time and labor.

Work required during disassembly Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original positions. When repairs involve the electrical system, disconnect the ground cable from the battery.

Checks during disassembly Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work efficiency will be degraded after all parts have been disassembled.

Keeping disassembled parts in order Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc. Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contaminated with water or oil. Keep them in one place and away from those having engine oil on them.

Cleaning disassembled parts Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned, scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems after reassembly.

Reinstallation Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.). Apply a coat of grease, liquid packing or sealer to designated parts.

Adjustment and operational checks Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for proper operation.

GE-3-1

PRECAUTIONS

CLEANING AND INSPECTION CLEANING The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include steam cleaning, light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely while the cleaning is in process.

METAL PARTS Light oil Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two washings.

Alkaline solution Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel and cast iron parts quite well. NOTE z

If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent (such as boric acid solution), since the alkaline solution must be immediately washed from the skin or eyes in the event of contact.

RUBBER PARTS Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.

OIL PASSAGES Pass a wire through oil passages to make sure that they are free. Clean the oil passages with solvent that is injected under pressure from a nozzle.

PROTECTION AGAINST CORROSION After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to prevent corrosion.

INSPECTION Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the specified clearance is exceeded, replace it and/or its mate as the occasion demands. Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limit from preventive maintenance viewpoint. All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method, whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities, the affected part(s) should be repaired or replaced, as required. All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed. Abnormalities z Uneven wear z Graded wear z Scratches z Cracks z Deformity z Fatigue or weakness (for springs and rubbers, etc.) z Bends z Loose fit z Unusual noise (for bearings) z Discoloration or jamming z Rust formation z Deterioration (for brake linings, etc.)

GE-3-2

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE The tightening torque of the bolts and other fasteners that secure the major components parts is specified in the text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened according to the following table of bolt standard tightening torque. NOTE z

All bolts and nuts are sized using the metric system. Do not use parts other than those designated. Nominal size

Bolt dia. mm

Pitch mm

M6

6.0

M8

8.0

M10

10.0

M12

12.0

M14

Standard tightening torque (Without lubricant) 4T

7T

9T

N·m

kgf·m

ft·lbf

N·m

kgf·m

ft·lbf

N·m

kgf·m

ft·lbf

1.0

5.1

0.52

3.8

8.4

0.86

6.2

12

1.2

9

1.25

13

1.3

9

21

2.1

15

29

3.0

22

1.0

13

1.3

9

22

2.2

16

31

3.2

23

1.5

25

2.5

18

41

4.2

30

59

6.0

43

1.25

25

2.6

19

43

4.4

32

62

6.3

46

1.75

42

4.3

31

71

7.2

52

98

10.0

72

1.25

46

4.7

34

77

7.9

57

108

11.0

80

14.0

1.5

74

7.5

54

127

13.0

94

177

18.0

130

M16

16.0

1.5

108

11.0

80

186

19.0

137

275

28.0

203

M18

18.0

1.5

167

17.0

123

275

28.0

203

392

40.0

289

M20

20.0

1.5

226

23.0

166

382

39.0

282

549

56.0

405

M22

22.0

1.5

304

31.0

224

510

52.0

376

736

75.0

542

NOTE

Special parts are excluded. z This standard is applicable to bolts having the following marks embossed on the bolt head. Mark 4T .............................. 4 7T .............................. 7 9T .............................. 9 z

Standard tightening torque of tubing connector Standard tightening torque

Item

N·m

kgf·m

4.76 (0.1874)

13 - 18

1.3 - 1.8

9 - 13

6.35 (0.2500)

16 - 24

1.6 - 2.4

12 - 17

8.0 (0.315)

29 - 39

3.0 - 4.0

22 - 29

10.0 (0.394)

39 - 49

4.0 - 5.0

29 - 36

12.0 (0.472)

59 - 78

6.0 - 8.0

43 - 58

15.0 (0.591)

69 - 93

7.0 - 9.5

51 - 69

Nipple nut [Tube O.D. 6.35 mm (0.2500 in)]

21 - 28

2.1 - 2.9

15 - 21

Eye connector [Tube O.D. 6.35 mm (0.2500 in)]

42 - 57

4.3 - 5.8

31 - 42

Flared nut

Tube O.D. mm (in)

GE-4-1

ft·lbf

- MEMO -

- MEMO -

MA

MAINTENANCE

CONTENTS SERVICE DATA ...................................... MA-1-1 SERVICE DATA ............................................... MA-1-1 TIGHTENING TORQUE ................................... MA-1-2 TOOLS .................................................... MA-2-1

PERIODIC MAINTENANCE SCHEDULES .......................................... MA-3-1 MAINTENANCE INTERVALS........................... MA-3-2 PERIODIC PARTS REPLACEMENT ............... MA-3-4

MAINTENANCE PROCEDURE............... MA-4-1 BASIC MECHANICAL SYSTEM....................... LUBRICATION SYSTEM .................................. COOLING SYSTEM.......................................... FUEL SYSTEM ................................................. INTAKE AND EXHAUST SYSTEM................... OTHERS ...........................................................

MA-4-1 MA-4-4 MA-4-9 MA-4-17 MA-4-27 MA-4-32

SERVICE DATA

SERVICE DATA SERVICE DATA Maintenance standard

Service limit

Intake

0.3 - 0.4 (0.012 - 0.016)

—

Exhaust

0.3 - 0.4 (0.012 - 0.016)

—

2,942 {30, 427}

1,961 {20, 284}

Less than 392 {4, 57}

—

Open

15° B.T.D.C.

—

Closed

40° A.B.D.C.

—

Open

53° B.B.D.C

—

Closed

9° A.T.D.C.

—

Open

15° B.T.D.C.

—

Closed

30° A.B.D.C.

—

Open

53° B.B.D.C

—

Closed

9° A.T.D.C.

—

10 - 15 (0.39 - 0.59)

—

7 - 12 (0.28 - 0.47)

—

With a force of about 98 N {10 kgf, 22 lbf} applied to the mid part

39 - 59 {0.4 - 0.6, 6 - 9}

—

Pressure side

74.5 - 78.5 (166 - 173)

71.5 - 81.5 (161 - 179)

82 (180)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

88 (190)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

76.5 (170)

More than 10/90 (0.39/194)

Less than 9/90 (0.35/194)

82 (180)

More than 10/95 (0.39/203)

Less than 9/95 (0.35/203)

88 (190)

More than 10/100 (0.39/212)

Less than 9/100 (0.35/212)

Item

Valve clearance mm (in)

Basic mechanical system

Cylinder compression pressure kPa {kgf/cm2, psi} Difference between cylinders

Valve timing

FE6A FE6B FE6TA 173 kW {235 PS}

Intake

FE6T FE6TA 157 kW {213 PS}

Intake

Exhaust

Exhaust

kPa {kgf/cm2, psi}

Fan pulley alternator pulley V-belt deflection mm (in) Fan pulley cooler compressor pulley Radiator cap operating pressure Cooling system

kPa {kgf/cm2, psi} Valve opening temperature °C (°F) Thermostat Valve lift/ temperature mm/°C (in/°F)

76.5 (170)

MA-1-1

Remarks

When engine is cold

At 200 rpm with engine warm

SERVICE DATA Maintenance standard

Service limit

14°

—

119 kW {162 PS}

15°

—

132 kW {180 PS}

12°

—

135 kW {183 PS}

12°

—

151 kW {205 PS}

10°

—

162 kW {220 PS}

9°

—

157 kW {213 PS}

3°

—

173 kW {235 PS}

12°

—

600

—

650

—

Item FE6A FE6B

Fuel system


FE6T

FE6TA FE6A, FE6B, FE6T Idle speed

rpm

157 kW {213 PS}

FE6TA

550

—

Maximum speed

173 kW {235 PS} rpm

3,200

—

No-load maximum engine speed

rpm

3,600

—

Remarks

“MD-TICS” system

TIGHTENING TORQUE Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Valve clearance adjusting screw lock nut Cylinder head mounting bolt Basic mechanical system

Lubrication system Cooling system

34 - 44 {3.5 - 4.5, 25 - 33} 177 - 196 {18.0 - 20.0, 130 - 145}

Air intake manifold mounting bolt and nut

16 - 20 {1.6 - 2.0, 12 - 14}

Exhaust manifold mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Compression gauge mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Crank damper mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51}

Oil pan drain plug

59 - 69 {6.0 - 7.0, 43 - 51}

Alternator adjusting bolt

34 - 44 {3.5 - 4.5, 25 - 33}

Alternator anchor bolt and nut

59 - 74 {6.0 - 7.5, 43 - 54}

Cooler tension pulley lock nut

35 - 47 {3.6 - 4.8, 26 - 35}

MA-1-2

SERVICE DATA Item

Injection pump drive coupling bolt and nut

Injection pump drive coupling cotter bolt

Fuel system

Delivery valve holder

FE6A, FE6B, FE6T, FE6TA 173 kW {235 PS}

29 - 34 {3.0 - 3.5, 22 - 25}

FE6TA 157 kW {213 PS}

59 - 64 {6.0 - 6.5, 43 - 47}


59 - 64 {6.0 - 6.5, 43 - 47}

FE6TA 157 kW {213 PS}

83 - 93 {8.5 - 9.5, 61 - 69}


49 - 54 {5.0 - 5.5, 36 - 40}

FE6TA 157 kW {213 PS}

103 - 113 {10.5 - 11.5, 76 - 83}

Injection nozzle retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Nozzle holder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Injection pump bleeder screw

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Fuel filter (center bolt type) center bolt

20 - 29 {2.0 - 3.0, 14 - 22}

Primary fuel filter center bolt


Tightening torque

Type I

20 - 29 {2.0 - 3.0, 14 - 22}

Type II

59 - 69 {6.0 - 7.0, 43 - 51}

Primary fuel filter drain plug (Type II only)

16 - 22 {1.6 - 2.2, 12 - 16}

Fuel strainer center bolt

15 - 20 {1.5 - 2.0, 11 - 14}

Fuel filter eye bolt

25 - 41 {2.5 - 4.2, 18 - 30}

T04B Compressor housing and back T04E plate mounting bolt N·m {kgf·cm, in·lbf} RHC62E RHC62V T04B Turbine housing and center hous- T04E ing mounting bolt N·m {kgf·cm, in·lbf} RHC62E RHC62V

MA-1-3

11.3 - 14.7 {115 - 150, 100 - 130} 7.4 - 8.3 {75 - 85, 65 - 74} 18.0 - 21.5 {184 - 219, 160 - 190} 27.0 - 28.9 {275 - 295, 239 - 256}

TOOLS

TOOLS Tool name and number

Description

Feeler gauge 99541 Z5000

For adjusting valve clearance Thickness mm (in): 0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4 (0.016), 0.45 (0.0177), 0.5 (0.020)

Timing plate 99646 Z5001

For measuring valve timing

Compression gauge 99640 Z5500

For measuring compression pressure

Compression gauge hose 99644 97000

Used with the compression gauge (99640 Z5500) when the gauge cannot be installed directly due to interference with the air duct, etc.

*Plate 157944-9520

For fixing nozzle holder

* Tool number designated by Zexel Co.

MA-2-1

Shape

TOOLS

Tool name and number

Description

Pin vice 99727 Z5005

For cleaning nozzle injection hole.

Nozzle cleaner 99726 Z5000

For cleaning injector tip.

MA-2-2

Shape

PERIODIC MAINTENANCE SCHEDULES

PERIODIC MAINTENANCE SCHEDULES Abbreviations: A = Adjust, R = Replace, I = Inspect. Correct, adjust or replace if necessary. C = Cleaning, RB = Rebuilding, T = Tighten to specified torque, = Initial maintenance NOTE

The maintenance or lubrication service shown below are to be performed at the indicated intervals (km, miles or months, whichever occurs first). z Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be continued at the same intervals as before except the initial maintenance. z Under the following severe operating conditions, more frequent servicing will be required. – Operation in heavy dust conditions – Operation at extremely low or high ambient temperature – Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight) – Extended low-speed operation – Frequent stop-and-go operation z Any replacement parts used for required maintenance service or repairs should be genuine Nissan Diesel parts. z

EMISSIONS CONTROL SYSTEMS MAINTENANCE (FOR TAIWAN ONLY) To maintain efficient emissions control systems operation, have the maintenance services shown in this section performed at the intervals indicated. CAUTION z

Do not modify, alter, disconnect or remove any part of the vehicle which could affect, directly or indirectly, vehicle emissions.

MA-3-1


MAINTENANCE INTERVALS Maintenance intervals Items

Kilometers x 1,000 Miles x 1,000

Daily

Months

1

5

10

15

20

25

30

35

40

45

50

55

60

0.6

3

6

9

12

15

18

21

24

27

30

33

36

—

1

2

3

4

5

6

7

8

9

10

11

12

Valve clearance

I

I

Cylinder head and manifold bolts

T

T I : After 200,000 km (125,000 miles)

Crank damper

I: Every 100,000 km (62,500 miles)

Cylinder compression pressure

I

Oil leakage

I

Oil level and contamination

I

Engine oil and filter

Remarks

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Full-flow type

R

R: Every 10,000 km (6,000 miles) or 6 months

(1)

Full-flow and bypass type

R

R: Every 15,000 km (9,000 miles) or 6 months

(1)

Coolant leakage

I

Coolant level

I

I

I

I

I

I

I I

I

Coolant (incl. anticorrosive)

I

I I

I

I

I I

I

R

I R

(3)

Coolant (incl. antifreeze)

R

(4)

Radiator cap

I

Fan clutch V-belt

I I

I

I

I

I

I

I

I

I

I

I

I

I

Thermostat

I

Injection timing

I

Nozzle (injection pressure and pattern)

I

Fuel leakage

I

I

I

I

I

I

I

I

I

I

I

I

I

Fuel filter element

R I I I I I I I I I I I I Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain

Primary fuel filter Primary fuel filter element

R

Fuel strainer Fuel level

R

I Drain

I Drain

I Drain

I Drain

I Drain

I/C Drain

I/C

I/C

I/C

I/C

I/C

I/C

(2)

R

(2)

I

Air cleaner element Air cleaner element (Dry type) Condition of exhaust

I

I

I

I

I

I

Turbocharger

I

I

I

I

I

I

I

I I

(5)

Remarks: (1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the scheduled replacement. (2) If the warning light comes on even before the scheduled replacement, clean or replace element. (3) Service every 6 months. (4) Service every 12 months. (5) With turbocharger engine equipped vehicles only.

MA-3-2


For Taiwan only Maintenance intervals Maintenance Item

Kilometers x 1,000 Miles x 1,000

Daily

Months

1

5

10

15

20

25

30

35

40

45

50

55

60

0.6

3

6

9

12

15

18

21

24

27

30

33

36

—

1

2

3

4

5

6

7

8

9

10

11

12

*Idle speed

I

Acceleration and deceleration

I

*Air intake system (duct, hose and clamp)

I

Intake* and exhaust manifold

I

I

I

I

I/C

I/C

I/C

I/C

I/C

Cylinder compression pressure

R I

*Valve clearance

A

I

Oil CC or CD class *Engine oil and oil filters Oil CD class *Engine oil and bypass oil filter Oil CD class (if equipped) Oil level and contamination

I I

I

*Air cleaner element

R

Every 10,000 km (6,000 miles) or 6 months : R

FE6 engine

R


FE6T, FE6T-Z and FE6TA engines

R


I

Oil pressure

I

Coolant and fuel level

I

Coolant, oil and fuel leakage

I

Strainer (if equipped)

I

*Fuel filter element

R

*Primary fuel filter element (if equipped)

I I I I I Drain Drain Drain Drain Drain

*Governor setting (checking seals)

R

I I I I I Drain Drain Drain Drain Drain

R

Every 30,000 km (18,000 miles) or 6 months : I

*Nozzle (injector tip)

Every 80,000 km (50,000 miles) : C

*Nozzle holder (injector)

Every 240,000 km (145,000 miles) : RB

*Injection timing

Every 60,000 km (36,000 miles) or 12 months : I

Fuel tubing

I

Accelerator linkage

I

Drive belt (V-belt)

I

Crank damper

Every 24 months : I

Cooling system (hose and clamp)

I

Engine coolant

R

Water filter (if equipped)

R

Thermostat

I

Fan clutch

I

Fan and fan shroud

I

Exhaust tubing and muffler

I

I

Alternator

I

Starter

I

*PCV valve *PCV system

*Turbocharger

Remarks

Every 80,000 km (50,000 miles) : R (hose and clamp)

I

I

I

I I

(piping) Every 240,000 km (145,000 miles) : C

“*” refers to items related to the Emission Control System Maintenance.

MA-3-3

I

FE6 engine

I

FE6 engine

I

FE6 engine FE6T, FE6T-Z and FE6TA engines


PERIODIC PARTS REPLACEMENT Periodic replacement parts are rubber parts such as the fuel hose, etc. which deteriorate with the lapse of time and require maintenance. It is absolutely necessary to replace those parts periodically to maintain driving safety. Items

PERIODIC PARTS REPLACEMENT INTERVAL Number of years

1

2

3

4

5

6

7

8

9

10

Remarks

ENGINE Fuel hose (engine side)

R

Fuel hose (fuel tank side) Air compressor rubber hose

R

R

R R

Remarks: (1) AOH brake vehicles.

MA-3-4

R

R

R

R R

R

R

(1)

MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE BASIC MECHANICAL SYSTEM VALVE CLEARANCE NOTE z

Ensure the engine is cool when checking and adjusting the valve clearance.

1. 2.

Remove the rocker cover. Remove the pointer cover from the upper section of the flywheel housing. Secure the pointer to the flywheel housing using bolts. Using a lever, rotate the ring gear on the outer edge of the flywheel in the standard direction (or counterclockwise as viewed from the flywheel side) until the mark “1·6” stamped on the outer edge of the flywheel is aligned with the pointer. If the mark goes past the pointer, back it off past the pointer and then rotate in the standard direction until the mark is aligned with the pointer. At this point, if the mark stamped on the fuel injection pump timer is nearly aligned with the mark on the pump housing, the No. 1 cylinder is at TDC (Top Dead Center) on the compression stroke. If the mark on the timer is not visible, the No. 6 cylinder is at TDC on the compression stroke. Valve clearances (1), (2), (4), (5), (8) and (9) can be checked and adjusted when No. 1 cylinder is at TDC on the compression stroke; valve clearances (3), (6), (7), (10), (11) and (12) can be checked and adjusted when the No. 6 cylinder is at TDC on the compression stroke.

3.

4.

5.

Place a feeler gauge between the valve stem and rocker arm to ensure that the gauge fits snugly. Unit: mm (in) Maintenance standard

Service limit

Intake

0.3 - 0.4 (0.012 - 0.016)

—

Exhaust

0.3 - 0.4 (0.012 - 0.016)

—

Item Valve clearance

Remarks When engine is cold

MA-4-1


Valve clearance adjustment 1. 2.

3. 4.

If the valve clearance is not correct, loosen the lock nut for the adjusting screw and adjust the screw until the specified clearance is obtained. After adjusting the valve clearance, hold the adjusting screw and tighten the lock nut. : 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf} Recheck the valve clearance. Rotate the flywheel one complete turn until the mark “1·6” is aligned with the pointer. Next, check and adjust the remaining valve clearances. If the engine operates erratically or vibrates even though the valve clearances are properly adjusted, problems may be due to improperly adjusted valve timing which results from incorrect assembling of the timing gear train, etc. If erratic operation is noticed, check the valve timing as described below.

Procedure for checking valve timing 1. 2.

Remove the V-belt, cooling fan and crank pulley assembly. Turn the flywheel in the normal direction until the No. 1 piston is at the TDC on the compression stroke. NOTE z If the flywheel has been rotated excessively, rotate it backwards beyond the desired position then gradually rotate it back in the normal direction until it is set in the proper position.

3. 4.

Attach the timing plate (99646 Z5001) to the end of the crankshaft. Also attach a needle pointer utilizing the front cover mounting bolt, and align the needle to “0”. Set a dial gauge so that the contact arm is in contact with the upper valve spring seats of the intake valve and exhaust valve.

MA-4-2

MAINTENANCE PROCEDURE 5.

If the needle of the dial gauge begins to move, it means that the valve is beginning to open; the movement of the needle will stop as the valve closes. Read the needle position on the timing plate on each occasion. Maintenance standard

Item

Valve timing

FE6A Intake FE6B FE6TA 173 kW Exhaust {235 PS} FE6T Intake FE6TA 157 kW {213 PS} Exhaust

Service Remarks limit

Open

15° B.T.D.C.

—

(1)

Closed

40° A.B.D.C.

—

(2)

Open

53° B.B.D.C.

—

(3)

Closed

9° A.T.D.C.

—

(4)

Open

15° B.T.D.C.

—

(1)

Closed

30° A.B.D.C.

—

(2)

Open

53° B.B.D.C.

—

(3)

9° A.T.D.C.

—

(4)

Closed

CYLINDER HEAD AND MANIFOLD BOLTS Check the cylinder head, air intake and exhaust manifold mounting bolts and nuts for proper torque. Also check the manifolds for damage or traces of leakage at the cylinder head connections. Cylinder head mounting bolt : 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf} Air intake manifold bolt : 16 - 20 N·m {1.6 - 2.0 kgf·m, 12 - 14 ft·lbf} Exhaust manifold bolt : 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}

CRANK DAMPER Check the crank damper for cracks or flaking, and the mounting bolts for looseness. Replace faulty parts if necessary. Crank damper mounting bolt : 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf}

CYLINDER COMPRESSION PRESSURE 1. 2.

Warm up the engine. Disconnect all nozzle tubes and remove all nozzle holders. Refer to the “DR” section for details.

MA-4-3


Install a compression gauge (99640 Z5500) on the nozzle hole using a nozzle holder gasket. Press the gauge bleeder to set the pointer to “zero”. Compression gauge mounting bolt : 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf} NOTE z Be careful to prevent foreign matter from getting into the other nozzle holder holes. z Be sure to remove the old nozzle holder gasket. 4. Move the engine stop lever completely in the “FUEL CUT” direction and hold it at that position. 5. Crank the engine until the gauge pointer stabilizes. Read the cylinder compression pressure. Measure compression pressure for the remaining cylinders as described above. If the measured values or the differences in compression pressure between cylinders are not within specifications, pistons and/or piston rings may be worn or the valve mechanism may be faulty. Overhaul the engine and repair as necessary. Unit: kPa {kgf/cm2, psi} Item Compression pressure Difference between cylinders

Maintenance standard

Service limit

Remarks

2,942 {30, 427}

1,961 {20, 284}

At 200 rpm with engine warm

Less than 392 {4, 57}

—

NOTE z

The above engine rpm range refers to that when the battery is fully charged and the starting motor is in good condition.

LUBRICATION SYSTEM OIL LEAKAGE Check the cylinder head, timing gear case cover, oil pan, oil filters and other related parts for sign of leakage. If necessary, replace gaskets. After replacing the gasket, check that point to ensure there is no leakage.

OIL LEVEL AND CONTAMINATION WARNING WARNING z

To help avoid serious personal injury from hot engine oil, perform lubrication system checks and maintenance only after the engine has cooled.

MA-4-4

MAINTENANCE PROCEDURE Check the engine oil level and for contamination of engine oil before driving the vehicle each day and when you stop for fuel. Check the oil level with the engine off. When checking the oil level after stopping the engine, wait at least 15 minutes to allow the oil to return to the oil pan.

To check the engine oil level 1. 2.

Park the vehicle on a flat surface. Remove the oil dipstick located on the left hand side of the engine. Wipe the dipstick clean with a rag and reinsert it. Remove the dipstick and check the oil level. Maintain the oil level between the H and L marks on the dipstick.

3.

If oil level is low, add engine oil of the proper viscosity for the anticipated temperature range during the service interval through the oil filler port located on the valve cover on top of the engine. Do not add oil above the H mark on the dipstick. CAUTION z Use care to keep dirt and debris from entering the crankcase through the oil filler port when adding engine oil. Avoid spilling oil. Clean up any engine oil that spills accidentally. 4.

Change the oil if it shows signs of contamination such as discoloration and changes in oil texture. See the instructions in this manual under the caption CHANGING ENGINE OIL. 5. After adding oil, wait at least 6 minutes, then recheck the oil level. 6. After checking, securely insert the oil dipstick. CAUTION z Do not drive the vehicle with the oil level below the L mark on the oil dipstick. An insufficient quantity of engine oil can cause engine seizure.

To check for engine oil contamination Remove the oil dipstick and check the oil on it for signs of contamination such as discoloration and changes in texture. See the instructions in this manual under the caption ENGINE OIL AND OIL FILTER.

MA-4-5


CHANGING ENGINE OIL AND OIL FILTER Engine oil WARNING WARNING z

To help avoid serious personal injury from hot engine oil, perform lubrication system checks and maintenance only after the engine has cooled.

NOTE z

Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

The engine oil and oil filter change interval varies with the type of engine oil used and vehicle driving conditions. If the vehicle is driven for extended periods of time at high or low speeds, in dusty areas, with frequent idling or carrying heavy loads, engine oil will deteriorate faster and require more frequent changing. As the temperature rises, the engine oil’s viscosity decreases, reducing its lubricating effect. To choose an oil with the proper viscosity for the anticipated ambient temperature range, refer to the viscosity chart in the “GE” section of this manual. To change the engine oil 1. Loosen the oil filler cap.

2. 3.

Undo the four engine undercover catchers (on the left and right sides of the engine), and remove the undercover assembly (if equipped). Place a container under the drain plugs in the bottom of the oil pan and oil filter. Remove the plugs and drain the oil into the container.

MA-4-6


5. 6. 7.

8.

When all the oil has been drained from the oil pan and oil filter, replace the drain plugs in the drain hole and tighten the drain plug. Oil pan drain plug : 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf} Replace the oil filter. See the instructions under the caption OIL FILTER. Add engine oil through the oil filler port to the specified level. After refilling the engine oil, wait for at least 6 minutes, then using the dipstick check the oil level. If the oil level is low, add additional oil. Wait 6 minutes, then recheck the oil level. Repeat this procedure until the engine oil reading on the dipstick is between H and L. Install the engine undercover (if equipped).

Oil filter WARNING WARNING z

Do not handle hot oil filter without hand protection. Failure to do so may result in burn injury.

NOTE

Use genuine filter or equivalent in quality and design. z Use of an inferior filter could hinder engine operation and emission controls. z Always replace the oil filter at the same time engine oil is replaced. z

MA-4-7

MAINTENANCE PROCEDURE To replace the oil filter 1. Undo the four engine undercover catchers (on the left and right sides of the engine), and remove the undercover assembly (if equipped). 2. Place a container under the oil filter and remove the drain plug in the bottom of the oil filter. Drain oil from the filter. 3. Remove the filter with a filter wrench and drain all oil into the container.

4.

Apply a thin coat of clean engine oil to the packing of a new oil filter. CAUTION z Installation of the oil filter without coating the packing with oil may damage the packing, resulting in loss of engine oil and damage to the engine and/or lubrication system.

5.

Install the new filter by hand. After the packing comes in contact with the bracket sealing surface, tighten an additional 3/4 turn (Full flow only type) or 1-1/8 to 1-1/8 turn (Full flow & bypass combination type). CAUTION z When installing an oil filter, tighten it by hand. Do not use a wrench or other tools which could result in overtightening and damage to the filter. 6. 7.

Run the engine. Check the filter and seal for leaks. After checking, install the under cover.

MA-4-8


COOLING SYSTEM The engine cooling system was filled at the factory with a high-quality, year-round, coolant solution with a 50/50 antifreeze/water mixture. The antifreeze solution contains rust and corrosion inhibitors. The solution provides protection against freezing to approximately 30°C (-22°F). The solution must remain in the system year round to provide protection against freezing, boiling, rust and corrosion. Do not use additional cooling system additives or inhibitors. They may interfere with the proper operation of the cooling system. Check the engine, radiator, hoses and pipes daily. Repair any leaks. Replace swollen and worn hoses and tighten loosen clamps. Check the OVERHEATING AND COOLANT LEVEL warning light daily to be sure that it does not operate. WARNING WARNING

To help avoid serious personal injury from hot coolant or steam release: z Do not open the radiator filler cap while the engine cooling system is hot. Wait until it cools down. z Be extremely careful when opening the radiator filler cap. Place a thick cloth on the cap and slowly loosen it to allow a reduction in pressure in the cooling system.

COOLANT LEAKAGE

Check the cooling system for leakage, especially at tube and hose connections. Also check piping for fractures, cracks or damage. Replace parts if faulty. If water leaks through the small hole in the water pump body, the water seal may be faulty. Disassemble and repair the water pump.

MA-4-9


WATER HOSE AND CLAMP Check the water rubber hose and clamp of the cooling system for installation, cracks or damage. Replace faulty parts if necessary.

COOLANT LEVEL WARNING WARNING To help avoid serious personal injury from hot coolant or steam release: z Do not open the radiator filler cap while the engine cooling system is hot; wait until it cools. z Be extremely careful when opening the radiator filler cap. Place a thick cloth on the cap and slowly loosen it to allow a reduction in pressure in the cooling system. z If the coolant is accidentally ingested, force the person to vomit and secure medical help immediately. If the coolant gets in the eye, flood the eye with lots of water and get medical attention immediately. Open the front lid. Check the coolant level daily only when the engine is cool. Check the coolant level in the coolant reservoir tank located behind the front lid. The coolant level should be between the HIGH and LOW lines. If the coolant level is below the LOW line, add the proper coolant solution to the HIGH line. Be sure to use an ethylene glycol antifreeze with water at the proper mixture ratio. To ensure the proper mixture ratio, carefully read the instructions on the container or obtain the instructions from the antifreeze manufacturer. Examples are shown below. Outside temperature down to

Antifreeze

Soft water

-10 (14)

30%

70%

-20 (-4)

40%

60%

-30 (-22)

50%

50%

°C (°F)

Antifreeze concentration greater than 60 to 70% will adversely affect freezing protection, corrosion inhibitor additives and heat transfer rates. Follow the instructions on the container or obtain the instructions from the antifreeze manufacturer for proper concentration. A complete drain, flush and refill with proper antifreeze and coolant is recommended once a year. This recommendation applies to all vehicles including those with low total annual mileage.

MA-4-10

MAINTENANCE PROCEDURE CAUTION

Antifreeze made with methoxy propanol or propylene glycol is not recommended for use with Nissan Diesel engines. These types of antifreeze can damage engine internal seals and coolant hoses and create a potential fire hazard due to lower flash points than ethylene glycol type antifreeze. z Use only municipally supplied water (tap water) in the cooling system. River, well or other water produces scale in the cooling system, which may cause damage to the engine or cooling system. z Do not add water without adding ethylene glycol antifreeze to the engine cooling system, except in an emergency. If plain water is added in an emergency, restore the proper mixture of antifreeze and water as soon as possible. z If the coolant should get extremely low and the engine very hot, let the engine cool before adding coolant; then, with the engine running, add coolant slowly. Adding cold coolant to a hot engine may crack the cylinder head or crankcase. Never use water alone. z

CHECKING AND CLEANING RADIATOR To maintain cooling system efficiency and keep the engine from overheating, always keep the front surface of the radiator core clean. Remove insects, dirt and other debris by directing pressurized air at the rear surface of the radiator core. CAUTION z

Do not direct pressurized air to the front surface of the radiator (that is, with the air hose pointed toward the engine). Doing so will force insects, dirt and other debris into the radiator core and possibly cause engine overheating.

CHANGING COOLANT WARNING WARNING To help avoid serious personal injury from hot coolant or steam release: z Do not open the radiator filler cap while the engine cooling system is hot. Wait until it cools down. z Be extremely careful when opening the radiator filler cap. Place a thick cloth on the cap and slowly loosen to allow a reduction in pressure in the cooling system.

MA-4-11

MAINTENANCE PROCEDURE Once a year the cooling system should be drained and thoroughly flushed. Unless the cooling system is treated with a corrosion preventive, rust and scale will eventually clog up passages in the radiator and water jackets. This condition is aggravated in some localities by formation of insoluble salts from the water used. CAUTION z

Do not use chemical mixtures to stop radiator leaks except in an emergency. Never use such solutions in place of needed radiator repair.

To clean the cooling system 1. 2. 3.

Move the heater control temperature lever to the HOT position. Open the radiator filler cap. Place containers under the radiator drain cock and the cylinder block drain cock.

4.

Connect a drain hose to the radiator drain cock.

5.

Open the radiator drain cock and the cylinder block drain cock. Drain all coolant solution from the system into the containers. Shut the drain cocks. Fill the cooling system with a proper mixture of water and a good quality cooling system detergent. (Refer to the additional instructions on the detergent container.) Start the engine and run it at a high idling speed until the indicator points to the middle region of the coolant temperature gauge. Maintaining the above coolant temperature with the thermostat open, run the engine and allow the detergent to circulate throughout the cooling system for at least 15 minutes. Stop the engine. Open the drain cocks and completely drain the detergent from the system.

6. 7.

8.

9.

MA-4-12

MAINTENANCE PROCEDURE 10. Shut the drain cocks and fill the cooling system with plain water. Start the engine and run it at a moderate speed in the same manner as described in step 8. 11. Stop the engine. Open the drain cocks and drain the rinsing water. 12. Repeat rinsing procedure 2 or 3 times until the discharged rinsing water appears clean. 13. Drain the coolant from the coolant reservoir tank as necessary. 14. Close the drain cocks and remove the drain hose from the radiator drain cock.

To fill up the cooling system (with coolant) Use the following refill procedure to remove air from the system and provide proper coolant level. 1. Fill the radiator slowly with the proper coolant solution up to the filler opening. Add coolant solution up to the HIGH level of the coolant reservoir tank. The cooling system holds approximately 22 liters (4-7/8 Imp gal) of coolant solution. Then properly close the radiator filler cap and the reservoir tank cap. 2. Operate the engine at a slightly higher than normal idling speed with the engine idling control button until the coolant temperature indicator points the middle region of the gauge. Run the engine an additional 10 minutes to allow the air to escape from the engine cooling system. 3. Stop the engine. After the engine has completely cooled down, remove the radiator filler cap and check the coolant level in the radiator. If low, add coolant to the radiator filler opening. Reinstall the radiator filler cap. 4. Check the coolant level in the coolant reservoir tank. If the level is between the LOW and HIGH lines, it is normal. If it is below the LOW level, add coolant solution up to the HIGH level. 5. If the added coolant solution is more than 500 milliliter (17.6 Imp fl oz), check and correct for any sign of leakage, then repeat steps 1 to 4. 6. Check the drain cock for leaks.

COOLIG FAN AND FAN SHROUD Check the cooling fan and fan shroud for proper installation, cracks or damage. Replace faulty parts. WARNING WARNING

Never get your hand near the fan, when the engine is operated. z If fan clutch is equipped, the fan rotating speed may seem to slow when the coolant is cool, but never try to touch the fan and other rotating parts while the engine is running. z

MA-4-13


RADIATOR CAP Attach the radiator cap to a cap tester, and measure the operating pressure of the radiator cap valve. If the measured value exceeds the maintenance standard, replace. Unit: kPa {kgf/cm2, psi} Maintenance standard

Service limit

39 - 59 {0.4 - 0.6, 6 - 9}

—

FAN CLUTCH Ensure that the engine is off when checking the fan clutch. 1. Check the fan clutch for oil leakage. If leakage is present, replace the fan clutch assembly. 2. Check the fan clutch for proper operation: z Rotate the cooling fan by hand (adjacent parts should be cool) to ensure it moves smoothly without binding. z Then, start the engine and operate it until the pointer of the water temperature gauge stays within the “H” range. Stop the engine to ensure that the cooling fan no longer rotates by hand. NOTE z

The fan clutch operates in a manner similar to a “direct drive” when the temperature of parts near the bimetal located at the front center of the clutch reaches approximately TºC (TºF). For this reason, it is best to measure the temperature of those parts to assure proper maintenance during inspection.

Unit: ºC (ºF) Item FE6A FE6B 119 kW {162 PS} FE6B 132 kW {180 PS} FE6B 132 kW {180 PS} FE6T 135 kW {183 PS} FE6T 151 kW {205 PS} FE6TA 157 kW {213 PS} FE6T 151 kW {205 PS} FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS} FE6TA 173 kW {235 PS}

FD1300L

ON - OFF type

Run the engine continuously

Operating temperature (T)

3,000 rpm

75±5 (167±9)

FDL1700 Linear type FDL2000

3,400 rpm

65±10 80±5 (149±18 176±9) 50±10 80±5 (122±18 176±9)

MA-4-14


V-BELT Be sure the engine is off and the transmission is in “Neutral”. Engage the parking brake securely. 1. Visually check the V-belt daily for cracks and damage. If the belt is cracked or damaged excessively, replace it. Also check that the belt does not come in contact with the bottom of the pulley groove. Replace the belt if necessary.

2.

Check the drive belt for proper deflection by depressing the midpoint with a force of 98 N {10 kgf, 22 lbf}. Unit: mm (in) Item


Service limit

Fan pulley - alternator pulley

10 - 15 (0.39 - 0.59)

—

Fan pulley - cooler pulley

7 - 12 (0.28 - 0.47)

—

Fan belt 1. Loosen the alternator anchor bolt and the adjusting bolt.

2.

3.

Adjust the alternator position so that the belt deflects as specified and tighten the adjusting bolt. : 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf} Tighten the alternator anchor bolt. : 59 - 74 N·m {6.0 - 7.5 kgf·m, 43 - 54 ft·lbf}

Cooler belt 1. Loosen the lock nut. 2. Adjust the belt tension to the specified value by the adjusting bolt. 3. Tighten the lock nut. : 35 - 47 N·m {3.6 - 4.8 kgf·m, 26 - 35 ft·lbf}

MA-4-15


THERMOSTAT 1. 2.

3. z

z

Drain coolant completely. Refer to the “CHANGING COOLANT” for procedures. Remove the upper radiator hose, water outlet and thermostat.

Check the thermostat as described below, and replace if faulty. Ensure that the valve contacts the seat at room temperature. Check the valve opening temperature and the “lift” of the valve. Item 76.5 (170) Valve opening temperature 82 (180) ºC (ºF)

Thermostat

88 (190) 76.5 (170) Valve lift/ temperature 82 (180) mm/ºC (in/ºF) 88 (190)


Service limit

74.5 - 78.5 (166 - 173)

71.5 - 81.5 (161 - 179)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

More than 10/90 (0.39/194)

Less than 9/90 (0.35/194)

More than 10/95 (0.39/203)

Less than 9/95 (0.35/203)

More than 10/100 (0.39/212)

Less than 9/100 (0.35/212)

NOTE z

z

4. 5.

The valve opening temperature (82, 88, etc.) is marked on the thermostat. Ensure that the difference between the valve opening and closing temperatures is less than 5ºC (9ºF). Install the thermostat, the outlet and the gasket. Connect the upper radiator hose. Three types of thermostats, which open at different temperatures, are used. Add coolant to the radiator. Refer to “CHANGING COOLANT” for procedures.

MA-4-16


FUEL SYSTEM WARNING WARNING Observe the following when removing parts of the fuel system: z Post a placard that reads: “CAUTION: FLAMMABLE”. z Prepare a fire extinguisher. z Disconnect the ground terminal from the battery.

GOVERNOR SETTING Make sure that the parts shown in the figure below are secured with sealing caps and wires. If the cap or wire is broken, check and adjust the injection pump and governor. CAUTION z

Any unauthorized adjustments in the injection pump and governor settings, other than as specified, can cause serious damage to the engine.

INJECTION TIMING 1. 2.

Remove the pointer cover. Secure the pointer to the flywheel housing using bolts. Crank the engine in the standard direction by turning the flywheel with a lever until the pointer is aligned with the timing mark. Maintenance standard

Service limit

14º

—

119 kW {162 PS}

15º

—

132 kW {180 PS}

12º

—

135 kW {183 PS}

12º

—

151 kW {205 PS}

10º

—

162 kW {220 PS}

9º

—

157 kW {213 PS}

3º

—

173 kW {235 PS}

12º

—

Item FE6A FE6B Fuel injection timing

FE6T

FE6T A

Remarks


NOTE z

If the mark goes past the pointer, move it back past the pointer and turn again in the standard direction until alignment is made.

MA-4-17


The flywheel is correctly positioned if the timing mark is set as shown in the figure.

4.

If the timing mark is slightly out of alignment, crank the engine until the correct alignment is made. There is no problem as long as the timing mark on the flywheel is somewhere between the following value. Engine model

FE6A FE6B

FE6T

FE6TA

Timing mark

Remarks

13º - 15º 119 kW {162 PS}

14º - 16º

132 kW {180 PS}

11º - 13º

135 kW {183 PS}

11º - 13º

151 kW {205 PS}

9º - 11º

162 kW {220 PS}

8º - 10º

157 kW {213 PS}

2º - 4º

173 kW {235 PS}

11º - 13º


If the timing mark is not within this range, adjust as follows:

Adjustment of fuel injection timing ..... Method 1 z Loosen the coupling bolts (two places).

MA-4-18

MAINTENANCE PROCEDURE z

z

Slightly back the timer off in the direction opposite to that in which the engine rotates, then move it in the standard direction until the timer mark is aligned. Tighten the coupling bolts (nut) and cotter bolt. Coupling bolt and nut : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf} : FE6TA 157 kW {213 PS} 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf} Cotter bolt : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf} : FE6TA 157 kW {213 PS} 83 - 93 N·m {8.5 - 9.5 kgf·m, 61 - 69 ft·lbf}

Adjustment of Fuel Injection Timing ..... Method 2 If the engine continues erratic operation even though method 1 above is conducted, the camshaft or bearings, etc. may be worn to such an extent that fuel injection timing is not properly adjusted. To check and adjust fuel injection timing, proceed as follows: 1. 2.

3. 4. 5. 6.

Remove the nozzle pipe. Remove the delivery valve holder of the No. 1 cylinder, take out the delivery valve spring, and tighten the delivery valve holder to the specified torque. : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 49 - 54 N·m {5.0 - 5.5 kgf·m, 36 - 40 ft·lbf} : FE6TA 157 kW {213 PS} 103 - 113 N·m {10.5 - 11.5 kgf·m, 76 - 83 ft·lbf} Rotate the flywheel in reverse direction until the No. 1 piston is 25º B.T.D.C. on compression stroke. Set the fuel control lever in the full-injection position. Slowly rotate the flywheel in the normal direction while feeding fuel by the priming pump. Fuel injection starts when fuel stops discharging from the delivery valve holder. At this point, the timing mark on the flywheel should be somewhere between the following value. Engine model

FE6A FE6B

FE6T

FE6TA

Timing mark

Remarks

13º - 15º 119 kW {162 PS}

14º - 16º

132 kW {180 PS}

11º - 13º

135 kW {183 PS}

11º - 13º

151 kW {205 PS}

9º - 11º

162 kW {220 PS}

8º - 10º

157 kW {213 PS}

2º - 4º

173 kW {235 PS}

11º - 13º


NOTE z

Perform this measurement at least three times, and calculate the average value. MA-4-19


IDLE SPEED NOTE z

z

1. 2. 3.

When checking engine idle speed, make sure that the engine idle control knob inside the cab is set to the lowspeed position. The state of the exhaust shutter (open or closed) is not specified. Start the engine and warm it up to the normal operating temperature. Allow the engine to idle and observe the engine speed on the tachometer. If idle speed is not within specified range, adjust as follows: Unit: rpm

Idle speed

Item


Service limit

FE6A, FE6B, FE6T

600

—

157 kW {213 PS}

650

—

173 kW {235 PS}

550

—

FE6T A

NOTE

If equipped with an air conditioner, the air conditioner switch must be turned off when checking idle speed. z Be sure to adjust the idling with the magnetic valve wiring of the exhaust shutter disconnected. If the wiring is connected, the idling cannot be adjusted correctly as the exhaust shutter is closed. z

Idle speed adjustment 1. 2. 3.

Loosen the lock nut on the idle adjusting bolt. Turn the idle adjusting bolt to obtain the correct idle speed. Tighten the lock nut. : 15 - 20 N·m {1.5 - 2.0 kgf·m, 11 - 14 ft·lbf} NOTE z Accelerate the engine two or three times. Allow the engine to return to idle speed and observe the tachometer reading. If the idle speed is not within the specified range, check the accelerator linkage for binding and repeat idle adjustment. 4.

After adjustment, connect the magnetic valve wiring of the exhaust shutter.

ACCELERATION AND DECELERATION 1. 2.

Start the engine and warm it up to the normal operating temperature. Depress the accelerator pedal to check that engine speed smoothly increases from idle to the maximum and that it returns to idle.

MA-4-20

MAINTENANCE PROCEDURE NOTE z

If the engine does not accelerate smoothly, disengage the accelerator linkage from the injection pump and operate the fuel control lever of the injection pump to check engine acceleration. If the engine rotates smoothly, the accelerator linkage may be faulty. Check and repair the linkage. If engine operation is erratic, the injection pump or governor may be faulty. Check and repair these parts.

3.

Attach the pickup of the tachometer to the No. 1 injection tube, and measure the no-load maximum engine rpm. Unit: rpm Item

No-load maximum engine speed


Service limit

3,600

—

ACCELERATOR LINKAGE Check accelerator linkage for bent rods, interference with nearby parts or looseness.

NOZZLE (INJECTOR PRESSURE AND PATTERN) Cleaning nozzle 1. 2. 3.

Remove the nozzle holder assembly from the engine. Refer to the “ENGINE DISASSEMBLY AND REASSEMBLY” section for details. Clamp the nozzle holder in a vise with a holder plate (157944-9520). Loosen the retaining nut, and then remove the nozzle from the nozzle holder. Do not drop the nozzle needle.

4. Pull the nozzle needle from the nozzle body. NOTE z Do not use the nozzle needle in another nozzle body. 5.

Remove carbon from around the openings by using the corner of a hard piece of wood. Do not use waste or any other material to push carbon into the openings.

MA-4-21


Removing carbon in openings Use the pin vice (99727 Z5005) and wire to clean the openings. Unit: mm (in)

Nozzle identification mark

Number of injection nozzle hole

Injection nozzle hole diameter

Wire diameter

Z D3

5

0.29 (0.0114)

0.26 (0.0102)

D2 A5 A6 A3

5

0.30 (0.0118)

0.29 (0.0114)

C1

5

0.245 (0.0096)

0.23 (0.0091)

z

z

z

7.

Allowing too much wire to protrude at the tip of the holder will permit the wire to bend inside the nozzle, and withdrawal becomes difficult. The wire should protrude less than 2 to 2.5 mm (0.079 to 0.098 in). Carefully push the carbon into the nozzle. Too much force will bend the wire. Proceed slowly. Remove carbon at the inside end of the openings with the nozzle cleaning tool (99726 Z5000). Exercise care to avoid damaging the surface which the nozzle needle contacts. The use of compressed air may clog the openings with foreign particles. Tighten the retaining nut. : 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}

NOZZLE HOLDER (INJECTOR) Rebuild the nozzle holder at the specified interval. Check and adjust the nozzle opening pressure and spray pattern. Refer to the “EF” section for rebuilding procedures. WARNING WARNING z

Fuel from the injection nozzle is injected under extremely high pressure. If it is directed at your hand, etc., serious injury may result. KEEP YOUR HANDS AWAY FROM THE NOZZLE DURING TESTS.

FUEL LEAKAGE Check the fuel system for leakage at tube or hose connections.

MA-4-22


REPLACEMENT OF FUEL FILTER NOTE z

Use genuine filter or equivalent in quality and design. Use of an inferior filter could hinder engine operation and emission controls.

Cartridge type 1. 2.

Remove the engine side cover (left side). Place a container under the filter. Remove the filter with a filter wrench. Drain any remaining fuel into the container.

3.

Apply a thin coat of clean engine oil to the gasket of the new filter. WARNING WARNING z Installation of the fuel filter without coating the gasket with oil may damage the gasket resulting in loss of fuel and fire hazard due to spilled fuel. 4.

Install the new fuel filter by hand. After the gasket comes in contact with the bracket sealing surface, tighten an additional 3/4 of a turn. CAUTION z When installing the fuel filter, tighten by hand. Do not use a wrench or other tools which could result in overtightening and damage to the filter. 5.

After installing the filter, purge air from the fuel system and check for fuel leaks. For air purging details, refer to “PURGING AIR FROM FUEL SYSTEM”.

Center bolt type 1. 2.

Place a container under the filter. Remove the drain plug, and empty out fuel and sediments.

MA-4-23


Loosen the center bolt and remove the filter case, set spring, element and other parts. 4. Check the element for clogging and contamination. 5. Clean the filter parts in light oil. 6. Replace the packings. 7. Reassemble the parts correctly. Center bolt : 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22 ft·lbf} WARNING WARNING z Make sure fuel leaks are not present after installing parts. Leaks will not only waste fuel but also create a fire hazard. NOTE z

Do not excessively tighten bolts.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

8.

1.

Drain plug

6.

Seat spring

2.

Packing

7.

Retainer

3.

Center bolt

8.

Element

4.

Packing

9.

Packing

5.

Filter case

10.

Filter cover

After installing the filter, purge air from the fuel system and check for fuel leaks. For air purging details, refer to “PURGING AIR FROM FUEL SYSTEM”.

PRIMARY FUEL FILTER Draining sediment from primary fuel filter NOTE z

It is not necessary to drain all the fuel in the primary fuel filter case.

Place a receiver under the filter, then loosen the drain plug to drain sediment. Put the drained precipitates in a glass container such as a test tube. If there is fuel on top of the water, dust and precipitates, it indicates that the precipitates have been removed. Bleed air from the fuel system after draining sediments.

MA-4-24


Replacing primary fuel filter element 1. 2.

Place a container under the filter. Place a suitable oil can under the drain cock, and drain the fuel and sediment. Also loosen the plug to speed up draining.

3.

Loosen the center bolt, and remove the filter case, set sprig and element. 4. Clean each part in light oil. 5. Replace the element packings. 6. Reassemble each part correctly. Center bolt : Type I 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22 ft·lbf} : Type II 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf} Drain plug (Type II only) : 16 - 22 N·m {1.6 - 2.2 kgf·m, 12 - 16 ft·lbf} z Do not excessively tighten the bolts and plugs. Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) Type I 1.

Plug

7.

Set spring

2.

Packing

8.

Retainer

3.

Drain cock

9.

Element

4.

Center bolt

10.

Packing

5.

Packing

11.

Filter cover

6.

Filter case

Type II

7.

1.

Drain plug

7.

Seat

2.

Packing

8.

Element

3.

Center bolt

9.

Packing

4.

Packing

10.

Filter cover

5.

Filter case

11.

Filter plug

6.

Spring

12.

O-ring

After installing the filter, purge air from the fuel system and check fuel leaks. For air purging details, refer to “PURGING AIR FROM FUEL SYSTEM”.

MA-4-25


FUEL STRAINER Draining sediment from fuel strainer 1. 2. 3.

Place a container under the drain plug. Loosen the drain plug, and drain sediment and water from the fuel strainer. After draining, securely tighten the drain plug.

Cleaning procedure 1.

Place a suitable oil can under the drain plug, and drain the fuel and sediment. 2. Loosen the center bolt, and remove the case, set spring baffle and other parts. 3. Clean each part in light oil. 4. Replace the packings. 5. Reassemble each part correctly. Center bolt : 15 - 20 N·m {1.5 - 2.0 kgf·m, 11 - 14 ft·lbf} NOTE z

Do not excessively tighten the bolts and plugs. 1.

Strainer cover

6.

Spring retainer

2.

Packing

7.

Strainer case

3.

Screen

8.

Packing

4.

Baffle

9.

Center bolt

5.

Set spring

10.

Drain plug

NOTE z

Numbers before part names do not indicate the disassembly sequence.

6.

After installing the filter, purge air from the fuel system and check fuel leaks. For air purging details, refer to “PURGING AIR FROM FUEL SYSTEM”.

PURGING AIR FROM FUEL SYSTEM Air entrapped in the fuel system will cause poor injection of the fuel, thus resulting in difficult starting, jerking, or even stoppage of the engine. After completing any service procedure on the fuel system (inspection, replacement of fuel filter element, or reconnection of any fuel pipe), be sure to bleed air from the fuel system.

MA-4-26


Twist the knob on the priming pump, which is connected to the injection pump, and the knob will rise up by itself.

2.

Loosen the bleeder screw on the injection pump front upper side. (MKB and LKC212 series only) Keep moving the priming pump knob up and down until moving it becomes difficult and you can no longer hear the sound of air hissing from the bleeder screw. Retighten the bleeder screw. : 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}

z

z

3.

4.

Move the priming pump’s knob up and down to send fuel from fuel tank into the filter. Continue this procedure until the overflow valve of the fuel filter no longer gives off a “hissing” sound and movement of the priming pump is difficult. The air bleeding operation is now complete. After bleeding air, return the pump knob to its original position. Start the engine, and make sure that no fuel is leaking from the fuel system. Fuel leaks can cause a fire. If a leak is discovered, immediately repair the affected part.

INTAKE AND EXHAUST SYSTEM AIR CLEANER ELEMENT Precautions for handling cleaner 1. 2.

Be sure to install the element and cover securely. Loose or improper installation will allow dust to enter, preventing normal functioning of the air cleaner. Do not touch the filter paper of the element directly with your hand. Wear gloves. Use special care not to stain the element with oils.

To inspect the air cleaner element Start the engine and check if the air cleaner warning light comes on. If the warning light comes on frequently, clean or replace the element as follows: NOTE z

If the air cleaner element reaches a checking or replacing period, clean or replace the element regardless of whether the warning light comes on or not.

MA-4-27


Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1.

Cover assembly

4.

Inner element

2.

Packing

5.

Evacuator valve

3.

Outer element

6.

Body assembly

1. 2.

Unlock the clips and remove the cover assembly. Pull out and remove the outer element.

3.

Check the outer element and packing, and replace if broken or deformed. If there is dirt or dust on the outer element, clean it by blowing compressed air at 196 to 294 kPa {2.0 to 3.0 kgf/cm2, 28 to 43 psi} from inside.

4. Pull out and remove the inner element. NOTE z Do not remove the inner element until the specified replacement time. In other words, the inner element need not be checked between replacements. 5.

When installing the elements, clean the inside of the body assembly and evacuator valve and assembly each part in the reverse order of disassembly.

MA-4-28


Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1.

Wing nut

7.

Outer element

2.

Packing

8.

Wing nut

3.

Cover assembly

9.

Packing

4.

Packing

10.

Inner element

5.

Wing nut

11.

Evacuator valve

6.

Packing

12.

Body assembly

1. 2.

Loosen the wing nut and remove the cover assembly. Loosen the wing nut securing the outer element and remove the outer element.

3.

Check the outer element and packing, and replace if broken or deformed. If there is dirt or dust on the outer element, clean it by blowing compressed air at 196 to 294 kPa {2.0 to 3.0 kgf/cm2, 28 to 43 psi} from inside.

4. First remove the wig nut and then the inner element. NOTE z Do not remove the inner element until the specified replacement time. In other words, the inner element need not be checked between replacements.

AIR INTAKE SYSTEM (DUCT, HOSE AND CLAMP) Check the air intake duct connections for loose clamps or cracked hoses. Check the connection between the air cleaner and air intake manifold especially. Tighten loose clamps, if any.

MA-4-29


EXHAUST TUBING AND MUFFLER Check the various connections of the exhaust tubing for looseness. Tighten loose parts as necessary. Also check for any sign of gas leakage from connections or muffler.

CONDITION OF EXHAUST Warm up the engine sufficiently, then visually inspect exhaust smoke during idling, acceleration and deceleration with the vehicle at a stop. Color of smoke

Judgment standard

Colorless or light blue

Normal

Black

Abnormal Incomplete combustion

White

Abnormal Engine oil is also burning. However, exhaust gases are often white when either the air or engine temperature is low.

TURBOCHARGER (FE6T AND FE6TA) NOTE

Before attempting any servicing of the turbocharger, clean its entire exterior surface. z Never use a caustic solution. Caustic solutions attack aluminum. z

To clean the compressor side 1. 2.

Remove the turbocharger from the engine. Remove the compressor housing and check the condition of the impeller (compressor wheel). If it is not excessively dirty, clean the impeller and the inner surface of the housing with a brush and a cloth dampened with diesel fuel. CAUTION z Do not use a wire brush or scraper.

3.

If the impeller is excessively dirty, overhaul and clean. Refer to the ENGINE “IE” section for cleaning instructions. 4. When the impeller is wet with cleaning solvent, dry with compressed air. CAUTION z Hold the impeller by hand to prevent it from turning while drying.

MA-4-30


Install the compressor housing in its original position. T04B and T04E : 11.3 - 14.7 N·m {115 - 150 kgf·cm, 100 - 130 in·lbf} RHC62E and RHC6V : 7.4 - 8.3 N·m {75 - 85 kgf·cm, 65 - 74 in·lbf}

To clean the turbine side 1.

Remove the turbine housing and check the condition of the turbine. If the turbine is not excessively dirty, clean the turbine and the inner surface of the turbine housing in a manner similar to that outlined under “To clean the compressor side”. 2. If the turbine is excessively dirty, overhaul and clean. 3. When the impeller is wet with cleaning solvent, dry with compressed air. CAUTION z Hold the impeller with your hand to prevent it from turning while cleaning. 4.

5.

Install the turbine housing in its original position. T04B and T04E : 18.0 - 21.5 N·m {184 - 219 kgf·cm, 160 - 190 in·lbf} RHC62E and RHC62V : 27.0 - 28.9 N·m {275 - 295 kgf·cm, 239 - 256 in·lbf} Check that the turbine wheel rotates smoothly by your hand. Install the turbocharger on the engine and check for gas or air leakage.

PCV VALVE Point of inspection Cover the hole at the center of the bottom of the valve with masking tape and suck on the valve outlet to check that air is sucked into the inlet hole on the bottom of the valve. z Next, cover the inlet hole on the bottom of the valve and suck on the outlet pipe to check that the diaphragm opens and closes properly. This can be confirmed by the operating sound which the diaphragm makes when opening and closing. If there are any abnormalities, replace the valve. NOTE z When sucking on the valve, be careful not to get any oil in mouth. First remove the oil from inside the valve. z

MA-4-31


PCV SYSTEM Hose and clamp Check hose connections for signs of chafing, leaks or deterioration. Replace faulty hoses or tighten clamps, as necessary.

Piping Check piping and connections for improper installation, cracks or damage. Remove the hose when the PCV valve is replaced and clean the inside of the hose with compressed air. Replace faulty hoses or retighten clamps, as necessary.

OTHERS ALTERNATOR Check the ball bearings for proper rotation and abnormal noise.

STARTING MOTOR Inspect the moving contactor of the magnetic switch.

MA-4-32

- MEMO -

TROUBLE DIAGNOSIS TD

CONTENTS DIAGNOSIS ............................................ TD-1-1 DIFFICULT ENGINE STARTING ..................... BLACK EXHAUST SMOKE .............................. WHITE EXHAUST SMOKE .............................. IRREGULAR ENGINE OPERATION................

TD-1-2 TD-1-3 TD-1-3 TD-1-4

DECREASED ENGINE POWER ...................... EXCESSIVE OIL CONSUMPTION................... EXCESSIVE FUEL CONSUMPTION ............... NOISY ENGINE ................................................ ENGINE OVERHEATS .....................................

TD-1-5 TD-1-6 TD-1-7 TD-1-8 TD-1-9

DIAGNOSIS

DIAGNOSIS DIAGNOSIS GUIDE The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling the engine on the basis of the symptoms of the problem complained of by the user and the result of checks performed in the shop with the engine mounted in the body.

HOW TO USE THE GUIDE 1. 2. 3.

Open the page of the guide corresponding to the trouble symptom complained of by the user. Check all of the points listed in the page. If there is any applicable item in the checking points, the cause of the trouble may be assumed in the following manner. z Each item in the “Symptoms and checking points” section corresponds to one or more items in the “Cause of trouble” section through the dot mark “z”. If there are more than one applicable “Cause of trouble” items, the item having the largest number of dot marks should be regarded as the central cause of the trouble. z The “cause” items having no dot mark can be regarded as not being the cause of the trouble. NOTE z If more than one cause is assumed, the repair should begin with the simplest operation.

TD-1-1

Faulty starter

z

Faulty starter switch and starter relay

z

Electrical system Fuel system Engine proper and others

Symptoms and checking points

Poor fuel consumption or oil consumption

z

Engine lacks power

Breaks in electrical wire

Engine cannot be cranked manually

z

Excessive exhaust smoke

Poor connection of connector and terminal

Moderate exhaust smoke

z

Little exhaust smoke

z

Cause of trouble

Sound of magnetic switch is heard with starter switch ON

Slow starter rotation (less than 100 rpm)

Discharged battery

DIFFICULT ENGINE STARTING

Insufficient starter rotation

Starter fails to rotate

DIAGNOSIS

z z

z

Faulty air heater

z

Lack of fuel

z

Faulty feed pump

z

Incorrectly installed fuel pipe

z

z

Faulty injection pump

z

z

Faulty nozzle

z

z z z z

z

z

z

z

z

Clogged fuel filter element

z

z

z

z

Air in fuel system

z

Incorrect injection timing

z

Broken or damaged fuel pipe

z

z

Clogged gauge filter

z

z

Damaged ring gear

z

Damaged or seized rotating engine parts

z

High engine oil viscosity

z z

z z

z z z

z

Incorrect valve clearance

z

z

z

z

Inadequate compression pressure

z

z

z

z

Incorrect valve timing

z

z

Clogged air cleaner element

z

z

Faulty clutch and subsequent power train (Check by connecting and disconnecting the clutch)

TD-1-2

z

z

z

Exhaust smoke gradually turns black

z

z

z


z

z

z

z

Engine knocks


Irregular idling

Intake system Fuel system

Oil leakage from compressor side of turbocharger

z

Excessive injection quantity

z

Uneven plunger wear

z

z

z

z

z

Turbocharger failure (jamming, etc.)

z

z

z

z

z

z

z

z

Faulty nozzle

z

z

z

z

z

z

z

z

z

z

z

Excessively advanced injection timing

z

Faulty boost compensator Engine proper

z

Malfunction of delivery valve Poor fuel quality

z

Excessive oil in oil pan

z

z z

Wear on piston rings, and cylinder liner

z

Low compression pressure

Engine lacks power

z

High blow-by gas pressure

Poor fuel consumption or oil consumption

Accumulation of sludge in air heater

BLACK EXHAUST SMOKE

Exhaust smoke suddenly turns black

Cause of trouble

Poor engine starting

DIAGNOSIS

z z

z

z

z

z

Engine proper and others

WHITE EXHAUST SMOKE Delayed injection timing

z

Engine temperature too low

z

z z

z

Engine oil leakage down through valve stem

z

z

z

z

z

z

Wear on piston ring or cylinder liner

z

Excessive oil in oil pan

z

z

z

z

z

z

z

Incorrect valve clearance

z

TD-1-3

z

z

z

Fuel system

z

z

z

z

z z

z

z

z

z

z

Improper fuel spray of nozzle

z

z

z

z

z

Improper adjustment of idle spring Malfunction of delivery valve

z z

z

Air in fuel system Engine proper

z

Uneven injection pressure of nozzle

Improper adjustment of damper spring

Others

z

z z

Improper placement of valve seat

z

z

Improper valve clearance

z

z

Incorrect valve timing

z

Incorrect compression pressure Engine temperature too low

z z

z

z

z

z

z

z

z

z z

z

z z

z

z

z

z

z

z

Rusted control wire

z

TD-1-4

z

z z

Deteriorated engine mount rubber Improper adjustment of idling

z

z

z z

z

z

z z

z


z

z

Malfunction of governor

Specified maximum rpm is exceeded

z

z

Specified maximum rpm is not achieved

Uneven injection quantity

z

Irregular idling

z

Engine often stalls

z

Engine stabilizes at two speeds

Fuel leakage from injection pipe

Engine knock

z

Poor fuel consumption

Difficulty in starting engine

z

White exhaust smoke

Incorrect adjustment of link or rod

Cause of trouble

Black exhaust smoke

Engine lacks power

IRREGULAR ENGINE OPERATION


DIAGNOSIS

z

z

z

z

z

z

z

z z

z

z

z

z

Clogged fuel filter element

z

Fuel system Intake and exhaust system Engine proper Others

z

z

z

z

z

z

z z

Improper fuel spray from nozzle

z

Improper injection timing

z

Malfunction of delivery valve

z

Malfunction of feed pump

z

Malfunction of injection pump

z

Faulty boost compensator

z

z

z

z

z

z

z

z

z


z

Thin or hot intake air

z

Accumulation of carbon to air heater

z

z z

z z z

z

z

z z

z

z

z

z

z

z

z

z

z

z

Half-opened exhaust shutter

z

z

z

z

z

Wear on piston rings and cylinder liner

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

Worn, sticking, or broken piston ring

z

Seized piston

z

z

z

z

Worn or seized valve stem

z

z

z

z

Improper seating of valve insert

z

z

z

z

Improper selection of gear while traveling

z z

z

Improper adjustment of control linkage

z

z

Poor returning of engine stop wire

z

z

TD-1-5

Low specific gravity of fuel

z

z

z

Clogged or crushed exhaust pipe or muffler Turbocharger malfunction

z

z

z

z

z


Specified maximum rpm is not achieved

Excessive blow-by gas

Low boost pressure

Engine overheats

z

Water or air in fuel system Low fuel pressure (overflow valve)


Poor oil consumption


White exhaust smoke

z

Irregular idling

Improper adjustment of injection quantity

z

Engine knock

Improper fuel quality

Black exhaust smoke

Cause of trouble

Little exhaust smoke

DECREASED ENGINE POWER


DIAGNOSIS

z

Turbocharger

Engine proper

z

z

Aligned piston ring end gaps

z

Insufficient piston ring tension

z

Improper break-in of piston ring

z

Inversely fitted piston rings

z

Broken or seized piston rings

z

z

z

z

z

Worn piston ring

z

z

z

z

z

Scuffing of cylinder liner

z

z z z

z

Worn valve stem or guide

z

z

Worn valve stem seal

z

z

Worn or broken seal ring

z

z

Oil return hole obstructed by carbon

z

z

Improper installation of seal ring

z

z

Excess of engine oil

Engine oil measuring method incorrect

z

z

Engine knock

z

Worn piston rings and cylinder liner

Leakage of engine oil Others


z



z

Oil attaching to exhaust pipe and manifold


z

Engine overheated previously

Engine lacks power

Engine emits white smoke after idling

Cause of trouble

Continuous emission of white smoke at high-speed running

EXCESSIVE OIL CONSUMPTION


DIAGNOSIS

z

z z

z

Improper quality of engine oil Clogged air cleaner element

z

TD-1-6

z

Others

Engine proper

Fuel system

Maladjusted nozzle injection pressure

z

Irregular idling


Low boost pressure

z

Maladjusted injection quantity

z

z

z

Improper seating of delivery valve seat

z

z

z

z

z

z

z

z


z

Faulty boost compensator

z

z

Worn or seized piston, or piston ring

z

z

Worn cylinder liner

z

z

Improper seating between valve seat and insert

z

z

Maladjusted valve clearance

z

z


z

z

z

Clogged or crushed exhaust pipe or muffler

z z

z

Seizure in drive line Insufficient tire inflation pressure Unnecessary acceleration and deceleration z

TD-1-7

z

z

z

z

z

z

Clutch slip

Prolonged idling

z

z

z z

Improper gear shifting

z

z

z

Half-opened exhaust shutter z

z

z

Dragged brake Chassis


z


Engine temperature too high

Driving habits

Poor oil consumption

Engine overheats

Engine knock

White exhaust smoke

Black exhaust smoke

Cause of trouble

Engine lacks power

EXCESSIVE FUEL CONSUMPTION


DIAGNOSIS

Others

Fuel system

Improper timer advance angle

z

Uneven injection quantity

z

z

Injection timing too early

z

z

Injection timing delayed

z

Uneven nozzle injection pressure

z


z

Malfunction of delivery valve

z

Poor fuel quality

z

Wear or seizure on rotating and sliding portions

z

z

Insufficient intake air quantity

z

z

Improper valve clearance, or seizure of valve

z

z

z

z

z

z

z

z

z

z

z

TD-1-8


Low boost pressure

High blow-by gas pressure z

z z z

z

z

z z

Engine too cold, or overheated

Excessive oil coming up into cylinder

Engine overheats z

z

z

z z

Low intake air temperature Insufficient compression pressure and compression air temperature


White exhaust smoke

Cause of trouble

Black exhaust smoke


NOISY ENGINE

Engine lacks power

DIAGNOSIS

z

z

z

z

z

Water pump

Improper fan belt tension

z

Worn or seized bearing

z

Air drawn from suction side

z

Improper water seal

z

Coolant passage

z

Accumulation of water scale in cylinder block

Radiator

Clogging by water seal

z

Coolant leakage

z

Malfunction of radiator cap

z

Engine coolant acidified

z

z

z

z

z

z

Clogged core due to accumulation of mud and insects State of combustion

z

z

Clogging by oxide of iron

Air bubbles is radiator

z z

Overflow of engine coolant due to blow-out of gas

Air bubbles appear in water tank only after engine racing

z z

z

Air bubbles appear in water tank only when water temperature is high

z

Damaged impeller Coolant leakage from engine coolant passage

Radiator remains cold even after engine warm up

z

Malfunction of thermostat

Others

Water temperature difference between water inlet and outlet is great

Water temperature difference between water inlet and outlet is small


Engine noisy in operation

Engine lacks power

Cause of trouble

Engine coolant reduces in quantity only after high-speed operation


ENGINE OVERHEATS

Excessive reduction of cooling water

DIAGNOSIS

z

z

z

z

z

z


z


z

Half-opened exhaust shutter

z

z

Clogged or crushed exhaust pipe or muffler

z

z

Gas leakage from cylinder head nozzle tube

z

z

z

z

Gas leakage from head gasket

z

z

z

z

Continuous operation under heavy load, or other improper operation Improper selection of gears while traveling Incorrect indication of thermometer

TD-1-9

- MEMO -

- MEMO -

ENGINE DISASSEMBLY AND REASSEMBLY DR

CONTENTS SERVICE DATA ...................................... DR-1-1 TIGHTENING TORQUE ................................... DR-1-1 TOOLS .................................................... DR-2-1 CONSTRUCTION.................................... DR-3-1 ENGINE ............................................................ DR-3-1 GEAR TRAIN.................................................... DR-3-5 ENGINE REAR PTO ........................................ DR-3-6

DISASSEMBLY AND REASSEMBLY ........................................ DR-4-1 OUTSIDE OF ENGINE ..................................... CYLINDER HEAD............................................. ENGINE PROPER ............................................ ENGINE REAR PTO.........................................

DR-4-1 DR-4-11 DR-4-17 DR-4-27

SERVICE DATA

SERVICE DATA TIGHTENING TORQUE Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Air intake manifold mounting bolt

16 - 20 {1.6 - 2.0, 12 - 14}

Alternator adjusting bolt

34 - 44 {3.5 - 4.5, 25 - 33}

Alternator anchor bolt and nut

59 - 74 {6.0 - 7.5, 43 - 54}

Camshaft gear mounting nut

186 - 226 {19.0 - 23.0, 137 - 166}

Connecting rod bearing cap nut

132 - 142 {13.5 - 14.5, 98 - 105}

Cooling fan mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51} 1st

Cylinder head bolt Engine mounting bolt and nut

Front side Rear side

275 - 294 {28.0 - 30.0, 203 - 217}

2nd

Loosen the nut.

3rd

834 - 883 {85.0 - 90.0, 615 - 651}

1st

98 {10.0, 72}

2nd

177 - 196 {18.0 - 20.0, 130 - 145}

Bracket

29 {3.0, 22}

Cushion

49 {5.0, 36}

Cushion

49 {5.0, 36}

Exhaust manifold connector mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Exhaust manifold mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Fan pulley mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

Flywheel housing mounting bolt and nut

M8

15 - 20 {1.5 - 2.0, 11 - 14}

M12

69 - 74 {7.0 - 7.5, 51 - 54}

Flywheel mounting bolt and nut Front end plate mounting bolt

235 - 255 {24.0 - 26.0, 174 - 188} 16 - 21 {1.6 - 2.1, 11.6 - 15}

Hydraulic pump drive gear mounting nut

49 - 64 {5.0 - 6.5, 36 - 47}

Idler gear plate mounting bolt

34 - 39 {3.5 - 4.0, 25 - 29}

Idler gear shaft mounting bolt

34 - 39 {3.5 - 4.0, 25 - 29}

Injection bracket mounting bolt

37 - 42 {3.8 - 4.3, 27 - 31}

Injection nozzle tube

23 - 27 {2.3 - 2.8, 17 - 20}

Injection pump drive coupling cotter bolt

Injection pump drive coupling bolt and nut

Secure camshaft before tightening.

10 - 12 {1.0 - 1.2, 7 - 9}

Crank damper mounting bolt Crank pulley nut

Remarks


59 - 64 {6.0 - 6.5, 43 - 47}

FE6TA 157 kW {213 PS}

83 - 93 {8.5 - 9.5, 61 - 69}


29 - 34 {3.0 - 3.5, 22 - 25}

FE6TA 157 kW {213 PS}

59 - 64 {6.0 - 6.5, 43 - 47}

DR-1-1

Tighten diagonally.

SERVICE DATA Unit: N·m {kgf·m, ft·lbf} Item Injection pump drive gear mounting nut Injection pump mounting bolt Injection pump stay mounting bolt

Cylinder block side Injection pump side

Locating plate mounting bolt Main bearing cap bolt Nozzle holder mounting bolt

Tightening torque 147 - 167 {15.0 - 17.0, 108 - 123} 20 - 25 {2.0 - 2.5, 14 - 18} 21 - 26 {2.1 - 2.7, 15 - 20} 29 - 39 {3.0 - 4.0, 22 - 29} 21 - 26 {2.1 - 2.7, 15 - 20} 177 - 196 {18.0 - 20.0, 130 - 145}

Apply oil to the bolt seat and thread.

25 - 29 {2.5 - 3.0, 18 - 22}

Oil cooler mounting bolt

25 {2.5, 18}

Oil filter mounting bolt

25 {2.5, 18}

Oil jet connector bolt

34 - 49 {3.5 - 5.0, 25 - 36}

Oil pan drain plug

59 - 69 {6.0 - 7.0, 43 - 51}

Oil pan mounting bolt and nut

18 - 25 {1.8 - 2.5, 13 - 18}

Oil pipe mounting bolt

20 {2.0, 14}

Oil pump mounting bolt

20 {2.0, 14}

Oil screen mounting bolt

9 - 12 {0.9 - 1.2, 6.5 - 8.7}

PTO companion flange mounting nut

Remarks

392 - 412 {40.0 - 42.0, 289 - 304}

PTO idler gear mounting bolt

98 {10.0, 72}

Rocker cover mounting bolts

10 - 15 {1.0 - 1.5, 7 - 11}

Do not overtighten.

Rocker shaft bracket mounting bolt

44 - 54 {4.5 - 5.5, 33 - 40}

Tighten center bolts first then move toward outer bolts.

Spill tube connector

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

Tighten nut before tightening connector.

Starting motor mounting bolt

59 - 78 {6.0 - 8.0, 43 - 58}

Timing gear case mounting bolt and nut

21 - 26 {2.1 - 2.7, 15 - 20}

Water pump mounting bolt and nut

10 - 13 {1.0 - 1.3, 7 - 9}

Cooler tension pulley lock nut

35 - 47 {3.6 - 4.8, 26 - 35}

Turbocharger assembly mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Turbocharger oil pipe Turbocharger oil drain pipe

12 - 15 {1.2 - 1.5, 9 - 11} 18 - 22 {1.8 - 2.2, 13 - 16}

DR-1-2

TOOLS


Description

Socket wrench 99535 Z5007

Used to remove and install crank pulley nut. Width across flats: 55 mm (2.17 in)

Guide bolt 99687 97001

Used to remove and install flywheel.

Engine stand attachment 99554 97001

Used as an attachment for engine stand when installing engine.

Engine stand 99550 96001

Used when disassembling and reassembling engine.

Piston insert tool 99631 Z5502

Used as a guide when inserting piston into cylinder liner.

DR-2-1

Shape

TOOLS


Description

Cylinder head bolt socket wrench 99664 Z5000

Used to remove, install and tighten cylinder head bolts.

Engine jack 99890 Z0001

Used to remove and install engine assembly.

DR-2-2

Shape

CONSTRUCTION

CONSTRUCTION ENGINE ENGINE MODEL FE6

DR-3-1

CONSTRUCTION

DR-3-2

CONSTRUCTION

ENGINE MODEL FE6T (Refer to FE6T for FE6TA construction)

DR-3-3

CONSTRUCTION

DR-3-4

CONSTRUCTION

GEAR TRAIN

DR-3-5

CONSTRUCTION

ENGINE REAR PTO

DR-3-6

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY AND REASSEMBLY OUTSIDE OF ENGINE FRONT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Fan and fan pulley 2. V-belt ,+ 3. Crank pulley assembly

4. Alternator 5. Hydraulic pump

, 6. Thermostat housing 7. Water pump

Marks “+” and “,” indicate that the key points of operation are explained in the text.

DR-4-1


Key point of disassembly 3 Crank pulley assembly Remove the pointer cover and pointer from the flywheel housing. Lock the flywheel ring gear to prevent it from turning. Loosen the crank pulley nuts using the socket wrench (99535 Z5007). NOTE If the crankshaft thread is staked, perform as follows: z Loosen the pulley nut and remove it. (The removed nut cannot be reused.) z Correct the staked portion of the crankshaft thread with a triangular rod file. z Using a new pulley nut, make sure that the nut turns smoothly on the crankshaft thread.

Key point of reassembly 6 Thermostat housing Install the thermostat housing using liquid gasket (THREE BOND 1216 or equivalent) and connect the hose. NOTE z Ensure the flange surface is clean and free from oil, water, dust, etc. before applying liquid gasket. z During application, be sure to overlap the start and end points of the liquid gasket. The gasket should be continuous. z Install parts properly and within 20 minutes after gasket application. z Do not apply pressure to parts for at least 40 minutes after installation.

DR-4-2

DISASSEMBLY AND REASSEMBLY 3 Crank pulley assembly 1. Install the crank pulley assembly and temporarily tighten the crank pulley nut. NOTE z Be sure to install the key. z If the crank pulley is reused, remove the adhesive agent coated on the tapered surface. z Apply one or two drops of Loctite “221” or “222” to the tapered surface of the crankshaft. z Be sure not to apply adhesive agent to the crankshaft tip thread. 2.

Lock the flywheel ring gear. Using the socket wrench (99535 Z5007), install the crank pulley nut. : 1st : 275 - 294 N·m {28.0 - 30.0 kgf·m, 203 - 217 ft·lbf} 2nd: Loosen the nut. 3rd : 834 - 883 N·m {85.0 - 90.0 kgf·m, 615 - 651 ft·lbf} NOTE z First, tighten the nut then loosen it. Secondly, retighten the nut to the specified torque. z Do not leave the pulley temporarily installed without tightening the nut.

DR-4-3


RIGHT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Air pipe 2. Alternator 3. Turbocharger

4. Exhaust manifold cover 5. Exhaust connector , 6. Exhaust manifold

, 7. Oil pipe , 8. Oil filter 9. Oil cooler


Key point of reassembly 8 Oil filter Install the oil filter using an O-ring. NOTE z Be careful not to damage the O-ring. z Tighten the filter by hand. (Refer to the MA section of “To replace the oil filter”.)

DR-4-4


7 Oil pipe Connect the oil pipe using an O-ring. NOTE z

Be careful not to damage the O-ring. : 20 N·m {2.0 kgf·m, 14 ft·lbf}

6 Exhaust manifold Install the exhaust manifold using a gasket. NOTE z

Start by tightening the middle nut and then alternate between the upper and lower ones.

z

These nuts are heat-resistant and should not be confused with other types. : 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}

DR-4-5


LEFT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Air duct 2. Fuel tube 3. Fuel filter 4. Air heater 5. Breather tube

6. Intake manifold 7. Nozzle assembly , 8. Timer coupling , 9. Injection pump assembly and stay 10. Starting motor

11. Drain cock ,+ 12. Air compressor or injection pump support 13. Oil pan


Key point of disassembly 12 Air compressor or injection pump support Remove the air compressor (AOH model only) or injection pump support. (VAC model only) NOTE z Measure the backlash of the front gear train before removing the air compressor (AOH model only) or injection pump support. (VAC model only)

DR-4-6


Key point of reassembly 12 Air compressor or injection pump support Install the air compressor (AOH model only) or injection pump support (VAC model only) using an O-ring (if removed after measuring front gear train backlash).

1.

Rotate the flywheel in the standard direction to determine the 1.6 point at TDC of No. 1 cylinder on the compression stroke. (TDC is the point at which both intake and exhaust valves for No. 1 cylinder are closed and there is a valve clearance.)

2.

Align the scribe mark on the injection pump drive gear tooth with the pointer at the check window on the upper side of the timing gear case. Then, install the compressor or injection pump support.

9 Injection pump assembly and stay, 8 Timer coupling 1. Install the injection pump stay on the injection pump body and tighten to the specified torque. :29 - 39 N·m {3.0 - 4.0 kgf·m, 22 - 29 ft·lbf}

2.

Put the injection pump body on the injection pump bracket and temporarily tighten the injection pump stay-to-cylinder block securing bolts.

DR-4-7

DISASSEMBLY AND REASSEMBLY 3.

Temporarily tighten the injection pump body securing bolts (1), (2), (3) and (4). NOTE z Be sure to equally tighten the bolts in the order enumerated above.

4.

Tighten the injection pump stay-to-cylinder block securing bolts to the specified torque. :21 - 26 N·m {2.1 - 2.7 kgf·m, 15 - 20 ft·lbf}

5.

Set a dial gauge probe to the periphery of the injection timer perpendicularly and horizontally as shown in the figure at right, then reset the pointer to zero (0).

6.

Equally tighten the bolts (1), (2), (3) and (4) in that order so that the dial gauge pointer stays in the 0±0.05 mm (0±0.0020 in) range. Then tighten these bolts to the specified torque. NOTE z Be sure to equally tighten the bolts in the order enumerated above. :20 - 25 N·m {2.0 - 2.5 kgf·m, 14 - 18 ft·lbf}

DR-4-8


Loosen the plate (coupling half side) and cross coupling securing bolts.

8.

Make sure the plate (coupling half side) is smoothly inserted into the cross coupling spigot joint. If it is not, loosen the injection pump securing bolts (1), (2), (3) and (4), readjust by repeating from step 3 above.

9.

Tighten the plate (coupling half side)-to-cross coupling securing bolts to the specified torque. : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf} : FE6TA 157 kW {213 PS} 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf}

10. Rotate the flywheel so that the pointer is aligned with the specified fuel injection timing mark. If the timing marks on the injection pump body and injection pump timer are not close each other, rotate the flywheel an additional turn until the No. 1 cylinder is set at TDC on the compression stroke. Maintenance standard

Service limit

14º

—

119 kW {162 PS}

15º

—

132 kW {180 PS}

12º

—

135 kW {183 PS}

12º

—

151 kW {205 PS}

10º

—

162 kW {220 PS}

9º

—

157 kW {213 PS}

3º

—

173 kW {235 PS}

12º

—

Item FE6A FE6B Fuel injection timing

FE6T

FE6T A

Remarks


DR-4-9

DISASSEMBLY AND REASSEMBLY 11. Align the line scribed on the injection pump timer with the line on the injection pump body.

12. Tighten the bolts to the specified torque. : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf} : FE6TA 157 kW {213 PS} 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf}

13. Tighten the coupling half cotter bolts to the specified torque. : FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS} 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf} : FE6TA 157 kW {213 PS} 83 - 93 N·m {8.5 - 9.5 kgf·m, 61 - 69 ft·lbf}

DR-4-10


CYLINDER HEAD DISASSEMBLY AND REASSEMBLY Step 1

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Breather hose 2-A. Breather (Type Z5506) 2-B. Breather (Type Z5507) 2-C. Air control valve

3. Gasket 4. O-ring 5. Breather adapter 6. O-ring

DR-4-11

7. Oil filler cap 8. Rocker cover 9. Baffle plate 10. Cover gasket


Step 2

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 11. Stopper bolt , 12. Rocker shaft bracket 13. Rocker arm

,+ 14. Rocker shaft 15. Push rod

16. Exhaust valve 17. Intake valve


DR-4-12


Step 3

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) , 18. Cylinder head bolt , 19. Cylinder head bolt , 20. Cylinder head bolt 21. Nozzle sleeve 22. Nozzle tube

23. O-ring 24. Valve guide 25. Push rod pipe 26. Front engine slinger

27. Stay 28. Rear engine slinger ,+ 29. Cylinder head 30. Head gasket


DR-4-13


Key point of disassembly 14 Rocker shaft Remove the rocker shaft assembly and push rods. NOTE z Loosen the rocker shaft assembly mounting bolts, starting with the outer bolt and moving toward the center.

29 Cylinder head Remove the cylinder head assembly. Attach chains or cables to the engine lifters and lift the cylinder head away from the cylinder block using a hoist. NOTE z

Loosen the head bolts diagonally, starting with the outer one and moving toward the center.

Key point of reassembly 29 Cylinder head Install the cylinder head using gaskets. NOTE z Ensure that the stamped part number side faces upward when installing the gasket.

20, 19, 18 Cylinder head bolt Tighten the cylinder head bolts to the specified torque using the socket wrench (99664 Z5000). Note that seven of the head bolts are also secured to the rocker shaft bracket. : 1st : 98 N·m {10.0 kgf·m, 72 ft·lbf} 2nd: 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf} : Refers to the bolts which are also secured to the rocker shaft bracket. [L = 180 mm (7.09 in)] O : Circled numbers refer to tightening sequence of head bolts.

DR-4-14

DISASSEMBLY AND REASSEMBLY 14 Rocker shaft Insert the push rod and install the rocker shaft assembly. NOTE z

Be sure to align the end of the rocker arm with that of the push rod.

12 Rocker shaft bracket Tighten seven rocker shaft bracket bolts. : 44 - 54 N·m {4.5 - 5.5 kgf·m, 33 - 40 ft·lbf} NOTE z

Tighten the middle bolt first and move toward the outer ones.

DR-4-15


- MEMO -

DR-4-16


ENGINE PROPER DISASSEMBLY AND REASSEMBLY

DR-4-17


DR-4-18


DR-4-19

DISASSEMBLY AND REASSEMBLY Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) ,+ 1. Flywheel 2. Oil pan 3. Gasket 4. Oil screen 5. Gasket 6. Timing gear case 7. O-ring 8. Oil seal 9. Revolution sensor ,+ 10. Hydraulic pump 11. Gasket 12. O-ring

,+ 13-A. Air compressor (AOH model) ,+ 13-B. Injection pump support (VAC model) 14. O-ring 15. Stiffener (If so equipped) ,+ 16. Flywheel housing 17. Oil seal 18. Gasket 19. Gasket 20. Gasket 21. Connecting rod cap and bearing shell

,+ 22. Piston assembly ,+ 23. Crankshaft assembly ,+ 24. Idler gear 25. Idler gear shaft + 26. Camshaft assembly 27. Cam follower 28. Gasket 29. Front end plate 30. Gasket 31. Oil jet


Key point of disassembly z

z

Install the engine stand attachment (99554 97001).

Lift the engine with a hoist and attach it to the engine stand (99550 96001).

1 Flywheel 1. Measure and record the surface runout of the flywheel that engages with the clutch disc. (Manual transmission model only)

DR-4-20


Remove the bolts. Using the two guide bolts (99687 97001), remove the flywheel.

10 Hydraulic pump, (13)-A Air compressor, (13)-B Injection pump support Measure and record the backlash of the front gear train. NOTE z Before measuring the backlash, install the air compressor (AOH model only) or injection pump support (VAC model only), if previously removed. z Before measuring the backlash of the hydraulic pump gear, install the timing gear case. Apply grease to a fuse and affix the fuse to a tooth of the pump gear. Install the pump gear on the timing gear case. Rotate the gear and measure the thickness of the smashed fuse to determine the backlash. 16 Flywheel housing Remove the flywheel housing. NOTE z

Before removing the flywheel housing, remove the engine rear PTO (if so equipped).

22 Piston assembly 1. Measure the side clearance of the large end of the connecting rod.

DR-4-21

DISASSEMBLY AND REASSEMBLY 2. Remove the piston assembly and connecting rod as a unit. NOTE z Before removing these parts, remove carbon from the upper inside wall of the cylinder liner.

23 Crankshaft assembly 1. Measure and record the end play of the crankshaft.

2.

Remove the crankshaft, thrust washer and upper main bearing shell. NOTE z Keep the upper and lower thrust washers together as a set. z Keep the upper and lower main bearing halves and main bearing cap as a set.

24 Idler gear Measure and record the end play of the idler gear.

26 Camshaft assembly Remove the camshaft gear and camshaft. NOTE z Turn the oil pan sideways so that the cam follower cannot drop into the oil pan when removing the camshaft.

DR-4-22


Key point of reassembly CAUTION z

Before reassembling the engine, replace all gaskets, packings and O-ring with new ones and apply a coat of engine oil to the frictional surfaces of all parts.

22 Crankshaft 1. Install upper main bearing shells. NOTE z Be sure to reinstall all shells in their original positions. 2.

Attach the upper thrust washer to both sides of No. 6 bearing. NOTE z Face the side with the stamped mark toward the cylinder block.

3.

Position the lower main bearing shell in the main bearing cap and install the bearing cap. : 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf} NOTE z Ensure that all main bearing shells are reinstalled in their original positions.

z

Install the main bearing cap with the arrow mark facing the front of the engine in the order of embossed numbers.

4.

Be sure to attach the lower thrust washer to both sides of No. 6 bearing. NOTE z Face the side with the stamped mark of the thrust washer toward the main bearing cap.

DR-4-23


Measure the end play of the crankshaft. Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.40 (0.0157)

22 Piston assembly 1. Insert the piston assembly (including the connecting rod, upper bearing shell and bolts) into the cylinder liner using the piston insert tool (99631 Z5502). NOTE z When installing the piston rings, ensure that their gaps are 180º opposite of each other and are not positioned in the direction of the piston pin and at a right angle to it. z Face the arrow mark on the piston toward the front of the engine when inserting the piston assembly. z Ensure that the number stamped on the large end of each connecting rod is the same as that on the cylinder when installing the piston assembly. Engine model FE6T

151 kW {205 PS}

FE6TA

Piston assembly type Type I

FE6A FE6B FE6T

Type II 135 kW {183 PS} 162 kW {220 PS}

Type III

DR-4-24


Install the connecting rod cap on which the lower bearing shell has already been installed. : 132 - 142 N·m {13.5 - 14.5 kgf·m, 98 - 105 ft·lbf} NOTE z Ensure that the stamped mark on the end face of the connecting rod cap is the same as that stamped on the large end of the connecting rod.

3.

Measure the side clearance of the large end of the connecting rod. Unit: mm (in) Maintenance standard

Service limit

0.10 - 0.30 (0.0039 - 0.0118)

—

24 Idler gear 1. Install the idler gear. NOTE z Align the timing mark on the camshaft gear with that on the crank gear. : 34 - 39 N·m {3.5 - 4.0 kgf·m, 25 - 29 ft·lbf}

2.

Measure the end play of the idler gear. Unit: mm (in) Maintenance standard

Service limit

0.03 -0.12 (0.0012 - 0.0047)

0.3 (0.012)

13-A Air compressor, 13-B Injection pump support 1. Install the air compressor (AOH model only) or injection pump support (VAC model only). : 147 - 167 N·m {15.0 - 17.0 kgf·m, 108 - 123 ft·lbf} NOTE z Align the timing mark on the injection pump drive gear with that on the idler gear. z Installing the air compressor in this step may facilitate subsequent operations.

DR-4-25


Measure the backlash of the front gear train (Refer to key point (10) for measurement of backlash of the hydraulic pump gear). Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.30 (0.0118)

10 Hydraulic pump Using grease, affix a fuse to a tooth of the hydraulic pump gear and install the hydraulic pump on the timing gear case. Rotate the pump gear and measure the thickness of the smashed fuse to determine the backlash. Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.30 (0.0118)

16 Flywheel housing Install the flywheel housing using a gasket. NOTE z On models equipped with the PTO, remove the idler gear bracket in advance.

1 Flywheel assembly 1. Install the flywheel using the two guide bolts (99687 97001), and tighten the bolts. : 235 - 255 N·m {24.0 - 26.0 kgf·m, 174 - 188 ft·lbf}

2.

Measure the surface runout of the flywheel that engages with the clutch disc. Unit: mm (in) Maintenance standard

Service limit

0.15 (0.0059) (max.)

0.18 (0.0071)

DR-4-26


ENGINE REAR PTO

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Connector bolt 2. Gasket 3. Oil tube 4. Gasket 5. Pointer cover 6. Gasket 7. Pointer 8. Gasket 9. Nut 10. Companion flange 11. Slinger 12. Oil seal

13. Tray 14. PTO holder 15. O-ring 16. Ball bearing 17. Retaining ring 18. O-ring 19. Retaining ring , 20. Sub gear 21. Retaining ring , 22. PTO gear 23. Ball bearing

24. Drive shaft 25. PTO cover 26. Cover gasket 27. Housing cover 28. Gasket 29. Idler shaft 30. Bushing , 31. Idler gear 32. Idler gear bracket 33. Flywheel housing 34. Housing gasket


DR-4-27


Key point of disassembly z

z

Measure and record the backlash between the idler gear and crankshaft gear. Measure and record the backlash between the PTO gear and idler gear.

Key point of reassembly 31 Idler gear Make sure that the backlash between the idler gear and crankshaft gear is within the maintenance standard. Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.3 (0.012)

22 PTO gear, 20 Sub gear 1. Install the spring into the PTO gear. Hang the tip of the spring from the 11 mm (0.43 in) diameter hole in the PTO gear and the other tip from the 11 mm (0.43 in) diameter hole in sub gear, and install the sub gear.

NOTE z

When installing the sub gear, face the F mark toward the outside and lock it with a retaining ring.

2.

Secure the PTO gear and turn the sub gear in the direction where the spring opens. When the 8 mm (0.31 in) diameter hole in the PTO gear aligns with that in the sub gear, insert an 8 mm (0.31 in) diameter pin.

DR-4-28


Assemble the PTO gear, aligning the oil hole of the drive shaft with the oil hole of the PTO gear.

4.

Align the pin position with the M24 threaded hole in the PTO holder and install the pin. 5. Install the holder assembly into the flywheel housing and extract the pin. NOTE z Be sure to extract the pin. 6.

With the gasket in place, plug the M24 threaded hole.

7.

Make sure that the backlash between the PTO gear and idler gear is within the maintenance standard. Unit: mm (in) Maintenance standard

Service limit

0.05 - 0.15 (0.0020 - 0.0059)

0.3 (0.012)

DR-4-29

- MEMO -

- MEMO -

ENGINE PROPER

EP

CONTENTS SERVICE DATA ...................................... EP-1-1 TOOLS .................................................... EP-2-1 INSPECTION........................................... EP-3-1 CYLINDER BLOCK .......................................... CRANKSHAFT ................................................. MAIN BEARING SHELL ................................... CYLINDER LINER ............................................ PISTON AND CONNECTING ROD.................. CAMSHAFT ...................................................... GEAR TRAIN.................................................... FLYWHEEL ...................................................... FLYWHEEL HOUSING AND TIMING GEAR CASE ....................................... CRANK PULLEY AND DAMPER .....................

EP-3-1 EP-3-2 EP-3-4 EP-3-4 EP-3-5 EP-3-10 EP-3-11 EP-3-12 EP-3-13 EP-3-13

V-BELT ............................................................. EP-3-13

REPAIR AND REPLACEMENT .............. EP-4-1 CYLINDER LINER REPLACEMENT ................ CAMSHAFT BUSHING REPLACEMENT......... CRANKSHAFT CORRECTION ........................ CONNECTING ROD REPLACEMENT............. REPLACING CONNECTING ROD SMALL-END BUSHING .................................... REPLACING IDLER GEAR BUSHING ............. OIL SEAL COLLAR REPLACEMENT............... FLYWHEEL CORRECTION ............................. REPLACING INJECTION PUMP BRACKET.... REAR OIL SEAL REPLACEMENT ...................

EP-4-1 EP-4-2 EP-4-3 EP-4-4 EP-4-4 EP-4-5 EP-4-5 EP-4-6 EP-4-6 EP-4-7

SERVICE DATA

SERVICE DATA Unit: mm (in) Maintenance standard

Service limit

Longitudinal direction

Less than 0.10 (0.0039)

—

Transverse direction

Less than 0.05 (0.0020)

—

0.02 (0.0008)

—

0.05T - 0.02L (0.0020T - 0.0008L)

—

Journal outside diameter

77.930 - 77.950 (3.0681 - 3.0689)

77.82 (3.0638)

Crank pin outside diameter

64.925 - 64.945 (2.5561 - 2.5569)

64.80 (2.5512)

Item

Upper surface warpage Cylinder block

Inner wall roundness at liner Clearance between main bearing cap and cylinder block

Crankshaft

Journal out-of-roundness

Less than 0.01 (0.0004)

0.02 (0.0008)

Crank pin out-of-roundness

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of journal

Less than 0.01 (0.0004)

—

Taper of crank pin

Less than 0.01 (0.0004)

—

Journal

Less than 0.07 (0.0028)

—

Contacting surface with oil seal

Less than 0.01 (0.0004)

—

Flywheel mounting surface

Less than 0.02 (0.0008)

—

End play

0.06 - 0.14 (0.0024 - 0.0055)

0.40 (0.0157)

Clearance to crankshaft journal

0.03 - 0.09 (0.0012 - 0.0035)

0.15 (0.0059)

Runout

Main bearing shell

Inside diameter (when installed in cylinder block)

Cylinder liner

108.00 - 108.03 (4.2520 - 4.2531)

Less than 0.02 (0.0008)

—

Taper

Less than 0.025 (0.0010)

—

0 - 0.07 (0 - 0.0028)

—

0.03 (0.0012)

—

FE6A FE6B FE6T 135 kW {183 PS}

107.825 - 107.855 (4.2451 - 4.2463)

—

FE6T 151 kW {205 PS} FE6T 162 kW {220 PS} FE6TA

107.940 - 107.970 (4.2496 - 4.2508)

—


0.145 - 0.205 (0.0057 - 0.0081)

—


0.050 - 0.070 (0.0020 - 0.0028)

—

36.00 - 36.02 (1.4173 - 1.4181)

—

Difference between adjacent cylinders

Outside diameter

Piston Clearance to cylinder liner

Piston pin bore inside diameter

EP-1-1

T = Tight L = Loose Refinishing allowance: 1.0 (0.039)

Indicator reading

Measuring position From top 108.23 (4.2610) 25, 50, 75, 100, 150, 200 (0.98, 1.97, 2.95, 3.94, 5.91, 7.87)

Out-of-roundness

Flange protrusion from block upper surface

Remarks

z Lateral to piston pin z Measure at 18.5 (0.728) posi-

tion from bottom surface, perpendicular to piston pin


Service limit

2nd

0.04 - 0.08 (0.0016 - 0.0031)

0.4 (0.016)

Oil

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

1st 2nd

0.30 - 0.45 (0.0118 - 0.0177)

1.5 (0.059)


0.15 - 0.35 (0.0059 - 0.0138)

1.5 (0.059)


0.25 - 0.45 (0.0098 - 0.0177)

1.5 (0.059)

35.993 - 36.000 (1.4170 - 1.4173)

—

0 - 0.03L (0 - 0.0012L)

0.05 (0.0020)

Small-end bushing inside diameter

36.025 - 36.041 (1.4183 - 1.4189)

—

Clearance between small-end bushing and piston pin

0.03 - 0.05 (0.0012 - 0.0020)

0.10 (0.0039)

Less than 0.15 (0.0059)

—

Less than 0.10 (0.0039)

—

Crank pin side clearance

0.10 - 0.30 (0.0039 - 0.0118)

—

Clearance between big-end bearing and crank pin

0.035 - 0.095 (0.0014 - 0.0037)

0.15 (0.0059)

No. 1

57.33 - 57.35 (2.2571 - 2.2579)

—

No. 2

57.13 - 57.15 (2.2492 - 2.2500)

—

No. 3

56.93 - 56.95 (2.2413 - 2.2421)

—

No. 4

56.73 - 56.75 (2.2335 - 2.2342)

—

FE6A FE6B FE6TA 173 kW {235 PS}

IN

48.47 - 48.51 (1.9083 - 1.9098)

47.99 (1.8894)

EXH

48.41 - 48.45 (1.9059 - 1.9075)

47.93 (1.8870)

FE6T FE6TA 157 kW {213 PS}

IN

48.79 - 48.83 (1.9209 - 1.9224)

48.31 (1.9020)

EXH

48.41 - 48.45 (1.9059 - 1.9075)

47.93 (1.8870)

0.02 - 0.10 (0.0008 - 0.0039)

0.15 (0.0059)

Less than 0.03 (0.0012)

0.06 (0.0024)

End play

0.08 - 0.28 (0.0031 - 0.0110)

0.3 (0.012)

Front gear train backlash

0.06 - 0.16 (0.0024 - 0.0063)

0.3 (0.012)

Idler gear end play

0.03 - 0.12 (0.0012 - 0.0047)

0.3 (0.012)

Clearance between idler gear bushing and shaft

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Item

Clearance between piston ring and ring groove

Piston ring Joint gap Oil

Outside diameter Piston pin Clearance to piston pin hole

Connecting Twist rod Bend

Journal outside diameter

Camshaft

Height of cam profile

Journal-to-bushing clearance

Runout (indicator reading)

Gear train

EP-1-2

Remarks

L = Loose

Runout of No. 1 & No. 4 with No. 2 & No. 3 supported Vblocks


Service limit

Remarks

Less than 0.15 (0.0059)

0.18 (0.0071)

Manual transmission model only

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

FE6B, FE6T, FE6TA

23.0 (0.906)

21.0 (0.827)

FE6B, FE6T, FE6TA

43.0 (1.693)

45.0 (1.772)

FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS}

48.0 (1.890)

50.0 (1.969)

Fan pulley - alternator pulley (A)

10 - 15 (0.39 - 0.59)

—

Fan pulley - cooler compressor pulley (B)

7 - 12 (0.28 - 0.47)

—

Backlash of PTO gear

0.05 - 0.15 (0.0020 - 0.0059)

0.3 (0.012)

Backlash of idler gear

0.06 - 0.14 (0.0024 - 0.0055)

0.3 (0.012)

Item Clutch disc contact surface runout Type I Thickness (A) Flywheel

Type II

Reduced size of worn surface Height (H)

V-belt

Engine rear PTO

Type II

FE6A, FE6B FE6T 135 kW {183 PS}

Deflection

EP-1-3

Refer to page EP-3-12 (FLYWHEEL). Manual transmission model only

Refer to page EP-3-13 (V-BELT). When midpoint is pressed with 98 N {10 kgf, 22 lbf}

TOOLS


Description

Straightedge 99645 Z5001

Used to measure flatness of cylinder block

Piston ring tool 99630 Z5001

Used to remove and install piston rings

Cylinder liner tool 99600 Z5002

Used to remove and install cylinder liners

Cam bushing remover 99590 Z5002

Used to remove camshaft bushings

Tool kit cam bushing replacer 99590 Z5003 (1) 99594 Z5002 (2) 99594 Z5003 (3) 99595 Z5004 (4) 99595 Z5005 (5) 99597 Z5001

Used to install camshaft bushings Cam bushing replace (1) For No. 1 (2) For No. 4 (3) For No. 2 (4) For No. 3 Cam bushing replace bar (5) For No. 2 and No. 3

EP-2-1

Shape

TOOLS


Description

Oil seal collar replacer 99718 Z5002

Used to press-fit oil seal collars

Injection pump bracket setting tool 99720 Z5500

Used to center injection pump bracket [For 25 mm (0.98 in) air compressor crankshaft rear edge outside diameter]

Injection pump bracket setting tool 99720 Z5501

Used to center injection pump bracket [For 30 mm (1.18 in) air compressor crankshaft rear edge outside diameter]

Oil seal and sleeve replacer 99691 Z5500 (1) 99718 Z5500 (2) 99687 97002

Used to press-fit rear oil seal and sleeve (1) Oil seal replacer (2) Guide bolt [For 110 mm (4.33 in) crankshaft rear edge outside diameter and 115 mm (4.53 in) oil seal sleeve outside diameter

Oil seal and sleeve replacer 99691 Z5501 (1) 99718 Z5504 (2) 99687 97002

Used to press-fit rear oil seal (1) Oil seal replacer (2) Guide bolt [For 120 mm (4.72 in) crankshaft rear edge outside diameter and 145 mm (5.71 in) oil seal outside diameter]

Oil seal replacer (1) 99718 Z5501 (2) 99687 97002

Used to press-fit rear oil seal (1) Oil seal replacer (2) Guide bolt [For 145 mm (5.71 in) and 148 mm (5.83 in) oil seal outside diameters]

Puller assembly 99718 Z5502

Used to remove oil seal sleeve [For 115 mm (4.53 in) oil seal sleeve outside diameter]

Puller assembly 99718 Z5503

Used to remove oil seal sleeve [For 125 mm (4.92 in) oil seal sleeve outside diameter]

EP-2-2

Shape

INSPECTION

INSPECTION z

z

Clean all disassembled parts in cleaning solvent. Check for scratches, cracks or damage and replace faulty parts. If measurement indicates that the service limit has exceeded, repair or replace faulty parts.

CYLINDER BLOCK Upper surface warpage Measure using the straightedge (99645 Z5001). Unit: mm (in) Item


Service limit


Less than 0.10 (0.0039)

—


Less than 0.05 (0.0020)

—

Inner wall roundness of liner Unit: mm (in) Maintenance standard

Service limit

0.02 (0.0008)

—

Camshaft bushing inside diameter Measure the inside diameter of the camshaft bushing.

EP-3-1

INSPECTION

Clearance between main bearing cap and cylinder block Unit: mm (in) Maintenance standard

Service limit

0.05T - 0.02L (0.0020T - 0.0008L)

—

Remarks T: Tight

L: Loose

CRANKSHAFT Journal outside diameter When the journal outside diameter exceeds the service limit, it must be corrected by grinding and undersized main bearing shells must be installed. Unit: mm (in) Maintenance standard 77.930 - 77.950 (3.0681 - 3.0689)

Service limit

Remarks

77.82 (3.0638)

Refinishing allowance: 1.0 (0.039)

Journal out-of-roundness When the journals exceeds the service limit in out-of-roundness, they must be corrected by grinding. Install new undersized main bearing shells. Unit: mm (in) Maintenance standard

Service limit

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of journal When the journals exceeds the service limit in taper, they must be corrected by grinding. Install new undersized main bearing shells. Unit: mm (in) Maintenance standard

Service limit

Less than 0.01 (0.0004)

—

Crank pin outside diameter When the outside diameter of the crank pin exceeds the service limit, it must be corrected by grinding, and install new undersized bearing shells. Unit: mm (in) Maintenance standard

Service limit

Remarks

64.925 - 64.945 (2.5561 - 2.5569)

64.80 (2.5512)

Refinishing allowance: 1.0 (0.039)

EP-3-2

INSPECTION

Crank pin out-of-roundness When the crank pin out-of-roundness exceeds the service limit, the crank pins must be ground and used with new undersized bearing shells. Unit: mm (in) Maintenance standard

Service limit

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of crank pin When the crank pin taper exceeds the service limit, the crank pin must be ground and used with new undersized bearing shells. Unit: mm (in) Maintenance standard

Service limit

Less than 0.01 (0.0004)

—

Runout Support the crankshaft at No. 2 and 6 journals, and measure the runout of each part. Unit: mm (in) Maintenance standard

Service limit

Journal A

Less than 0.07 (0.0028)

—

Contacting surface with oil seal B

Less than 0.01 (0.0004)

—

Flywheel mounting surface C

Less than 0.02 (0.0008)

—

Item

Remarks

Indicator reading

End play When end play measured at the time of engine disassembly exceeds the service limit, replace the thrust washers selectively as a set. Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.40 (0.0157)

Types of thrust washer Size symbol STD

Thickness mm (in)

A

2.965 - 2.995 (0.1167 - 0.1179)

B

2.930 - 2.965 (0.1154 - 0.1167)

C

2.900 - 2.930 (0.1142 - 0.1154)

0.20 OS

3.150 - 3.200 (0.1240 - 0.1260)

0.40 OS

3.350 - 3.400 (0.1319 - 0.1339)

Remarks STD: Standard

OS: Oversize

EP-3-3

INSPECTION

MAIN BEARING SHELL Clearance to crankshaft journal Install the main bearing shell in the cylinder block, and tighten the main bearing cap to the specified torque. Then measure the shell inside diameter and calculate the shell clearance from the journal outside diameter. : 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf} Unit: mm (in) Maintenance standard

Service limit

0.03 - 0.09 (0.0012 - 0.0035)

0.15 (0.0059)

CYLINDER LINER Measure the cylinder liners with installed in the cylinder block. [The measuring positions are 25, 50, 75, 100, 150 and 200 mm (0.98, 1.97, 2.95, 3.94, 5.91 and 7.87 in) from the block upper surface.]

Inside diameter Unit: mm (in) Maintenance standard

Service limit

108.00 - 108.03 (4.2520 - 4.2531)

108.23 (4.2610)

Out-of-roundness Unit: mm (in) Maintenance standard

Service limit

Less than 0.02 (0.0008)

—

Taper Unit: mm (in) Maintenance standard

Service limit

Less than 0.025 (0.0010)

—

Flange protrusion from block upper surface Unit: mm (in) Maintenance standard

Service limit

0 - 0.07 (0 - 0.0028)

—

Difference between adjacent cylinders Unit: mm (in) Maintenance standard

Service limit

0.03 (0.0012)

—

EP-3-4

INSPECTION

PISTON AND CONNECTING ROD Before inspection, disassemble the piston and connecting rod assemblies. Keep the disassembled parts of each cylinder together so that they may be reinstalled in the cylinder from which they were removed. NOTE z

The piston rings for all cylinders should be replaced as an assembly during overhaul. 1.

1st ring

8.

Bolt

2.

2nd ring

9.

Connecting rod

3.

Oil ring

10.

Bearing shell (upper)

4.

Piston

11.

Bearing shell (lower)

5.

Snap ring

12.

Connecting rod cap

6.

Piston pin

13.

Nut

7.

Bushing

Disassembling piston and connecting rod z

z

Remove the snap rings and piston pin.

Remove the piston rings using the piston ring tool (99630 Z5001).

EP-3-5

INSPECTION

PISTON Outside diameter The piston outside diameter should be checked at 18.5 mm (0.728 in) from the piston bottom and perpendicular to the piston pin. Unit: mm (in) Item


Service limit

FE6A, FE6B, FE6T 135 kW {183 PS}

107.825 - 107.855 (4.2451 - 4.2463)

—


107.940 - 107.970 (4.2496 - 4.2508)

—

Clearance to cylinder liner Calculate the clearance from the cylinder liner inside diameter and piston outside diameter. Unit: mm (in) Item


Service limit

FE6A, FE6B, FE6T 135 kW {183 PS}

0.145 - 0.205 (0.0057 - 0.0081)

—


0.050 - 0.070 (0.0020 - 0.0028)

—

Piston pin bore inside diameter Unit: mm (in) Maintenance standard

Service limit

36.00 - 36.02 (1.4173 - 1.4181)

—

EP-3-6

INSPECTION

PISTON RING Clearance between piston ring and ring groove NOTE z

The 1st ring clearance cannot be measured because of the ring groove shape. Unit: mm (in) Item


Service limit

2nd

0.04 - 0.08 (0.0016 - 0.0031)

0.4 (0.016)

Oil

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Joint gap Unit: mm (in) Item


Service limit

0.30 - 0.45 (0.0118 - 0.0177)

1.5 (0.059)


0.15 - 0.35 (0.0059 - 0.0138)

1.5 (0.059)


0.25 - 0.45 (0.0098 - 0.0177)

1.5 (0.059)

1st 2nd

Oil

PISTON PIN Outside diameter Unit: mm (in) Maintenance standard

Service limit

35.993 - 36.000 (1.4170 - 1.4173)

—

EP-3-7

INSPECTION

Clearance to piston pin hole Calculate the clearance from the piston pin outside diameter and pin hole inside diameter. Unit: mm (in) Maintenance standard

Service limit

0 - 0.03L (0 - 0.0012L)

0.05 (0.0020)

Remarks L = Loose

CONNECTING ROD Small-end bushing inside diameter Unit: mm (in) Maintenance standard

Service limit

36.025 - 36.041 (1.4183 - 1.4189)

—

Clearance between small-end bushing and piston pin Unit: mm (in) Maintenance standard

Service limit

0.03 - 0.05 (0.0012 - 0.0020)

0.10 (0.0039)

Clearance between big-end bearing and crank pin Fit each bearing shell to the connecting rod having the same cylinder No., then the connecting rod and cap to the specified torque. : 132 - 142 N·m {13.5 - 14.5 kgf·m, 98 - 105 ft·lbf} Calculate the clearance between the crank pin O.D. and bearing shell I.D. from the measured values. Unit: mm (in) Maintenance standard

Service limit

0.035 - 0.095 (0.0014 - 0.0037)

0.15 (0.0059)

EP-3-8

INSPECTION

Bend and twist To check connecting-rod alignment, install the piston pin in the small-end bushing. Mount the connecting rod with the cap on the aligner. Then measure the clearance at aligner pin A or B to determine the bend and twist of the rod. If the distance between pins A and B is not 200 mm (7.87 in), make the following calculation. Amount of bend or twist

=

200 (7.87)

x Measured value [mm (in)]

Distance between pins

Unit: mm (in) Maintenance standard

Service limit

Remarks

Bend

Less than 0.10 (0.0039)

—

Twist

Less than 0.15 (0.0059)

—

Distance between pins: 200 (7.87)

Item

Crank pin side clearance Check the measurements made during engine overhaul. Unit: mm (in) Maintenance standard

Service limit

0.10 - 0.30 (0.0039 - 0.0118)

—

Assembling piston and connecting rod 1.

Install the piston rings using the piston ring tool (99630 Z5001). NOTE

z

Install the rings with the mark facing up.

Piston ring design 1st ring

Type I

FE6A, FE6B, FE6T [135 kW {183 PS}]

Type II

FE6T [151 kW {205 PS}], FE6T [162 kW {220 PS}], FE6TA

2nd ring Oil ring

Engine model

FE6A, FE6B, FE6T, FE6TA Type I

FE6A, FE6B, FE6T [135 kW {183 PS}]

Type II

FE6T [151 kW {205 PS}], FE6TA

Type III

FE6T [162 kW {220 PS}]

EP-3-9

INSPECTION 2.

Assemble the piston, piston pin, snap rings and connecting rod. NOTE z Assemble so that the triangular mark on the piston head points to the left side with respect to the cylinder number (facing the front) stamped on the connecting rod.

CAMSHAFT End play Unit: mm (in) Maintenance standard

Service limit

0.08 - 0.28 (0.0031 - 0.0110)

0.3 (0.012)

Removing camshaft gear 1.

Nut

5.

Locating plate

2.

Lock washer

6.

Key

3.

Plain washer

7.

Camshaft

4.

Camshaft gear

Journal outside diameter Unit: mm (in) Item


Service limit

No. 1

57.33 - 57.35 (2.2571 - 2.2579)

—

No. 2

57.13 - 57.15 (2.2492 - 2.2500)

—

No. 3

56.93 - 56.95 (2.2413 - 2.2421)

—

No. 4

56.73 - 56.75 (2.2335 - 2.2342)

— EEP3-025

Journal-to-bushing clearance Calculate the clearance from the journal outside diameter and bushing inside diameter. Unit: mm (in) Maintenance standard

Service limit

0.02 - 0.10 (0.0008 - 0.0039)

0.15 (0.0059)

EP-3-10

INSPECTION

Height of cam profile Unit: mm (in) Item FE6A IN FE6B FE6TA 173 kW EXH {235 PS} FE6T IN FE6TA 157 kW EXH {213 PS}


Service limit

48.47 - 48.51 (1.9083 - 1.9098) 47.99 (1.8894) 48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870) 48.79 - 48.83 (1.9209 - 1.9224) 48.31 (1.9020) 48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870)

Runout Support the camshaft at No. 2 and 3 journals and measure the runout of No. 1 and 4 journals. Unit: mm (in) Maintenance standard

Service limit

Remarks

Less than 0.03 (0.0012)

0.06 (0.0024)

Indicator reading

Installing camshaft gear 1. 2. 3.

Install the locating plate on the camshaft. Insert the key into the keyway and install the camshaft gear. Install the plain washer, lock washer and nut in sequence. : 186 - 226 N·m {19.0 - 23.0 kgf·m, 137 - 166 ft·lbf}

GEAR TRAIN Front gear train backlash Unit: mm (in) Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.3 (0.012)

EP-3-11

INSPECTION

Clearance between idler gear bushing and shaft Unit: mm (in) Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Idler gear end play Unit: mm (in) Maintenance standard

Service limit

0.03 - 0.12 (0.0012 - 0.0047)

0.3 (0.012)

FLYWHEEL Clutch disc contact surface runout Unit: mm (in) Maintenance standard

Service limit

Less than 0.15 (0.0059)

0.18 (0.0071)

REDUCED SIZE OF WORN SURFACE NOTE z

Be careful since dimension “A” may exceed service limits. Dimension “H” is within service limits on type II flywheel where the clutch contacting surface was ground to the specification. Unit: mm (in) Item

FE6A, FE6B Type I FE6TA 135 kW {183 PS} Thickness (A) FE6B, FE6T Type II FE6TA FE6B, FE6T FE6TA Height (H)

Type II FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS}


Service limit

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

23.0 (0.906)

21.0 (0.827)

43.0 (1.693)

45.0 (1.772)

48.0 (1.890)

50.0 (1.969)

EP-3-12

INSPECTION

FLYWHEEL HOUSING AND TIMING GEAR CASE NOTE z

Oil seals should be replaced each time the engine is overhauled.

CRANK PULLEY AND DAMPER Check the entire assembly for cracks or damage. Also, check for separation of the damper from the disc.

V-BELT Check the V-belt for cracks or damage. Also check if it is out of contact with the pulley grooves. Unit: mm (in) Maintenance standard

Service limit

Remarks

A

10 - 15 (0.39 - 0.59)

—

B

7 - 12 (0.28 - 0.47)

—

When midpoint is pressed with 98 N {10 kgf, 22 lbf}

Item Deflection

EP-3-13

REPAIR AND REPLACEMENT

REPAIR AND REPLACEMENT CYLINDER LINER REPLACEMENT 1.

Remove and install the cylinder liners using the cylinder liner tool (99600 Z5002). NOTE z When installing the cylinder liners, clean the cylinder block inner walls and cylinder liner outer surfaces. Then coat them with a thin coat of engine oil.

2.

When replacing the cylinder liners, use liners whose marks on the outer skirts coincide with the stamp (“0” or “1”) on the upper surface of the cylinder block.

EP-4-1

REPAIR AND REPLACEMENT 3.

After press-fitting the cylinder liners, check the inside diameter, out-of-roundness, taper and flange protrusion. NOTE z The main bearing caps should be tightened to the specified torque. : 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf} Unit: mm (in) Item

Inside diameter


Service limit

Measuring position From top 108.00 - 108.03 108.23 25, 50, 75, 100, 150, (4.2520 - 4.2531) (4.2610) 200 (0.98, 1.97, 2.95, 3.94, 5.91, 7.87)

Out-of-roundness

Less than 0.02 (0.0008)

—

Taper

Less than 0.025 (0.0010)

—

0 - 0.07 (0 - 0.0028)

—

0.03 (0.0012)

—

Flange protrusion from block upper surface Difference between adjacent cylinders

Remarks

CAMSHAFT BUSHING REPLACEMENT Removing bushings Using the cam bushing remover (99590 Z5002), remove bushings No. 1 and No. 2 toward the rear of the engine and No. 3 and No. 4 toward the front.

EP-4-2


Installing bushings 1. 2.

Install bushings No. 2 and No. 3 using the Cam Bushing Replacer (3), (4) and (5). Install bushings No. 1 and No. 4 using the Cam Bushing Replacer (1) and (2). 99590 Z5003 (Tool kit cam bushing replacer) (1) 99594 Z5002 (for No. 1) (2) 99594 Z5003 (for No. 4) (3) 99595 Z5004 (for No. 2) (4) 99595 Z5005 (for No. 3) (5) 99597 Z5001 (for No. 2 and No. 3)

NOTE z

Install the bushing with their notched section on the right side of the block, facing to the front. Make sure that the oil passages are aligned with the oil holes in the bushings.

CRANKSHAFT CORRECTION Journals When correcting the crankshaft journals by grinding, they must be ground undersized so that the clearance between the new undersized bearing shell and the journal is within the maintenance standard.

Crank pins When correcting the crank pins by grinding, they must be ground undersized so that the clearance between the new undersized bearing shell and the crank pin is within the maintenance standard.

NOTE

Be careful not to extend the width of the journal and crank pin. z Finish both shoulders by rounding, referring to the figure to the right. Crankshaft journals R 3.5 mm (0.138 in) Crank pins R 4.0 mm (0.157 in) z

EP-4-3


Size symbol

Journal grinding standard mm (in)

STD

Grinding not required

0.25US

77.680 - 77.700 (3.0583 - 3.0590)

0.50US

77.430 - 77.450 (3.0484 - 3.0492)

0.75US

77.230 - 77.250 (3.0405 - 3.0413)

1.00US

76.930 - 76.950 (3.0287 - 3.0295)

US: Undersized Size symbol

Crank pin grinding standard mm (in)

STD

Grinding not required

0.25US

64.675 - 64.695 (2.5463 - 2.5470)

0.50US

64.425 - 64.445 (2.5364 - 2.5372)

0.75US

64.175 - 64.195 (2.5266 - 2.5274)

1.00US

63.925 - 63.945 (2.5167 - 2.5175)

US: Undersized

CONNECTING ROD REPLACEMENT When a connecting rod is replaced, stamp the cylinder No. on it in the same position as before.

REPLACING CONNECTING ROD SMALL-END BUSHING 1.

Drive the bushing into the chamfered side of the connecting rod small end. NOTE z Align the oil holes. The difference in height of the bushing above or below the chamfered surface should be less than 1 mm (0.04 in). Engine model

Connecting rod type

FE6A FE6B FE6T 135 kW {183 PS} FE6T 151 kW {205 PS} FE6TA

Type I

FE6T 162 kW {220 PS}

Type II

EP-4-4


After driving in the bushing, cut both ends of it by aligning with the tapered surface of the connecting rod. (Type II only)

3.

Measure the inside diameter of the busing and outside diameter of the piston pin to determine the bushing-to-piston pin clearance. If the clearance is less than maintenance standards, grind the inside diameter of the bushing to within the specified maintenance standard. Unit: mm (in) Maintenance standard

Service limit

0.03 - 0.05 (0.0012 - 0.0020)

0.10 (0.0039)

REPLACING IDLER GEAR BUSHING 1.

Press-fit the bushing so that the end face of the boss on the front of the engine is level with the end face of the bushing. NOTE z The fitted face of the boss at the front should be 1.5 mm (0.059 in) lower than the rear end face (H). 2.

After fitting the bushing, finish the inside diameter so that the clearance with the idler gear shaft is within the maintenance standard. Unit: mm (in) Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

OIL SEAL COLLAR REPLACEMENT 1. 2.

Remove the oil seal collar by heating. Using the collar replacer (99718 Z5002), press-fit the oil seal collar until it contacts the crank gear. NOTE z Face the side with a groove on the end to the front.

EP-4-5


FLYWHEEL CORRECTION The runout of the surface which contacts the clutch disc should be corrected to the maintenance standard by grinding and/or cutting. NOTE

The flywheel is serviceable until wear on the contacting surface with the clutch disc is 2.0 mm (0.079 in) and thickness (A) reaches the service limit. However, if the flywheel is to be ground, do not grind more than 1.5 mm (0.059 in). z When grinding, also grind the flange so that height (H) is within the maintenance standard. z If the flywheel has to be ground more than 1.5 mm (0.059 in), replace the flywheel. z

Unit: mm (in) Item FE6A, FE6B Type I FE6TA 135 kW {183 PS} Thickness (A) FE6B, FE6T Type II FE6TA FE6B, FE6T FE6TA Height (H)

Type II FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS}


Service limit

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

23.0 (0.906)

21.0 (0.827)

43.0 (1.693)

45.0 (1.772)

48.0 (1.890)

50.0 (1.969)

REPLACING INJECTION PUMP BRACKET When replacing the cylinder block or injection pump bracket, center the injection pump bracket. 1. Temporarily install a shim (of the same thickness as the one removed) to the pump bracket. Types (thickness) of shim: 0.05, 0.10, 0.20 and 0.30 mm (0.0020, 0.0039, 0.0079 and 0.0118 in)

EP-4-6


Using the injection pump bracket setting tool, install the coupling A to the shaft of the air compressor. Then hold the setting tool C, slide the shaft B, and insert it into the coupling A. If the shaft can be fitted in place, it is properly centered. If it interfaces, adjust with shim(s). Tool name

Injection pump bracket setting tool

Tool number

Remarks

99720 Z5500

For 25 mm (0.98 in) air compressor crankshaft rear edge outside diameter

99720 Z5501

For 30 mm (1.18 in) air compressor crankshaft rear edge outside diameter

3.

After centering, tighten the pump bracket to the specified torque. : 37 - 42 N·m {3.8 - 4.3 kgf·m, 27 - 31 ft·lbf}

4.

After reaming, driven in the dowel pin and caulk the dowel pin hole. The dowel pin should be driven in so that it is slightly below 1 mm (0.04 in) or so the bracket surface.

REAR OIL SEAL REPLACEMENT 1. Remove the oil seal. 2. Apply engine oil to the lip of the oil seal. 3. Using the oil seal replacer, press-fit the oil seal to the flywheel housing. Unit: mm (in) Oil seal and Oil seal or Guide Outside bolt diameter of sleeve replacer sleeve assembly No. replacer No. No. oil seal 99691 Z5500 —

99718 Z5500

99687 99718 Z5501 97002

Outside diameter of the rear edge of the crankshaft

135 (5.31)

110 (4.33)

145 (5.71) 148 (5.83)

120 (4.72)

EP-4-7

REPAIR AND REPLACEMENT 1. Remove the oil seal. 2. Using the puller assembly, pull out the oil seal sleeve. Unit: mm (in)

3. 4.

Puller assembly No.

Outside diameter of sleeve


99718 Z5502

115 (4.53)

110 (4.33)

99718 Z5503

125 (4.92)

120 (4.72)

Apply sealant (LOCTITE 962T or equivalent) to the inside surface of the oil seal sleeve. Using the oil seal sleeve replacer, press-fit the oil seal sleeve to the crankshaft. Unit: mm (in)

Oil seal and Oil seal or sleeve sleeve replacer replacer No. assembly No. 99691 Z5500 99718 Z5500 99691 Z5501 99718 Z5504

5. 6.

Guide bolt No.

99687 97002

Outside diameter of sleeve


115 (4.53)

110 (4.33)

125 (4.92)

120 (4.72)

Apply engine oil to the lip of the oil seal. Using the oil seal replacer, press-fit the oil seal to the flywheel housing. Unit: mm (in)

Oil seal and Oil seal or sleeve sleeve replacer replacer No. assembly No. 99691 Z5500 99718 Z5500 99691 Z5501 99718 Z5504

Guide bolt No.

99687 97002

Outside diameter of oil seal


135 (5.31)

110 (4.33)

145 (5.71)

120 (4.72)

EP-4-8

- MEMO -

CYLINDER HEAD AND VALVE MECHANISM

CONTENTS SERVICE DATA ...................................... HV-1-1 SERVICE DATA ............................................... HV-1-1 TIGHTENING TORQUE ................................... HV-1-3 TOOLS .................................................... HV-2-1 CONSTRUCTION.................................... HV-3-1 REMOVAL............................................... HV-4-1 DISASSEMBLY....................................... HV-5-1 CYLINDER HEAD ............................................ HV-5-1 ROCKER SHAFT ............................................. HV-5-2 INSPECTION........................................... HV-6-1 CYLINDER HEAD ............................................ HV-6-1 VALVE INSERT ................................................ HV-6-1 VALVE .............................................................. HV-6-1 VALVE GUIDE.................................................. HV-6-2 VALVE SPRING ............................................... HV-6-2

VALVE ROCKER PARTS ................................. HV-6-3 PUSH ROD ....................................................... HV-6-4 CAM FOLLOWER............................................. HV-6-4 REPAIR AND REPLACEMENT .............. HV-7-1 REPAIRING CYLINDER HEAD ........................ HV-7-1 REPAIRING VALVE AND VALVE INSERT ...... HV-7-1 REPLACING VALVE INSERT .......................... HV-7-2 LAPPING VALVE AND VALVE INSERT .......... HV-7-3 REPLACING VALVE GUIDE ............................ HV-7-3 REPLACING VALVE ROCKER BUSHING....... HV-7-4 REPLACING NOZZLE TUBE ........................... HV-7-4 REASSEMBLY ........................................ HV-8-1 CYLINDER HEAD............................................. HV-8-1 ROCKER SHAFT.............................................. HV-8-2 INSTALLATION....................................... HV-9-1

HV

SERVICE DATA

SERVICE DATA SERVICE DATA Unit: mm (in) Maintenance standard

Service limit

Remarks

89.9 - 90.1 (3.539 - 3.547)

89.7 (3.531)

Max. allowable grinding limit: 0.3 mm (0.012 in)


Less than 0.05 (0.0020)

0.2 (0.008)


Less than 0.05 (0.0020)

0.2 (0.008)

Intake

50.0 - 50.02 (1.9685 - 1.9693)

—

Exhaust

41.0 - 41.02 (1.6142 - 1.6150)

—

1.25 - 1.35 (0.0492 - 0.0531)

—

Intake

30º - 30º30’

—

Exhaust

45º - 45º30’

—

Intake

2.2 - 2.4 (0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3 (0.079 - 0.091)

3.5 (0.138)

Intake

29º30’ - 30º

—

Exhaust

44º30’ - 45º

—

Intake

8.96 - 8.98 (0.3528 - 0.3535)

—

Exhaust

8.92 - 8.94 (0.3512 - 0.3520)

—

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

Intake

1.33 - 1.83 (0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53 (0.0406 - 0.0602)

2.3 (0.091)

Intake

0.3 - 0.4 (0.012 - 0.016)

—

Exhaust

0.3 - 0.4 (0.012 - 0.016)

—

Item

Cylinder head

Height of cylinder head

Flatness

Diameter of valve insert bore

Valve insert

Thickness of head gasket Seat face angle

Contact width of valve and valve insert

Valve face angle

Valve

Outside diameter of valve stem

Valve head thickness Depth of valve below lower surface of cylinder head

Valve clearance

HV-1-1

When bolts are tightened to specified torque

When engine is cold


Service limit

Intake

9.00 - 9.02 (0.3543 - 0.3551)

—

Exhaust

9.00 - 9.02 (0.3543 - 0.3551)

—

Intake

0.02 - 0.05 (0.0008 - 0.0020)

0.15 (0.0059)

Exhaust

0.05 - 0.09 (0.0020 - 0.0035)

0.20 (0.0079)

15 (0.59)

—

Outer

62.8 (2.472)

55.0 (2.165)

Inner

60.9 (2.398)

58.0 (2.283)

Outer

246.2 - 271.7 {25.1 - 27.7, 55.3 - 61.1}

—

When spring is compressed to 44.6 mm (1.756 in)

Inner

126.5 - 140.2 {12.9 - 14.3, 28.4 - 31.5}

—


Less than 2.0 (0.079)

—

Inner and outer springs

19.98 - 20.00 (0.7866 - 0.7874)

19.90 (0.7835)

0.06 (0.0024)

0.1 (0.004)

Inside diameter of valve rocker bushing

20.02 - 20.04 (0.7882 - 0.7890)

20.10 (0.7913)

Clearance between valve rocker bushing and rocker shaft

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

60.0 (2.362)

49.0 (1.929)

21.6 - 31.4 {2.2 - 3.2, 4.9 - 7.1}

16.7 {1.7, 3.7}

Less than 0.30 (0.0118)

—

Outside diameter

19.96 - 19.98 (0.7858 - 0.7866)

19.85 (0.7815)

Clearance to cylinder block cam follower bore

0.02 - 0.06 (0.0008 - 0.0024)

0.12 (0.0047)

Item

Valve guide

Inside diameter of valve guide

Clearance to valve stem

Protrusion above “drive-in” surface of cylinder head

Valve spring

Free length

Tension

N {kgf, lbf}

Squareness

Valve rocker parts

Outside diameter of rocker shaft Rocker shaft runout

Free length Inside spring

Tension N {kgf, lbf}

Cam follower

Runout of push rod

HV-1-2

Remarks

Intake and exhaust valves Intake and exhaust valves

When spring is compressed to 33.5 mm (1.319 in) When measured with each spherical end supported

SERVICE DATA


Item

Service limit

Remarks

Valve clearance adjustment sequence: Cylinder No.

1

Other

Valve arrangement No. 1 piston at TDC on compression stroke No. 6 piston at TDC on compression stroke

2

3

4

5

6

1

2

3

4

5

6

7

8

9

10

11

12

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

z

z

z

z

z

z

z

z

z

z

z

z


Tightening torque

Engine slinger mounting bolt

29 - 49 {3.0 - 5.0, 22 - 36}

Nozzle sleeve

34 - 38 {3.5 - 3.9, 25 - 28}

Cylinder head bolts

1st

98 {10.0, 72}

2nd

177 - 196 {18.0 - 20.0, 130 - 145}

Rocker shaft bracket mounting bolts

44 - 54 {4.5 - 5.5, 33 - 40}

Exhaust manifold mounting nuts

34 - 44 {3.5 - 4.5, 25 - 33}

Air intake manifold mounting bolts

16 - 20 {1.6 - 2.0, 12 - 14}

Nozzle holder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}


23 - 27 {2.3 - 2.8, 17 - 20}

Spill tube connector

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

HV-1-3

Remarks

Tighten center bolts first then move toward outer bolts.

TOOLS


Description

Split collar tool 99624 Z5001

Used to remove and install split collar

Valve insert remover 99660 Z5503 (1) 99669 Z5502 (2) 99669 Z5503 (3) 99668 95000 (4) 99532 95000 (5) 99531 Z6000 (6) 89-11246-1A (7) 89-15446-1A

Used to remove intake and exhaust valve insert (1) Puller (for inlet) (2) Puller (for exhaust) (3) Bridge (4) Puller bolt (5) Bolt (M8 x 1.25) (6) Nut (M16 x 1.5) (7) Plain washer

Valve insert replacer 99665 Z5002

Used to install valve insert on cylinder head (cold-fit)

Valve insert caulking tool (1) 99675 Z5002 (2) 99676 Z5000 (3) 81-20616-1A

Used to caulk valve insert (for exhaust) (1) Caulking tool (2) Guide (3) Bolt

Valve guide remover 99667 Z5000

Used to remove valve guide

HV-2-1

Shape

TOOLS


Description

Valve guide replacer 99666 Z5001

Used to press valve guide into place

Reamer 99662 Z5500

Used to finish I.D. of valve guide

Nozzle holder sleeve wrench 99656 Z5501

Used to remove and install nozzle holder sleeve

Nozzle tube remover 99655 Z5500

Used to remove nozzle tube

Nozzle tube setting tool 99651 Z5500

Used to press nozzle tube into place

Stem seal replacer 99674 Z5001

Used to press valve stem seal into place

HV-2-2

Shape

CONSTRUCTION

CONSTRUCTION

HV-3-1

REMOVAL

REMOVAL 1.

Remove the following parts: Fuel tubes z Fuel filter assembly and bracket as a unit z Injection nozzle tubes and spill tubes z Injection nozzles NOTE z Use a container to catch fuel. Wipe up any fuel spilled on the exterior of the engine with a rag. z

2. Remove the rocker shaft assembly and push rods. NOTE z Loosen the rocker shaft assembly mounting bolts, starting with the outer bolts and moving toward the center.

3.

Remove the cylinder head assembly. Attach chains or cables to the engine lifter and lifters and lift the cylinder head away from the cylinder block using a hoist. NOTE z Loosen the head bolts diagonally, starting with the outer one and moving toward the center.

HV-4-1

DISASSEMBLY

DISASSEMBLY CYLINDER HEAD

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Push rod ,+ 2. Split collar 3. Upper spring seat , 4. Outer valve spring , 5. Inner valve spring , 6. Valve stem seal

7. Lower spring seat ,+ 8. Intake valve ,+ 9. Exhaust valve 10. Water jet 11. Water jet 12. Exhaust valve insert

, 13. Intake valve insert 14. Push rod pipe 15. Valve guide 16. Nozzle sleeve 17. Nozzle tube 18. O-ring


HV-5-1

DISASSEMBLY

Key point of disassembly Before disassembling the cylinder head, measure the depth of the valve head below the cylinder head. NOTE z

Be sure to remove carbon from these parts before measurement.

2 Split collar Remove the split collar using the split collar tool (99624 Z5001).

8 Intake valve, 9 Exhaust valve Remove the upper spring seat, outer and inner valve springs, valve stem seal and lower spring seat from each cylinder. NOTE z

Arrange all removed parts for each valve.

ROCKER SHAFT Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1.

Stopper bolt

6.

Inside spring

2.

Shaft bracket

7.

Exhaust valve rocker

3.

Adjusting screw

8.

Bushing

4.

Intake valve rocker

9.

Rocker shaft

5.

Bushing

HV-5-2

INSPECTION

INSPECTION z

z


CYLINDER HEAD Flatness Unit: mm (in) Item


Service limit


Less than 0.05 (0.0020)

0.2 (0.008)


Less than 0.05 (0.0020)

0.2 (0.008)

VALVE INSERT Contact width of valve and valve insert Unit: mm (in) Item


Service limit

Intake

2.2 - 2.4 (0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3 (0.079 - 0.091)

3.5 (0.138)

VALVE Depth of valve below lower surface of cylinder head Check that the depth is the same as that measured before disassembly. Unit: mm (in) Item


Service limit

Intake

1.33 - 1.83 (0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53 (0.0406 - 0.0602)

2.3 (0.091)

Valve head thickness Unit: mm (in) Item


Service limit

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

HV-6-1

INSPECTION

Outside diameter of valve stem Unit: mm (in) Item


Service limit

Intake

8.96 - 8.98 (0.3528 - 0.3535)

—

Exhaust

8.92 - 8.94 (0.3512 - 0.3520)

—

VALVE GUIDE Clearance to valve stem Unit: mm (in) Item


Service limit

Intake

0.02 - 0.05 (0.0008 - 0.0020)

0.15 (0.0059)

Exhaust

0.05 - 0.09 (0.0020 - 0.0035)

0.20 (0.0079)

VALVE SPRING Free length Unit: mm (in) Item


Service limit

Remarks

Outer

62.8 (2.472)

55.0 (2.165)

Inner

60.9 (2.398)

58.0 (2.283)

Intake and exhaust

Tension Unit: N {kgf, lbf} Item


Service limit

Remarks

Outer

246.2 - 271.7 {25.1 - 27.7, 55.3 - 61.1}

—

When compressed to 44.6 mm (1.756 in)

Inner

126.5 - 140.2 {12.9 - 14.3, 28.4 - 31.5}

—


Squareness For the outer spring, measure clearance at points A and B shown in the figure. Unit: mm (in) Maintenance standard

Service limit

Remarks

Less than 2.0 (0.079)

—

Inner and outer springs

HV-6-2

INSPECTION

VALVE ROCKER PARTS Outside diameter of rocker shaft Unit: mm (in) Maintenance standard

Service limit

19.98 - 20.00 (0.7866 - 0.7874)

19.90 (0.7835)

Rocker shaft runout Unit: mm (in) Maintenance standard

Service limit

0.06 (0.0024)

0.1 (0.004)

Inside diameter of valve rocker bushing Unit: mm (in) Maintenance standard

Service limit

20.02 - 20.04 (0.7882 - 0.7890)

20.10 (0.7913)

Clearance between valve rocker bushing and rocker shaft Unit: mm (in) Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Inside spring Unit: mm (in) Item


Service limit

Free length

60.0 (2.362)

49.0 (1.929)


21.6 - 31.4 {2.2 - 3.2, 4.9 - 7.1}

16.7 {1.7, 3.7}

Remarks When compressed to 33.5 mm (1.319 in)

HV-6-3

INSPECTION

PUSH ROD Runout Measure push rod runout while supporting the center of the spherical surface at each end of the push rod as shown. Unit: mm (in) Maintenance standard

Service limit

Less than 0.30 (0.0118)

—

CAM FOLLOWER Outside diameter Unit: mm (in) Maintenance standard

Service limit

19.96 - 19.98 (0.7858 - 0.7866)

19.85 (0.7815)

Clearance to cylinder block cam follower bore Unit: mm (in) Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.12 (0.0047)

HV-6-4


REPAIR AND REPLACEMENT REPAIRING CYLINDER HEAD Grind the cylinder head using a surface grinder. The maximum allowable grinding limit is 0.3 mm (0.012 in). Unit: mm (in) Maintenance standard (B)

Service limit (A)

89.9 - 90.1 (3.539 - 3.547)

89.7 (3.531)

REPAIRING VALVE AND VALVE INSERT 1.

Dress the valve face using a valve refacer. If thickness of the valve head after dressing reaches the service limit, replace the valve. NOTE z Ensure that the valve face is free from stepped wear, etc. Unit: mm (in) Item


Service limit

Valve face angle

Intake

29º30’ - 30º

—

Exhaust

44º30’ - 45º

—

Valve head thickness

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

2.

Dress the end of the valve stem using a valve refacer or oil stone. NOTE z Ensure that the end of the valve stem is dressed at a right angle to the axis and is free from roughness or damage.

3.

Dress the surface (A) of the valve insert using a valve seat grinder. NOTE z Ensure that the surface (A) is free from stepped wear, etc. Item Seat face angle


Service limit

Intake

30º - 30º30’

—

Exhaust

45º - 45º30’

—

HV-7-1


REPLACING VALVE INSERT 1. 2.

Remove both the intake and exhaust valve inserts using valve insert removers (99660 Z5503). Install the intake and exhaust valve inserts using a cold-fit method.

Cold-fit procedure a.

Immerse the valve inserts in dry ice for at least five minutes before fitting. Some alcohol may be added to the dry ice for better results. WARNING WARNING z Do not touch the valve insert or dry ice with bare hands to prevent injury.

b.

Immerse the cylinder head in hot water of at least 80ºC (176ºF). WARNING WARNING z Do not touch the cylinder head or hot water with bare hands to prevent injury.

c.

Remove the valve inserts and the cylinder head. Using the valve insert replacer (99665 Z5002), press the inserts into place on the cylinder head.

3.

After positioning the valve inserts, caulk only the exhaust valve at four points using the insert caulking tool. NOTE z When caulking the exhaust valve, use a press pressure of 14,711 N {1,500 kgf, 3,308 lbf}. Tool name Caulking tool Valve insert caulking tool Guide Bolt

Tool number 99675 Z5002 99676 Z5000 81-20616-1A

HV-7-2


LAPPING VALVE AND VALVE INSERT When the valve or valve insert is repaired or replaced, lap both parts using a grinding compound. 1. Apply grinding compound evenly to the mating surface of the valve.

2.

3.

4.

Apply engine oil to the valve stem and insert the valve into the valve guide. Attach a suction cup to the top of the valve head and turn the valve while lightly tapping the insert with the valve. After properly lapping these parts, thoroughly clean the compound off the parts. Then apply oil to the mating surfaces of the parts and relap.

Clean oil from the mating surfaces. Apply Prussian blue and repeat lapping both parts until they are lapped properly. Unit: mm (in) Item

Contact width of valve and valve insert


Service limit

Intake

2.2 - 2.4 (0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3 (0.079 - 0.091)

3.5 (0.138)

REPLACING VALVE GUIDE 1.

Drive the valve guide from the lower surface of the cylinder head using the valve guide remover (99667 Z5000).

2.

Using the valve guide replacer (99666 Z5001), drive the valve guide form the upper surface of the cylinder head until the replacer contacts the head surface. NOTE z Clean the valve guide hole in the cylinder head. Apply engine oil beforehand.

HV-7-3


Press the valve guide into place. Ream it using the reamer (99662 Z5500) so that the inside diameter is within the maintenance standard. Unit: mm (in) Item

Inside diameter


Service limit

Intake

9.00 - 9.02 (0.3543 - 0.3551)

—

Exhaust

9.00 - 9.02 (0.3543 - 0.3551)

—

REPLACING VALVE ROCKER BUSHING 1.

While supporting the valve rocker, drive out the bushing with a 23 mm (0.91 in) dia. rod. NOTE z Scribe alignment marks on the mating surfaces of the bushing and valve rocker before driving out the bushing. z Be careful not to damage the mating surfaces.

2. Align the marks and drive the bushing into place. NOTE z Also check that the oil holes in the bushing and valve rocker are aligned.

3.

Ream the bushing so that the inside diameter is within the maintenance standard. Unit: mm (in) Maintenance standard

Service limit

20.02 - 20.04 (0.7882 - 0.7890)

—

REPLACING NOZZLE TUBE 1.

Remove the nozzle holder sleeve using the nozzle holder sleeve wrench (99656 Z5501).

HV-7-4

REPAIR AND REPLACEMENT 2. 3.

Drive the nozzle tube form the lower surface of the cylinder head using the nozzle tube remover (99655 Z5500). Remove the O-ring from the nozzle tube.

4. Attach a new O-ring to the nozzle tube. NOTE z Apply soapy water to the O-ring before installation. To avoid breaking or deforming the O-ring, install the O-ring 8 mm (0.31 in) below the top of the tube (see “A” in the figure). 5. Apply LOCTITE #601 to the mating periphery of the tube. NOTE z Clean the mating surface of the cylinder head. Be careful not to apply excess Loctite to the tube. 6.

Attach the guide of the nozzle tube setting tool (99651 Z5500) to the nozzle tube and insert the tube into the cylinder head by hand. NOTE z Be careful not to damage the O-ring.

7.

8.

Using the nozzle holder mounting bolts, install the bridge of the nozzle tube setting tool (99651 Z5500) on the cylinder head. Tighten the set bolt and press the nozzle tube into place. When the nozzle tube contacts the seat of the cylinder head, resistance is felt on the bolt. From the point where resistance is felt, further tighten the set bolt approximately 10º.

9.

Apply THREE BOND #1344 to the thread of the nozzle holder sleeve. 10. Tighten the nozzle holder sleeve using the nozzle holder sleeve wrench (99656 Z5501). : 34 - 39 N·m {3.5 - 4.0 kgf·m, 25 - 29 ft·lbf}

HV-7-5

REASSEMBLY

REASSEMBLY CYLINDER HEAD Key point of reassembly Before assembling parts, apply engine oil to the sliding surfaces. 9 Exhaust valve, 8 Intake valve Install the intake and exhaust valves. NOTE z

Be sure to install the valves in their original positions.

6 Valve stem seal Install the stem seal on the valve guide using the stem seal replacer (99674 Z5001). NOTE z

Insert the stem seal by hand.

5 Inner valve spring, 4 Outer valve spring Install the inner and outer valve springs and the upper spring seat. NOTE z

Face the narrow pitch sides (painted blue) of the inner and outer springs toward the lower spring seats.

2 Split collar 1. Install the split collar using the split collar tool (99624 Z5001).

2.

Check that the depth of the valve below the lower surface of the cylinder head is correct. Unit: mm (in) Item


Service limit

Intake

1.33 - 1.83 (0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53 (0.0406 - 0.0602)

2.3 (0.091)

HV-8-1

REASSEMBLY

ROCKER SHAFT Key point of reassembly Before assembling parts, apply engine oil to the sliding surfaces. Assemble the rocker shaft assembly. NOTE z

Face the oil hole downward when assembling. 1.

Stopper bolt

6.

Inside spring

2.

Shaft bracket

7.

Exhaust valve rocker

3.

Adjusting screw

8.

Bushing

4.

Intake valve rocker

9.

Rocker shaft

5.

Bushing

HV-8-2

INSTALLATION

INSTALLATION 1. Install the cylinder head gasket and cylinder head. NOTE z Ensure that the stamped part number side faces upward when installing the gasket.

2.

Tightening the cylinder head bolts to the specified torque using the socket wrench (99664 Z5000). Note that seven of the head bolts are also secured to the rocker shaft bracket. : 1st : 98 N·m {10.0 kgf·m, 72 ft·lbf} 2nd: 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf}

: Refers to the bolts which are also secured to the rocker shaft bracket. [L = 180 mm (7.09 in)] O : Circled numbers refer to tightening sequence of head bolts. 3. Position the rocker shaft assembly on the head. NOTE z Be careful that the rocker arm tip and push rod do not dislocate. 4. Install the rocker shaft mounting bolts. NOTE z Be sure to tighten the bolts, starting from the inside and working outside. : 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf} 5. Install the following parts: z Injection nozzles z Injection nozzle tubes and spill tubes z Fuel filter assembly and bracket as a unit z Fuel tubes Unit: N·m {kgf·m, ft·lbf} Location

Tightening torque

Injection nozzle holder

25 - 29 {2.5 - 3.0, 18 - 22}


23 - 27 {2.3 - 2.8, 17 - 20}

Spill tube

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

6.

Start the engine. Check connections and other parts for signs of water leakage. Recheck the cooling water level and add cooling water if necessary.

HV-9-1

- MEMO -

- MEMO -

LUBRICATION SYSTEM

CONTENTS SERVICE DATA ...................................... LB-1-1 SPECIFICATIONS............................................ SERVICE DATA ............................................... TIGHTENING TORQUE ................................... LUBRICATION SYSTEM..................................

TOOLS .................................................... OIL PUMP ............................................... CONSTRUCTION............................................. REMOVAL ........................................................ DISASSEMBLY ................................................ INSPECTION.................................................... REASSEMBLY .................................................

LB-1-1 LB-1-1 LB-1-2 LB-1-3 LB-2-1 LB-3-1 LB-3-1 LB-3-1 LB-3-2 LB-3-3 LB-3-4

OIL COOLER........................................... LB-4-1 CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION ....................................................

OIL FILTER.............................................. CONSTRUCTION ............................................. REPLACING OIL FILTER ................................. INSPECTION ....................................................

OIL JET.................................................... CONSTRUCTION ............................................. REMOVAL ........................................................

LB-4-1 LB-4-2 LB-4-2 LB-4-3 LB-5-1 LB-5-1 LB-5-2 LB-5-3 LB-6-1 LB-6-1 LB-6-1

LB

SERVICE DATA

SERVICE DATA SPECIFICATIONS Lubrication type


Oil pump

Gear pump Cartridge type (Full flow only type and full flow & by pass combination type)

Oil filter Oil cooler


Engine oil capacities (Approximately) liter (lmp gal)

Engine oil pan (H-level)

Total


12 (2-5/8)

FE6TA*

14 (3-1/8)


15 (3-1/4)

FE6TA*

17 (3-3/4)

NOTE z

*Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).


Service limit

Side clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.20 (0.0079)

Backlash between pump gears

0.16 - 0.27 (0.0063 - 0.0106)

0.50 (0.0197)

Clearance between O.D. of driven gear shaft and gear bushing

0.03 - 0.08 (0.0012 - 0.0031)

0.20 (0.0079)

Relief pressure kPa {kgf/cm2, psi}

1,030 {10.5, 149}

—

Free length of spring

40.0 (1.575)

—

Spring tension N {kgf, lbf}

260.9 - 288.3 {26.6 - 29.4, 58.7 - 64.8}

—

kPa {kgf/cm2, psi}

981 {10, 142}

—

Item

Oil pump

Relief valve

Oil cooler

Water pressure test

LB-1-1

Remarks

Fully opening pressure 1,765 {18, 256}



Service limit

275 - 314 {2.8 - 3.2, 40 - 46}

—


58.5 (2.303)

—


47.515 - 52.516 {4.845 - 5.355, 10.683 - 11.808}

—


98 - 137 {1.0 - 1.4, 14 - 20}

—


62.0 (2.441)

—


28.882 - 31.922 {2.945 - 3.255, 6.494 - 7.177}

—


422 - 461 {4.3 - 4.7, 61 - 67}

—


61.0 (2.402)

—


102.48 - 113.27 {10.45 - 11.55, 23.04 - 25.47}

—


275 - 314 {2.8 - 3.2, 40 - 46}

—


58.5 (2.303)

—


50.0 {5.1, 11.2}

—


98 - 137 {1.0 - 1.4, 14 - 20}

—


97.0 (3.819)

—


60.8 {6.2, 13.7}

—


422 - 461 {4.3 - 4.7, 61 - 67}

—


62.0 (2.441)

—


115.7 {11.8, 26.0}

—

Item Relief pressure kPa {kgf/cm2, psi} Oil cooler short valve

Type I

Oil filter short valve

Regulating valve Oil filter

Oil pipe

Type II

Oil cooler short valve

Oil filter short valve

Regulating valve

Remarks







TIGHTENING TORQUE Unit: N·m {kgf·m, ft·lbf} Location

Tightening torque

Oil pump relief valve mounting plug

47 - 71 {4.8 - 7.2, 35 - 52}

Oil pump mounting bolt

20 {2.0, 14}

Oil pump cover mounting bolt

14 - 20 {1.4 - 2.0, 10 - 14}

Oil filter short valve mounting cap

25 - 34 {2.5 - 3.5, 18 - 25}

Regulating valve mounting cap

25 - 34 {2.5 - 3.5, 18 - 25}

Oil jet bolt

34 - 49 {3.5 - 5.0, 25 - 36}

Cooler element mounting nut

20 - 29 {2.0 - 3.0, 14 - 22}

Oil cooler mounting bolt and nut

25 {2.5, 18}

LB-1-2

SERVICE DATA

LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM

LUBRICATION CIRCUIT

LB-1-3

TOOLS


Description

Hydraulic pump 99570 Z5000

For testing oil pressure of oil cooler element.

Oil cooler attachment 99573 Z5500 (1) 99578 Z5500 (2) 99578 Z5501

Used when performing the oil cooler core oil pressure test. (1) Leak test attachment (2) Leak test attachment

LB-2-1

Shape

OIL PUMP

OIL PUMP CONSTRUCTION

REMOVAL Key point of removal Remove the drain plug from the oil pan and drain engine oil into a container. WARNING WARNING z

Do not drain oil while engine is hot to avoid scalding yourself.

NOTE z

Do not disassemble the oil pump except for the removal of the valve and driven gear.

LB-3-1

OIL PUMP

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Plug 2. Gasket 3. Spring

4. Ball 5. Cover 6. Gasket

7. Driven gear assembly ,+ 8. Pump gear assembly

Marks “,” and “+” indicate that the key points of operation are explained in the text.

Key point of disassembly The oil pump gears and the drive gear are shrink-fitted to the drive shaft. Disassembly of the oil pump must be limited to the valve and driven gear assembly. 8 Pump gear assembly 1. Measure the side clearances between the pump gears (drive and driven) and cover.

2.

Measure the clearance between tips of the pump gears (drive and driven) and pump body.

LB-3-2

OIL PUMP 3.

Measure the backlash between the drive and driven gears using a fuse.

INSPECTION z

z


Side clearance Unit: mm (in) Maintenance standard

Service limit

0.04 - 0.10 (0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance Unit: mm (in) Maintenance standard

Service limit

0.04 - 0.10 (0.0016 - 0.0039)

0.20 (0.0079)

Backlash between pump gears Unit: mm (in) Maintenance standard

Service limit

0.16 - 0.27 (0.0063 - 0.0106)

0.50 (0.0197)

Clearance between O.D. of driven gear shaft and gear bushing Unit: mm (in) Maintenance standard

Service limit

0.03 - 0.08 (0.0012 - 0.0031)

0.20 (0.0079)

Relief valve Item


Service limit


1,030 {10.5, 149}

—

Free length of spring mm (in)

40.0 (1.575)

—


260.9 - 288.3 {26.6 - 29.4, 58.7 - 64.8}

—

Remarks Fully opening pressure 1,765 {18, 256}


LB-3-3

OIL PUMP

REASSEMBLY Key point of reassembly 8 Pump gear assembly Attach the driven gear to the pump gear assembly. Measure the clearances and backlash to ensure that they do not exceed the maintenance standard. Unit: mm (in) Item


Service limit

Side clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.20 (0.0079)

Backlash between pump gears

0.16 - 0.27 (0.0063 - 0.0106)

0.50 (0.0197)

LB-3-4

OIL COOLER

OIL COOLER CONSTRUCTION Type I

Type II

Type I: Former Type II: New

LB-4-1

OIL COOLER

REMOVAL Key point of removal Remove the drain plug from the oil pan and drain engine oil into a container. WARNING WARNING z

Do not drain while the engine is hot to prevent scalding yourself.

DISASSEMBLY Type I and Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cooler housing 2. Gasket

3. Cooler element

LB-4-2

4. Housing gasket

OIL COOLER

INSPECTION z

z


Water pressure test Conduct hydraulic tests on the element using the oil cooler attachment (99573 Z5500) and hydraulic pump (99570 Z5000). If any abnormality is noticed, replace the element. NOTE z

After completing the test, discharge the water completely and dry the oil cooler. Maintenance standard

Service limit

Water leakage should not occur when a pressure of 981 kPa {10kgf/cm2, 142psi}, is directed to the element

—

LB-4-3

OIL FILTER

OIL FILTER CONSTRUCTION Type I (Full flow only type)

Type II (Full flow & by pass combination type)

LB-5-1

OIL FILTER

REPLACING OIL FILTER Refer to the “MA” section for LUBRICATION SYSTEM.

Type I (Full flow only type)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Regulating valve cap 2. Packing 3. Regulating valve spring 4. Regulating valve 5. Bracket 6. Short valve cap 7. Packing

8. Short valve spring 9. Short valve 10. Clog warning switch 11. Packing 12. Short valve spring 13. Contactor case 14. Contactor

LB-5-2

15. Contactor spring 16. Short valve 17. Snap ring 18. Oil cooler short valve 19. Oil cooler short valve spring 20. Oil filter element assembly

OIL FILTER

Type II (Full flow & by pass combination type)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Regulating valve cap 2. Packing 3. Regulating valve spring 4. Regulating valve 5. Bracket 6. Short valve cap

7. Packing 8. Short valve spring 9. Oil filter short valve 10. Clog warning switch 11. Packing 12. Short valve spring

INSPECTION z

z


Oil cooler short valve Unit: mm (in) Maintenance standard

Service limit

Type I Type II

58.5 (2.303)

—

Type I

47.515 - 52.516 {4.845 - 5.355, 10.683 - 11.808}

—


Type II 50.0 {5.1, 11.2}

—


Item Free length of spring


Remarks

LB-5-3

13. Contactor case 14. Contactor 15. Contactor spring 16. Short valve 17. Oil filter element assembly

OIL FILTER

Oil filter short valve Unit: mm (in) Maintenance standard

Service limit

Type I

62.0 (2.441)

—

Type II

97.0 (3.819)

—

Type I

28.882 - 31.922 {2.945 - 3.255, 6.494 - 7.177}

—


Type II 60.8 {6.2, 13.7}

—




Remarks

Regulating valve Unit: mm (in) Maintenance standard

Service limit

Type I

61.0 (2.402)

—

Type II

62.0 (2.441)

—

Type I

102.48 - 113.27 {10.45 - 11.55, 23.04 - 25.47}

—


Type II

115.7 {11.8, 26.0}

—




Remarks

LB-5-4

OIL JET

OIL JET CONSTRUCTION 1.

Straight pin

2.

Oil jet

3.

Oil jet bolt

NOTE z


REMOVAL Key point of removal Remove the oil jet bolt, being careful not to drop the gasket into the cylinder block.

LB-6-1

- MEMO -

COOLING SYSTEM

CONTENTS SERVICE DATA ...................................... EC-1-1 SPECIFICATIONS............................................ SERVICE DATA ............................................... TIGHTENING TORQUE ................................... COOLING SYSTEM .........................................

EC-1-1 EC-1-2 EC-1-3 EC-1-4 TOOLS .................................................... EC-2-1 WATER PUMP ........................................ EC-3-1 CONSTRUCTION............................................. EC-3-1 EXTERNAL APPEARANCE CHECK AND CORRECTION EC-3-1 DISASSEMBLY ................................................ EC-3-2 INSPECTION.................................................... EC-3-4

REASSEMBLY.................................................. EC-3-4

THERMOSTAT ........................................ EC-4-1 REMOVAL ........................................................ EC-4-1 INSPECTION .................................................... EC-4-1 INSTALLATION ................................................ EC-4-1

RADIATOR AND COOLANT RESERVOIR TANK EC-5-1 FLUSHING COOLING SYSTEM ...................... EC-5-1 INSPECTION .................................................... EC-5-1 FAN CLUTCH .......................................... EC-6-1 CONSTRUCTION ............................................. EC-6-1 INSPECTION .................................................... EC-6-2

EC

SERVICE DATA

SERVICE DATA SPECIFICATIONS Cooling system


Water pump


Thermostat

Wax pellet type

Fan clutch

Refer to the description in this manual.

Type of water pump Unit: mm (in) Item

Type I

Type IV

Type II

Type V

Type III

A

100 (3.94)

116 (4.57)

B

80 (3.15)

96 (3.78)

C

36 (1.42)

55 (2.17)

Screw hole in impeller

Provided

Packed grease

None

Provided

None

General specification

Disassembly and reassembly Former and new

Provided

Type VI

None

Cold resistant specification

OK

NG

OK

NG

OK

NG

Former

New

Former

New

Former

New

Packed grease differs from that for Type II.

Packed grease differs from that for Type V.

Remarks

—

Type of thermostat Unit: mm (in) Item

Type I

Type III

Type IV

Type V

A

51 (2.01)

46 (1.81)

B

27 (1.06)

33 (1.30)

C

10 (0.39)

15 (0.59)

Valve opening temperature ºC (ºF) Former and new

Type II

76.5 (170)

82 (180) Former

EC-1-1

88 (190)

76.5 (170)

82 (180) New

Type VI

88 (190)

SERVICE DATA

Fan clutch Item FE6A FE6B 119 kW {162 PS} FE6B 132 kW {180 PS}

FD1300L

FE6B 132 kW {180 PS} FE6T 135 kW {183 PS} FE6T 151 kW {205 PS} FE6TA 157 kW {213 PS}

FDL1700

FE6T 151 kW {205 PS} FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS} FE6TA 173 kW {235 PS}

FDL2000

Run the engine continuously

Operating temperature ºC (ºF)

3,000 rpm

75±5 (167±9)

ON-OFF type

65±10 - 80±5 (149±18 - 176±9) Linear type

3,400 rpm 50±10 - 80±5 (122±18 - 176±9)

SERVICE DATA Unit: mm (in) Item


Service limit

Type I

0.4 - 2.0 (0.016 - 0.079)

—

Type II Type III

0.3 - 2.1 (0.012 - 0.083)

—

13.03 - 13.05 (0.5130 - 0.5138)

—

0.03T - 0.06T (0.0012T - 0.0024T)

—

45 (1.77)

—

74.5 - 78.5 (166 - 173)

71.5 - 81.5 (161 - 179)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

76.5ºC (170ºF)

More than 10/90 (0.39/194)

Less than 9/90 (0.35/194)

82ºC Valve lift/temperature (180ºF) mm/ºC (in/ºF)

More than 10/95 (0.39/203)

Less than 9/95 (0.35/203)

88ºC (190ºF)

More than 10/100 (0.39/212)

Less than 9/100 (0.35/ 212)

Radiator cap operating pressure kPa {kgf/cm2, psi}

39 - 59 {0.4 - 0.6, 6 - 9}

—

Test air pressure for radiator leakage kPa {kgf/cm2, psi}

157 {1.6, 23}

—

Fan pulley - alternator pulley

10 - 15 (0.39 - 0.59)

—

Fan pulley - cooler pulley

7 - 12 (0.28 - 0.47)

—

Water pump (Type I, Type II and Type III only)

Clearance between housing and impeller

Outside diameter of shaft at impeller location Fit of impeller and shaft Valve port diameter 76.5ºC (170ºF)

Thermostat

V-belt deflection

Valve opening tem82ºC perature (180ºF) ºC (ºF) 88ºC (190ºF)

EC-1-2

Remarks Side clearance

T: Tight

Pressure side

With a force of about 98 N {10 kgf, 22 lbf} applied to the mid part

SERVICE DATA


Tightening torque

Water pump grease nipple

10 - 15 {1.0 - 1.5, 7 - 11}

Water pump mounting bolt

10 - 13 {1.0 - 1.3, 7 - 9}

Fan pulley mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

Cooling fan mounting bolt

10 - 12 {1.0 - 1.2, 7 - 9}

Fan clutch mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

EC-1-3

SERVICE DATA

COOLING SYSTEM

EC-1-4

TOOLS

TOOLS WATER PUMP Type I Tool name and number

Description

Pulley hub puller 99749 Z5503

Used to remove flange and impeller

Drive shaft remover 99758 Z5500

Used to remove drive shaft

Bearing replacer 99759 Z5503

Used to remove and install ball bearing

Water seal replacer 99759 Z5504

Used to remove water seal

Drive shaft guide 99789 Z5500

Used to install drive shaft

Fan pulley hub replacer 99788 Z5501

Used to drive flange into place

EC-2-1

Shape

TOOLS

Type II and Type III Tool name and number

Description

Pulley hub puller 99749 Z5504

Used to remove flange and impeller

Drive shaft remover 99758 Z5500

Used to remove drive shaft


Used to remove ball bearing


Used to install ball bearing

Water seal replacer 99759 Z5507

Used to remove and install water seal

Drive shaft guide 99789 Z5501

Used to install drive shaft

Fan pulley hub replacer 99788 Z5503

Used to drive flange into place

EC-2-2

Shape

WATER PUMP

WATER PUMP CONSTRUCTION

EXTERNAL APPEARANCE CHECK AND CORRECTION The water pump should not be disassembled if no defects are found by visual inspection. 1. If coolant leaks at the hole on the lower side of the water pump housing or if there are signs of coolant leakage on the pump housing, check the seal and impeller and replace both at the same time if necessary. 2. If grease leaks at the hole on the lower side of the water pump housing or on the pulley side, replace the ball bearing on that side. 3. If the impeller interferes with the pump housing due to a worn ball bearing, or if the axial play of the ball bearing is excessive, replace both ball bearings as a unit.

EC-3-1

WATER PUMP

DISASSEMBLY Type I, Type II and Type III

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) , 1. Grease nipple ,+ 2. Impeller ,+ 3. Flange 4. Retaining ring

+ 5. Drive shaft assembly ,+ 6. Ball bearing 7. Spacer ,+ 8. Ball bearing

9. Washer , 10. Drive shaft ,+ 11. Water seal*

*Before installing the water seal, install the flange. Marks “,” and “+” indicate that the key points of operation are explained in the text.

Type IV, Type V and Type VI z

Disassembly is not possible as there are no screw holes in the impeller. If any abnormality is found by checking the exterior appearance, replace the assembly.

EC-3-2

WATER PUMP

Key point of disassembly 2 Impeller Secure the flange and remove the impeller using the puller bolt. NOTE z To secure the flange and puller bolt, use the pulley hub puller. Tool name Pulley hub puller

Tool number

Type I

99749 Z5503

Type II, Type III

99749 Z5504

3 Flange Drive out the flange using the pulley hub puller. Tool name Pulley hub puller

Tool number

Type I

99749 Z5503

Type II, Type III

99749 Z5504

5 Drive shaft assembly Remove the retaining ring and drive shaft assembly from the impeller side using the drive shaft remover (99758 Z5500).

6, 8 Ball bearing Drive out the ball bearing together with the spacer and washer using the bearing replacer. Tool name Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5505

EC-3-3

WATER PUMP 10 Water seal Drive out the water seal using the water seal replacer. Tool name Water seal replacer

Tool number

Type I

99759 Z5504

Type II, Type III

99759 Z5507

INSPECTION z

z


Outside diameter of shaft at impeller location Unit: mm (in) Maintenance standard

Service limit

13.03 - 13.05 (0.5130 - 0.5138)

—

Fit of impeller and shaft Unit: mm (in) Maintenance standard

Service limit

0.03T - 0.06T (0.0012T - 0.0024T)

—

Remarks T = Tight

REASSEMBLY Key point of reassembly 10 Drive shaft Attach the drive shaft guide to the pump body, and press the drive shaft assembly into place. Tool name Drive shaft guide

Tool number

Type I

99789 Z5500

Type II, Type III

99789 Z5501

8 Ball bearing Install the washer and press the ball bearing into place on the impeller side using the bearing replacer. NOTE z Apply bearing grease to the rolling surface of the bearing. Tool name Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5506

EC-3-4

WATER PUMP 6 Ball bearing Install the spacer and press the ball bearing into place on the flange side using the bearing replacer. NOTE z

Apply bearing grease to the rolling surface of the bearing. Tool name

Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5506

3 Flange Press the flange onto the drive shaft using the fan pulley hub replacer. Tool name Fan pulley hub replacer

Tool number

Type I

99788 Z5501

Type II, Type III

99788 Z5503

11 Water seal Apply a coat of THREE BOND #1702 to the outer periphery of the water seal. Press the water seal into the pump body using the water seal replacer. Tool name Water seal replacer

Tool number

Type I

99759 Z5504

Type II, Type III

99759 Z5507

2 Impeller Press the impeller into place so that the clearance between the pump housing and impeller is within maintenance standards. Unit: mm (in) Item Clearance between pump housing and impeller


Service limit

0.4 - 2.0 (0.016 - 0.079)

—

Type II, 0.3 - 2.1 (0.012 - 0.083) Type III

—

Type I

1 Grease nipple Pour bearing grease into the grease nipple. Unit: g (oz) Item

Amount of grease

Type I

38 (1.34)

Type II, Type III

42 (1.48)

EC-3-5

THERMOSTAT

THERMOSTAT REMOVAL

INSPECTION Check thermostat operation as shown in the figure on the right. Item 76.5ºC (170ºF)

Valve opening 82ºC temperature (180ºF) ºC (ºF) 88ºC (190ºF) 76.5ºC (170ºF)

Valve lift/ 82ºC temperature (180ºF) mm/ºC (in/ºF) 88ºC (190ºF)


Service limit

74.5 - 78.5 (166 - 173)

71.5 - 81.5 (161 - 179)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

More than 10/90 (0.39/194)

Less than 9/90 (0.35/194)

More than 10/95 (0.39/203)

Less than 9/95 (0.35/203)

More than 10/100 (0.39/212)

Less than 9/100 (0.35/212)

INSTALLATION Install a new gasket so that it covers the periphery of the thermostat as shown in the figure.

EC-4-1

RADIATOR AND COOLANT RESERVOIR TANK

RADIATOR AND COOLANT RESERVOIR TANK FLUSHING COOLING SYSTEM 1.

Drain approximately 5% of the engine coolant from the cooling system and replenish with the same amount of cleaning solvent (genuine product. Cooling Mate). Allow the engine to idle for approximately 30 minutes. NOTE z Engine coolant temperature should be maintained at approximately 80ºC (176ºF). 2. Drain the cooling system and replenish with tap water. WARNING WARNING z Do not remove the radiator cap quickly. Otherwise, you may be sprayed and scalded with hot flashing fluid. Cover the cap with a thick and heavy rag, and remove it gradually. 3. 4.

Start the engine again and continue to flush the cooling system. Repeat the flushing operation until drained water is clean. Remove dust, leaves, and other foreign matter from the radiator core fins, water tubes, etc.

INSPECTION Check the radiator and coolant reservoir tank for cracks or damage. If necessary, repair or replace.

Water leakage test Plug the inlet and outlet of the radiator with suitable taps and immerse the entire radiator in water. While holding the radiator in water, apply 157 kPa {1.6 kgf/cm2, 23 psi} of compressed air to the radiator core to check for air leakage. If leakage is present, repair or replace as necessary.

Radiator cap operating pressure Unit: kPa {kgf/cm2, psi} Maintenance standard

Service limit

39 - 59 {0.4 - 0.6, 6 - 9}

—

Remarks Pressure side

EC-5-1

RADIATOR AND COOLANT RESERVOIR TANK

Engine coolant Check density of anti-freeze solution or LLC (Long Life Coolant) using a tester. If it is low, add anti-freeze solution or LLC as required to suit the areas where the vehicle is to be operated.

EC-5-2

FAN CLUTCH

FAN CLUTCH CONSTRUCTION FD1300L

FDL1700

EC-6-1

FAN CLUTCH

FDL2000

INSPECTION After removing the fan clutch, inspect it visually, and if there are any cracks or oil leakage (silicone oil), replace the fan clutch assembly.

OPERATING TEMPERATURE CHECK 1. 2. 3. 4. 5.

Remove the fan and fan shroud. Reinstall the fan. Set a thermometer between the fan and radiator. Start the engine and keep it running at a steady N rpm. As the thermometer reaches the range for TºC (TºF) ascertain that fan speed gradually increases from low speed to high speed. If there is any abnormality, replace the fan clutch.

EC-6-2

FAN CLUTCH Unit: ºC (ºF) Item FE6A ON-OFF FE6B 119 kW {162 PS} FD1300L type FE6B 132 kW {180 PS} FE6B 132 kW {180 PS} FE6T 135 kW {183 PS} FDL1700 FE6T 151 kW {205 PS} FE6TA 157 kW {213 PS} Linear type FE6T 151 kW {205 PS} FE6T 162 kW {220 PS} FDL2000 FE6TA 157 kW [213 PS} FE6TA 173 kW {235 PS}

Run the Operating engine temperature continuously (T) 3,000 rpm

75±5 (167±9) 65±10 - 80±5 (149±18 176±9)

3,400 rpm 50±10 - 80±5 (122±18 176±9)

EC-6-3

- MEMO -

FUEL SYSTEM

CONTENTS SERVICE DATA ...................................... EF-1-1 SPECIFICATIONS............................................ SERVICE DATA ............................................... TIGHTENING TORQUE ................................... FUEL SYSTEM.................................................

TOOLS ....................................................

EF-1-1 EF-1-2 EF-1-4 EF-1-6 EF-2-1

= FE6A, FE6B, FE6T AND FE6TA [173 kW 235 PS] = EF-3-1 EF-3-6 EF-3-7 EF-3-16 EF-3-24 EF-3-25 EF-3-27

= FE6TA [157 kW {213 PS}] = INJECTION PUMP ASSEMBLY ............. EF-4-1 CONSTRUCTION............................................. REMOVAL ........................................................ FUEL FEED PUMP AND PRIMING PUMP ...... INSTALLATION ................................................ FUEL INJECTION QUANTITY ADJUSTMENT

NOZZLE AND NOZZLE HOLDER ..........

CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY.................................................. ADJUSTMENT.................................................. INSTALLATION ................................................

EF-5-1 EF-5-1 EF-5-2 EF-5-3 EF-5-4 EF-5-4 EF-5-5

= TWO-SPRING TYPE =

INJECTION PUMP ASSEMBLY ............. EF-3-1 INJECTION PUMP PROPER ........................... FEED PUMP..................................................... TIMER .............................................................. GOVERNOR..................................................... ADJUSTMENT ................................................. INITIAL INJECTION TIMING ADJUSTMENT... FUEL INJECTION QUANTITY ADJUSTMENT

= CONVENTIONAL TYPE =

EF-4-1 EF-4-11 EF-4-12 EF-4-15 EF-4-16 EF-5-1

CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY.................................................. ADJUSTMENT.................................................. INSTALLATION ................................................

EF-5-6 EF-5-6 EF-5-7 EF-5-8 EF-5-9 EF-5-9 EF-5-16 FUEL FILTER .......................................... EF-6-1 CONSTRUCTION ............................................. EF-6-1 REPLACING FUEL FILTER ELEMENT............ EF-6-3 ENGINE CONTROL SYSTEM................. EF-7-1

= FE6A, FE6B, FE6T AND FE6TA [173 kW {235 PS}] = CONSTRUCTION ............................................. EF-7-1 ADJUSTMENT.................................................. EF-7-1

= FE6TA [157 kW {213 PS}] = CONSTRUCTION ............................................. EF-7-4 ADJUSTMENT.................................................. EF-7-4 “MD-TICS” SYSTEM............................... EF-8-1

EF

SERVICE DATA

SERVICE DATA SPECIFICATIONS Engine model

FE6A

Max. gross output

kW {PS/}rpm


FE6B

FE6T

118 {160}/ 119 {162}/ 132 {180}/ 135 {183}/ 151{205}/ 162 {220}/ 173 {235}/ 3,000 3,000 3,000 3,000 2,800 2,800 2,800 14º

15º

12º

10º

Ignition order

12º

3º

Plunger diameter mm (in)

9.5 (0.374)

Injection pump Cam lift mm (in) Feed pump

8.0 (0.315)

9.0 (0.354)

9.5 (0.374)

11.0 (0.433)

9.0 (0.354)

9.0 (0.354)

10.0 (0.394) 6.0 (0.236)

Type

Centrifugal RAD-B RLD-E RFD-B

RLD-E

RAD-B RLD-E RFD-B

RLD-E

Type Timer

Bosch (TC-MD type)

Bosh (PE-A type)

Governor Type name

RLD-F

RLD-J

SAG

—

Centrifugal

Type name

SA

SA/SAG

Injection timing control

SA

Electronic (MD-TICS)

—

Nozzle holder

Flange type

Nozzle

Multi-jet

Identification mark


9º

157 {213}/ 2,800

1-4-2-6-3-5 Type

Fuel injection pump

FE6TA

Z

D2

Z


Injection opening pressure

D3

A5

A6

A3

19,614 {200, 2,844}

1st stage: 16,672 {170, 2,417} 2nd stage: 21,575 {220, 3,128}

*1 C1/F4

*2 C1

5

19,614 {200, 2,844}

2

kPa {kgf/cm , psi}

NOTE

*1: For HONG KONG only (“F4” FE6-206670—) z *2: For NORWAY only z

EF-1-1

21,575 {220, 3,128}

19,614 {200, 2,844}

SERVICE DATA

SERVICE DATA INJECTION PUMP ASSEMBLY FE6A, FE6B, FE6T AND FE6TA [173 KW {235 PS}] Unit: mm (in)

Housing and associated parts

Camshaft

Item


Service limit

I.D. of housing tappet

24.00 - 24.03 (0.9449 - 0.9461)

24.15 (0.9508)

Pump housing to tappet clearance

0.03 - 0.07 (0.0012 - 0.0028)

0.2 (0.008)

Pump housing to bearing cover clearance

0.01 - 0.05 (0.0004 - 0.0020)

0.1 (0.004)

O.D. of contact surface of oil seal

20.0 (0.787)

19.8 (0.780)

Runout

Less than 0.05 (0.0020)

0.15 (0.0059)

End play of camshaft

0 - 0.02 (0 - 0.0008)

0.1 (0.004)

23.95 - 23.97 (0.9429 - 0.9437)

23.9 (0.941)

—

0.2 (0.008)

Tappet O.D. Tappet

Play of tappet roller Depth of tappet roller adjusting bolt

—

0.2 (0.008)

0.15 (0.0059)

0.3 (0.012)

0.03 - 0.08 (0.0012 - 0.0031)

0.12 (0.0047)

—

Less than 1.471 N {150 g, 5.29 oz}

3.0±0.05 (0.1181±0.0020)

—

±0.5º

±1º

Clearances between pins and holes in tension lever, speed setting lever and guide lever

0.01 - 0.09 (0.0004 - 0.0035)

0.2 (0.008)

Clearance of flyweight pin bushing

0.02 - 0.05 (0.0008 - 0.0020)

0.08 (0.0031)

Rod control lever-to-bushing clearance

0.03 - 0.08 (0.0012 - 0.0031)

0.15 (0.0059)

Roller I.D.-to-roller pin O.D. clearance

0.04 - 0.08 (0.0016 - 0.0031)

Tappet roller pin hole-to-roller pin O.D.

0.02 - 0.07 (0.0008 - 0.0028)

Roller I.D.

14.98 - 15.00 (0.5898 - 0.5906)

14.6 (0.575)

Housing-to-piston clearance

0.03 - 0.06 (0.0012 - 0.0024)

0.15 (0.0059)

Control rack to pinion backlash Control sleeve to plunger flange play Plunger and delivery valve

Sliding resistance of control rack Static fuel injection starting (Cam lift) Difference in injection interval among cylinders

Governor

Feed pump

Remarks

Support center holes at both ends.

Measure at right angle to roller pin.

When static

Total play 0.3 (0.012)

Less than 30 sec. (Time required for oil pressure to reach 177 kPa {1.8 kgf/cm2, 26 psi} with the engine running at 600 rpm

Discharge pressure

Overflow valve opening pressure

Discharge flow rate

Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged for 15 seconds with engine running at 1,000 rpm)

Priming pump

25 times (Number of cycles required for priming pump running at a stroke of 60 - 100 per minute)

Injection pump outlet Fuel filter

kPa {kgf/cm2, psi}

157 {1.6, 23}

—

kPa {kgf/cm2, psi}

108 - 147 {1.1 - 1.5, 16 - 21}

—

EF-1-2

When suction pipe of 8.0 mm (0.315 in) I.D. and 2.0 m (6.56 ft) length is used When cam lift is 6.0 mm (0.236 in)

SERVICE DATA

FE6TA [157 kW {213 PS}] Unit: mm (in)

Housing and associated parts

Camshaft

Tappet

Item


Service limit

I.D. of housing tappet

28.000 - 28.021 (1.1024 - 1.1032)

28.15 (1.1083)

Pump housing to tappet clearance

0.020 - 0.062 (0.0008 - 0.0024)

0.2 (0.008)

Pump housing to bearing cover clearance

0 - 0.06 (0 - 0.0024)

0.1 (0.004)

O.D. of contact surface of oil seal

25.0 (0.984)

19.8 (0.780)

Runout

Less than 0.05 (0.0020)

0.15 (0.0059)

End play of camshaft

0.02 - 0.06 (0.0008 - 0.0024)

0.1 (0.004)

Tappet O.D.

27.959 - 27.980 (1.1007 - 1.1016)

27.9 (1.098)

—

0.2 (0.008)

Play of tappet roller Depth of tappet roller adjusting bolt

—

0.2 (0.008)

0 - 0.056 (0 - 0.0022)

0.3 (0.012)

0.025 - 0.083 (0.0010 - 0.0033)

0.12 (0.0047)

Sliding resistance of control rack

1.275 N {130 g, 4.59 oz}

1.471 N {150 g, 5.29 oz}

Static fuel injection starting (Cam lift)

5.6±0.03 (0.2205±0.0012)

—

±0.25º

±1º

Control rack to pinion backlash Control sleeve to plunger flange play Plunger and delivery valve

Difference in injection interval among cylinders

Clearances between pins and holes in tension lever, speed setting lever and guide lever

0.01 - 0.09 (0.0004 - 0.0035)

0.2 (0.008)

Clearance of flyweight pin bushing

0.018 - 0.039 (0.0007 - 0.0015)

0.08 (0.0031)

Rod control lever-to-bushing clearance

0.031 - 0.075 (0.0012 - 0.0030)

0.15 (0.0059)

Housing and push rod clearance

0.003 - 0.018 (0.0001 - 0.0007)

0.1 (0.004)

Housing and piston clearance

0.014 - 0.056 (0.0006 - 0.0022)

0.15 (0.0059)

Governor

Remarks

Support center holes at both ends.

Measure at right angle to roller pin.

At standstill

Shaft to tension lever guide 0.05 - 0.08 (0.0020 - 0.0031) Lever shaft to bushing 0.022 - 0.051 (0.0009 - 0.0020)

Less than 30 sec. (Time required for oil pressure to Feed pump

Overflow valve opening pressure kPa {kgf/cm2, psi}

Discharge pressure

reach 177 kPa 1.8 {kgf/cm2, 26 psi} with the engine running at 600 rpm)

Discharge flow rate

Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged for 15 seconds with engine running at 1,000 rpm)

Priming pump

25 times (Number of cycles required for priming pump running at a stroke of 60 to 100 per minute)

Injection pump outlet Fuel filter

255 {2.6, 37}

—

108 - 147 {1.1 - 1.5, 16 - 21}

—

EF-1-3

when suction pipe of 8.0 mm (0.315 in) I.D. and 2.0 m (6.56 ft) length is used when cam lift is 6.0 mm (0.236 in)

SERVICE DATA

NOZZLE AND NOZZLE HOLDER Unit: kPa {kgf/cm2, psi} Item Conventional type Valve opening pressure (Regulated pressure)


Service limit

Z, D2, A5 A6, C1, F4

20,104 - 20,595 {205 - 210, 2,915 - 2,986}

—

D3, F4

22,066 - 22,556 {225 - 230, 3,200 - 3,271}

—

17,162 - 17,947 {175 - 183, 2,489 - 2,602}

—

23,046 - 23,537 {235 - 240, 3,342 - 3,413}

—

Nozzle cover method

24,321 - 24,910 {248 - 254, 3,527 - 3,612}

—

Push rod contacting method

1st stage Two-spring type

A3

2nd stage

Remarks

TIGHTENING TORQUE INJECTION PUMP ASSEMBLY Unit: N·m {kgf·m, ft·lbf} Item Injection pump assembly


Tightening torque PE-A type

M20

39 - 44 {4.0 - 4.5, 29 - 33}

M24

49 - 54 {5.0 - 5.5, 36 - 40}

TC-MD type

103 - 113 {10.5 - 11.5, 76 - 83}

Bearing cover mounting bolt Timer

Timer round nut

7 - 9 {0.7 - 0.9, 5.1 - 6.5} SAG type

54 - 59 {5.5 - 6.0, 40 - 43}

SA type

83 - 98 {8.5 - 10.0, 61 - 72}

Flyweight round nut

RAD-B RLD-E, F RFD-B Governor

RLD-J

Actuator housing

Governor housing mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51} M6

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

M8

15 - 18 {1.5 - 1.8, 11 - 13}

Governor cover mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Idle spring assembly lock nut

18 - 22 {1.8 - 2.2, 13 - 16}

Ungleich spring assembly lock nut

16 - 20 {1.6 - 2.0, 12 - 14}

Speed setting bolt lock nut

10 - 14 {1.0 - 1.4, 7 - 10}

Flyweight round nut

49 - 59 {5.0 - 6.0, 36 - 43}

Governor housing mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Governor cover mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Idle spring assembly lock nut

39 - 59 {4.0 - 6.0, 29 - 43}

Speed setting bolt lock nut

10 - 14 {1.0 - 1.4, 7 - 10}

Actuator housing mounting bolt

1.0 - 1.5 {0.10 - 0.15, 0.7 - 1.1}

EF-1-4

SERVICE DATA

NOZZLE AND NOZZLE HOLDER Unit: N·m {kgf·m, ft·lbf} Item Conventional type

Two-spring type

Cap nut

Tightening torque Z, D2, D3, A5, A6

39 - 49 {4.0 - 5.0, 29 - 36}

C1, F4

29 - 39 {3.0 - 4.0, 22 - 29}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

Cap nut

39 - 49 {4.0 - 5.0, 29 - 36}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

Nut

20 - 25 {2.0 - 2.5, 14 - 18}

Set screw

49 - 59 {5.0 - 6.0, 36 - 43}

Nozzle holder assembly mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

FUEL FILTER Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Fuel filter (center bolt type) center bolt Primary fuel filter center bolt

20 - 29 {2.0 - 3.0, 14 - 22} Type I

20 - 29 {2.0 - 3.0, 14 - 22}

Type II

59 - 69 {6.0 - 7.0, 43 - 51}

Primary fuel filter drain plug (Type II only)

16 - 22 {1.6 - 2.2, 12 - 16}

Fuel strainer center bolt

15 - 20 {1.5 - 2.0, 11 - 14}

EF-1-5

SERVICE DATA

FUEL SYSTEM

EF-1-6

TOOLS

TOOLS Injection pump (Part numbers designated by ZEXEL) Tool name and number

Description

Measuring device 105782-4080

For measuring camshaft in the axial direction


For measuring plunger pre-stroke

Adjusting device 105782-6170

For measuring control lever angle (RLD governor)

Adjusting device 105782-6220

For measuring governor control lever


For measuring control rack travel

Timing checker 157830-3320

For testing timer advance angle

Sensor 157830-3420

EF-2-1

Shape


Description

Lamp 157830-3520

Holder 157842-5220

For testing timer advance angle Cut the reflection plate to a size of 5.0 x 7.0 mm (0.197 x 0.276 in)

Reflection plate 157951-1100

Handle 157910-1120

Used together with socket wrench and special wrench

Socket wrench 157914-0500

For dismounting and mounting delivery valve holder

Wrench 157915-0100

For dismounting and mounting flyweight fixing nut

Socket wrench 157914-0300

For dismounting and mounting round nut (SA type timer)

EF-2-2

Shape

TOOLS


Description

Wrench 157915-0300

For dismounting and mounting round nut (SAG type timer)

Spanner 157916-4620

For fixing coupling for timer

Extractor 157926-6210

For removing timer assembly

Seal guide 157920-5400

For protecting lip of camshaft oil seal

Tappet insert 157921-0120

For inserting tappet assembly

Plunger insert 157921-5620

For inserting plunger


For removing oil seal


For removing bearing

EF-2-3

Shape


Description


For removing flyweight

Holder 157931-2500

For holding tappet

Holder 157931-4100

For holding plunger spring

Tappet inserter 157931-6120

For installing tappet

Universal vise assembly 105794-0090 Vise 157944-8520 Bracket 197944-8720

For disassembling and reassembling pump vise

Lock 157976-3100

For locking control rack

Wrench 157916-2620

For adjusting idling (RAD and RFD governors)

EF-2-4

Shape

TOOLS


Description

Wrench 157913-3520

For adjusting boost compensator stroke

Wrench 157913-3620

For adjusting governor torque cam (RLD governor)

Wrench 157913-5320

For adjusting governor shaft (RLD governor)

Wrench 157913-5400

For adjusting idling (RLD governor)

Rod 157923-5800 [18 mm, (0.71 in)] dia. 157923-5900 [22 mm, 0.87 in)] dia. 157923-6000 [26 mm, (1.02 in)] dia.

For press-fitting plate plug (RLD governor)

Plug 029111-4050

For adjusting injection timing (M14 x 1.5) (RLD governor)


For measuring the load control lever angle (RAD governor)

EF-2-5

Shape

TOOLS


Description


For measuring control rack

Coupling 105784-0510

For measuring timing device advance angle

Coupling 157842-4420

For driving injection pump

Box wrench 157916-2800

For removing and installing timing device round nut

Spanner 157916-5420

For fixing timing device and pump coupling


For removing governor flyweight

EF-2-6

Shape

TOOLS

Tool name and number Tappet holder 157931-7320 Pin 157931-7300 Holder 157931-7400

Description

Shape

For holding tappet

Timer (Part numbers designated by ZEXEL) SAG type Tool name and number

Description

Base 157924-2520

For disassembling and reassembling the timer

Spring compressor 157921-9820

For disassembling and reassembling the flyweight assembly

Shape

SA type Tool name and number

Description

Block 157924-0800

For inserting the oil seal on the flange side

Thrust bushing 157924-0500

For disassembling the timer

EF-2-7

Shape

TOOLS


Description

Guide 157924-0900

For inserting the oil seal on timer case side

Guide bolt 157924-1100

For inserting the oil seal

Oil seal guide 157924-0700

For inserting the oil seal

Guide bushing 157924-1200

For inserting the oil seal on flange side

Guide bushing 157924-1300 or 157924-1400

For inserting the oil seal on timer case side

Supporter 157932-0100

For supporting the timer spring

Bolt 029001-2220

For reassembling the timer

Washer 029301-2260

Band spanner 157916-6120

For removing or installing the timer case

EF-2-8

Shape

TOOLS


Description

Base 157924-0110

For disassembling and reassembling the timer

Guide bolt 157924-0300


Guide 157924-0400


Thrust bushing 157924-1500

For inserting the oil seal on flange and timer case side

Shape

Nozzle and nozzle holder Tool name and number

Description

Pin vise 99727 Z5005

For cleaning nozzle injection hole

Nozzle cleaner 99726 Z5000

Used to remove carbon from rear of nozzle

* Nozzle tester 105785-0960

Used to measure nozzle opening pressure and to check spray characteristics and oil leakage from nozzle seat (Conventional type)

* Nozzle tester 105785-1010

Used to confirm the first and second valve opening pressures (regulated pressures) of the nozzle Used to bleed air from the retaining nut and to check fuel leakage (Two-spring type)

* Part numbers designated by ZEXEL

EF-2-9

Shape

TOOLS


Description

* Plate 157944-9520

For fixing nozzle holder

Retaining nut 157892-2020 (1) 157892-2000 (2) 026508-1140 (3) 157892-1600

Used to adjust the first valve opening pressure (regulated pressure) and the overall lift of the needle valve (Two-spring type) (1) Retaining ring (2) Gasket (3) Plug

Dial gauge 157954-3800

Used to adjust the pre-lift and the overall lift of the needle valve (Two-spring type)

Pin 157892-1100

Used to adjust the pre-lift (Two-spring type) L = 60.5 mm (2.382 in)

Pin 157892-1200

Used to adjust the overall lift of the needle valve (Two-spring type)

Base 157892-1800

Used to adjust the pre-lift (Two-spring type)

Adjusting device 105789-0560 (1) 157892-0220 (2) 157892-1320

Used to adjust the pre-lift and the overall lift of the needle valve (Two-spring type) (1) Adjusting device (2) Connector

* Part numbers designated by ZEXEL

EF-2-10

Shape

- MEMO -

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

= FE6A, FE6B, FE6T AND FE6TA [173 kW {235 PS}] = INJECTION PUMP ASSEMBLY INJECTION PUMP PROPER DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Gasket + 2. Cover 3. Eyebolt 4. Gasket 5. Adapter 6. Overflow valve 7. Gasket 8. Adapter + 9. Plug 10. Bearing cover 11. O-ring 12. Oil seal

,+ 13. Camshaft + 14. Ball bearing 15. Shim 16. Ring 17. Gasket 18. Center bearing ,+ 19. Tappet assembly 20. Shim 21. Spring seat 22. Plunger spring 23. Upper spring seat

24. Control sleeve 25. Lock plate + 26. Delivery valve holder 27. O-ring 28. Stopper 29. Delivery valve spring 30. Gasket 31. Delivery valve , 32. Plunger assembly 33. Rack limiter 34. Rack guide screw , 35. Control rack


EF-3-1


Key point of disassembly Set the injection pump on the universal vise assembly (1057940090).

2 Cover Remove the pump cover plate and, using the special wrench (157916-4620), turn the camshaft. When the tappet reaches top dead center, insert the tappet holder (157931-7320) into the tappet hole, so that the tappet can be released from the cam.

9 Plug Remove the screw plug at bottom of the housing using the handle (157910-1120).

13 Camshaft Rotate the camshaft until its drive side key groove is facing vertically upward. Then attach the seal guide (157920-5400) to the camshaft.

14 Ball bearing 1. Use the extractor (159725-0520) and remove the outer race from the bearing cover. Install the outer race extractor and tighten the nut to force the flared portion of the tool between the outer race and the oil seal. Hold the bearing cover and tap the tool with a hammer.

EF-3-2

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 2.

Place the extractor (157925-6520) over the inner race of the bearing and pull the inner race from the camshaft. At the same time remove the shim plate and washer.

19 Tappet assembly 1. Insert the tappet insert (157921-0120) from the screw plug hole, compress the plunger spring by pushing the tappet up and pull the plunger spring holder out.

2.

After pulling the tappet holder, insert the tappet inserter (157931-6120) from the bearing insertion hole of the pump housing and pull the tappet out with the shim.

3.

After removing the tappet, insert the plunger insert (1579215620) from the screw plug hole and pull the plunger with the lower spring seat.

26 Delivery valve holder Using a socket wrench (157914-0500), remove the delivery valve holder, stopper and delivery spring.

EF-3-3

A, B, T, TA 173 kW {235 PS}


Key point of reassembly Before assembling the fuel injection pump, clean parts thoroughly and apply a thin coat of engine oil to rotating and sliding parts.

35 Control rack Tilt the pump housing onto its side and set the punch mark at both sides of the control rack to the same dimension from the ends of the pump housing.

32 Plunger assembly Install the plunger to the special tool plunger insert (157921-5620) and assemble to the barrel. At this time, the lower spring seat must be installed to the plunger. NOTE z Since the plunger and barrel are precision manufactured as pair, they must not be matched with those of another cylinder. z Assemble the plunger with the matching mark facing the front (cover side) of the pump housing.

19 Tappet assembly Assemble the tappet to the pump housing using the tappet inserter (157931-6120) and tappet insert (157921-0120) the same as when disassembling. Push the tappet itself forcefully and install the tappet holder.

13 Camshaft 1. Install the camshaft, together with the center bearing, to the pump housing so that the “assembly mark” is at the timer side. (This work can be facilitated by coating the center bearing with a small amount of grease and sticking it to the camshaft.)

EF-3-4

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 2. Install the bearing cover to the pump housing. NOTE z Since the oil seal may be damaged by the key groove of the camshaft when installing the bearing cover, install the seal guide (157920-5400) to the threaded part of the camshaft.

3.

Measure the end play of the camshaft with the measuring device (105782-4080). Adjust the end play by changing the thickness of the adjusting shim at the inside of the bearing. In this case, first measure the end play of the camshaft with the measuring device and then adjust to 0 to 0.02 mm (0 to 0.0008 in) dividing the end play equally at the front and rear with the shim. Unit: mm (in)

4.


Service limit

0 - 0.02 (0 - 0.0008)

0.1 (0.004)

After injection pump reassembly, use a spring balance to check that the control rack moves smoothly over its complete stroke. Unit: N {g, oz} Item


Service limit

Sliding resistance of control rack

—

Less than 1.471 {150, 5.29}

Remarks When static

5.

Ensure control rack stroke is 21.0 mm (0.827 in), from the position where the control rack is fully pushed toward the governor to the position where it is fully pulled toward the drive side. Use a vernier caliper or depth gauge to perform measurement. NOTE z If the control rack stroke is not within 21.0 mm (0.827 in) reengage the control pinion with the control rack to obtain the control rack stroke of 21.0 mm (0.827 in).

EF-3-5

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

FEED PUMP CONSTRUCTION

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Priming pump 2. O-ring 3. Spring 4. Valve 5. Eyebolt 6. Eyebolt

7. Adapter 8. Gasket 9. Spring 10. Valve 11. Plug

12. Gasket 13. Piston spring 14. Piston 15. Straight pin 16. Housing

EF-3-6


TIMER CONSTRUCTION SAG type

SA type

EF-3-7

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

DISASSEMBLY AND REASSEMBLY SAG type


,+ ,+ , ,

1. Plug 2. Gasket 3. Screw 4. Cover 5. Flange 6. Eccentric cam (large) 7. Eccentric cam (small)

+ 8. Snap ring 9. Seat 10. Shim 11. Shim 12. Spring 13. Spring

14. Seat 15. Pilot pin 16. Spacer , 17. Flyweight 18. O-ring 19. Housing


Key point of disassembly 1.

Using a socket wrench (157915-0300), handle (1579101120) and special wrench (157916-4620), remove the round nut and then remove the timer assembly, using an extractor (157926-6210).

EF-3-8


Record the relationship between the housing punch mark and the location of the holder key groove before disassembly.

3.

Clamp the base (157924-2520) in a vise and set it on the timer assembly.

4 Cover Remove the six screws holding the cover and then remove the cover. NOTE z At this time, be careful not to damage the lip of the oil seal.

5 Flange Remove the holder together with the flyweight assembly from the housing. NOTE z Sometimes large and small cams may be left in the housing. Do not change the order of those cams at this time. Install them in the holder correctly, and note the directions and locations of the key groove and cams. 8 Snap ring Compress springs using the spring compressor (157921-9820) and draw out the snap ring.

EF-3-9

A, B, T, TA 173 kW {235 PS}


Key point of reassembly Install large and small cams in the position specified. The specified position for cams can be identified by the Bosch No. marked on the outer periphery of the housing.

17 Flyweight Install the flyweight as shown in the figure so that the holder key groove faces the upper portion, and the right-hand flyweight pin faces the upper portion. (The left-hand flyweight pin will face the bottom portion.)

6, 7 Eccentric cam 1. Install the large and small cams in each specified position. Large cams: t1 is wider than t2 Small cams: t3 is narrow

2.

Measure the pitch of the housing pin.

3.

Set the pitch of the small cam housing pin hole to the measured value found in step 2.

EF-3-10

A, B, T, TA 173 kW {235 PS}


Make sure that the distance between both the small cam hole and holder center is the same. NOTE z If not, repeat step 2.

5 Flange 1. With both housing punch mark and holder key groove in position, install the housing into the holder. At this time, be careful not to damage the oil seal. NOTE z If the housing pin cannot be inserted into the small cam hole, repeat step 1 and subsequent steps.

2.

Check that cams are assembled correctly. The figure shows the cams from the cover side.

4 Cover Lubrication of timing device. Lubricating oil: Mobil oil #20 Oil level: Approximately 1 mm (0.04 in) below the upper surface of flyweights.

EF-3-11

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

SA type

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Plug 2. Gasket ,+ 3. Timer case 4. Oil seal

5. O-ring , 6. Flange 7. Timer spring , 8. Adjusting shim

9. Flyweight , 10. Oil seal 11. Flyweight holder


Key point of disassembly Using a socket wrench (157914-0300), handle (157910-1120) and special wrench (157916-4620), remove the round nut and then remove the timer assembly, using an extractor (157926-6210).

EF-3-12

INJECTION PUMP ASSEMBLY 3 Timer case 1. Clamp the base (157924-0110) in a vise and thread in the guide bolt (157924-0300).

2. 3.

Remove one of the screw from the flyweight holder. Attach the flyweight to the base (157924-0110) and secure with the guide (157924-0400). Unscrew the staked section of the timer case and flyweight holder. Remove the timer case by turning it clockwise with the band spanner (157916-6120).

Key point of reassembly 1.

Clamp the base (157924-0110) in a vise and install in the guide bolt (157924-1100).

2.

Place the block (157924-0800) over the base pin.

3.

Fit the oil seal to the flange hole. With the guide bushing (157924-1200) intervening, thread in the thrust bushing (157924-1500) to force in the oil seal.

EF-3-13

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 10 Oil seal 1. Clamp the base (157924-0110) in a vise and install the guide bolt (157924-1100). 2. Place the block (157924-0800) over the base and install the guide (157924-0900).

3.

Insert the oil seal, fit the guide bushing (157924-1300 or 157924-1400), and thread in the thrust bushing (1579241500), completing the job.

8 Adjusting shim 1. Clamp the base (157924-0110) in a vise and install the guide bolt (157924-0300). 2. Place the flyweight holder over the pin of the base (1579240110) and fit the rubber ring.

3.

Insert the adjusting shim at one end of the timer spring at the seat portion of the flyweight holder pin. Insert the supporter (157932-0100) beneath the spring, and thread the guide (157924-0400) over the guide bolt.

6 Flange Mount the flange, apply a special wrench (157916-4620) to the flange claw, and fit the thrust bushing (157924-0500), washer (029301-2260), and bolt (029001-2220) to the flange.

EF-3-14

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 3 Timer case Position the oil seal guide (157924-0700). Install the timer case and tighten it with the band spanner (157916-6120).

EF-3-15

A, B, T, TA 173 kW {235 PS}


GOVERNOR DISASSEMBLY AND REASSEMBLY RAD type

EF-3-16

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Bracket 2. Cover 3. O-ring 4. Cap nut 5. Gasket 6. Cap nut 7. Gasket 8. Damper spring 9. Plug 10. Gasket 11. Idling stopper bolt 12. Full-load stopper bolt 13. Control lever 14. Shim 15. Oil seal 16. Bushing 17. Plug 18. Tension lever shaft 19. Plug

, 20. Governor cover assembly 21. Gasket 22. Speed adjusting bolt 23. Spring 24. Tube 25. Torque control spring assembly 26. Nut + 27. Idling spring assembly 28. Stroke adjusting bolt 29. Tension lever 30. Speed setting lever 31. Governor spring 32. Guide lever assembly 33. Lever shaft 34. Snap ring 35. Snap ring 36. Spring seat 37. Spring seat

38. Snap ring 39. Floating lever 40. Collar 41. Shim 42. Sleeve assembly 43. Rack limiter 44. Start spring 45. Spring eye + 46. Round nut 47. Lock washer ,+ 48. Flyweight assembly 49. Key 50. Snap ring 51. Governor housing 52. Gasket 53. Impeller 54. Adapter 55. Control lever


Key point of disassembly 20 Governor cover assembly 1. Removal of governor cover assembly z Remove the governor shaft plate plug (1) then loosen the lock nut with the wrench (157913-5320).

z

Remove the idling spring plate plug (2) then loosen the lock nut with the wrench (157913-5400). Next, use a Phillips screwdriver to remove the idling spring assembly.

EF-3-17


Using a Phillips screwdriver, remove the seven bolts to separate the governor cover from the governor housing. Then remove the governor cover. NOTE z Be sure to keep an oil pan under the governor to receive lubricating oil.

27 Idling spring assembly Loosen the lock nut with a socket wrench (157914-0500) and handle (157910-1120). Then loosen the nut and remove the idling spring assembly.

46 Round nut, 48 Flyweight assembly 1. Using the special wrench (157916-4620), hold the timer so that the camshaft will not turn. Then, using the wrench (157915-0100) and handle (157910-1120), remove the round nut securing the flyweight.

2.

Screw the extractor (157926-5110) onto the threaded part of the flyweight holder to pull out the flyweight assembly.

Key point of reassembly 48 Flyweight assembly Using the spanner (157916-5420), hold the timer so that the cam shaft will not turn. Then, using the wrench (157915-0100) and handle (157910-1120), install the round nut securing the flyweight.

EF-3-18

A, B, T, TA 173 kW {235 PS}

- MEMO -


RLD type

EF-3-20

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Plate plug 2. Lock nut , 3. Idling spring assembly 4. Plate plug 5. Lock nut 6. Plate plug 7. Plate plug 8. Lock nut 9. Idling-speed setting bolt 10. Maximum-speed setting bolt and lock nut 11. Spring 12. Tube 13. Support 14. Control lever 15. Adjusting shim 16. Adjusting shim 17. Oil seal 18. Bushing 19. Plate plug 20. Tension lever shaft 21. Governor cover 22. Gasket 23. Control lever shaft 24. Cancel spring 25. Supporting lever

26. Snap ring 27. Floating lever 28. Guide lever 29. Cancel spring 30. Lock screw 31. Adjusting nut 32. Spring inner 33. Spring outer 34. Rod 35. Snap ring 36. Torque cam 37. Snap ring 38. Pin 39. Tension lever 40. Shifter 41. Adjusting shim 42. Sleeve sub-assembly 43. Governor shaft 44. Spring seat 45. Governor spring outer 46. Round nut 47. Rack connecting link 48. Start spring 49. Spring eye 50. Round nut

, 51. Flyweight assembly 52. Woodruff key 53. Full-load set lever 54. Return spring 55. Shim 56. O-ring 57. Full-load lever shaft 58. Cancel spring 59. Snap ring 60. Sensor lever 61. U-shaped lever 62. Stop lever 63. Cap 64. Return spring 65. Shim 66. O-ring 67. Bushing 68. Collar 69. Shaft 70. Guide screw 71. Lock nut 72. Full-load setting bolt 73. Governor housing 74. Gasket 75. Adapter


Key point of reassembly 51 Flyweight assembly Using the special wrench (157916-4620), hold the timer so that the cam shaft will not turn. Then, using the wrench (157915-0100) and handle (157910-1120), install the lock nut securing the flyweight.

3 Idling spring assembly Install the idling spring assembly using the Phillips screwdriver and tighten the lock nut using the wrench (157913-5400).

EF-3-21


RFD type

EF-3-22

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Bracket 2. Closing cover 3. O-ring 4. Cap nut 5. Gasket 6. Damper spring 7. Plug 8. Gasket 9. Stopper bolt 10. Idling stopper bolt 11. Full load stopper bolt 12. Spring 13. Tube 14. Lock washer 15. Control lever 16. Shim 17. Oil seal 18. Bushing 19. Plug 20. Bushing

21. O-ring 22. Snap ring 23. Lever 24. Woodruff key 25. Collar 26. Shim 27. Oil seal 28. Bushing 29. O-ring 30. Snap ring 31. Plug 32. Tension lever shaft 33. Governor cover 34. Gasket 35. Governor spring 36. Swivel lever ,+ 37. Idling spring assembly 38. Stroke adjusting bolt 39. Tension lever 40. Guide lever assembly

41. Lever shaft 42. Sliding lever 43. Snap ring 44. Snap ring 45. Floating lever 46. Collar 47. Smoke limiter 48. Adjusting shim 49. Sleeve assembly 50. Start spring 51. Spring eye 52. Round nut ,+ 53. Flyweight assembly 54. Control lever 55. Stopper bolt 56. Governor housing 57. Impeller 58. Adapter 59. Gasket


Key point of disassembly 37 Idling spring assembly Loosen the lock nut with a socket wrench (157914-0500), and remove the idling spring assembly.

53 Flyweight assembly 1. Using a box wrench (157916-2800) and handle (1579101120), remove the round nut and then remove timer assembly using an extractor (157926-6210). 2. Attach the coupling (151842-4420) for disassembly and reassembly to the pump camshaft.

3.

Hold the timer, using a special wrench (157916-4620), and remove the round nut from the flyweight side, using a wrench (157915-0100) and handle (157910-1120).

EF-3-23


Screw the extractor (157926-5110) onto the threaded part of the flyweight holder to pull out the flyweight assembly.

Key point of reassembly 53 Flyweight assembly 1. Hold the timer, using a spanner (157916-5420).

2.

Using the wrench (157915-0100) and torque wrench, tighten the flyweight with the lock washer and round nut.

37 Idling spring assembly Install the idling spring assembly with the socket wrench (1579140500) and handle (157910-1120).

ADJUSTMENT When the injection pump has been disassembled, plungers or plunger springs have been replaced, or other reasons exist, use a pump tester and adjust the injection pump.

EF-3-24

A, B, T, TA 173 kW {235 PS}


Injection pump preparations Remove the cap of the control rack and install the measuring device (105782-6280).

INITIAL INJECTION TIMING ADJUSTMENT The start of injection is considered as the time at which the top of the plunger covers the fuel intake hole of the barrel. The pump tester must be capable of developing a pressure in the range of 2,942 to 3,923 kPa {30 to 40 kgf/cm2, 427 to 569 psi} in order to overcome tension of the delivery valve spring (to force the delivery valve open).

Adjusting the injection timing of the standard cylinder 1. 2. 3.

Fix the control rack to full rack position. Removing the 1st cylinder delivery valve holder. To do this, use the socket wrench (157914-0500). Install the measuring device (105782-4330) to the No. 1 cylinder as viewed from the drive side.

EF-3-25

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 4. 5. 6.

7.

8.

Set the tappet to top dead center of the camshaft and set the scale of the dial gauge to “0”. Loosen the bleeder screw of the pump and bleed the air from the fuel system. When the drive shaft of the tester is slowly turned in the drive direction while feeding fuel to the fuel inlet of the pump, the fuel will stop flowing from the pipe of the test use nozzle holder. This is the injection start position. The injection timing is normal if the tappet has risen by the specified value from bottom dead center. When the flow of fuel does not stop when the tappet has been lifted within 3.35 to 3.45 mm (0.1319 to 0.1358 in) from bottom dead center, adjust the adjusting shim using the plunger spring holder (157931-4100). When the fuel flow stops before the tappet is raised 3.45 mm (0.1358 in), add adjusting shims until the fuel flow stops at a life of 3.35 mm (0.1319 in).

Adjusting injection interval 1.

2.

After completing adjustment of initial injection timing of the reference No. 1 cylinder (timer side), turn the camshaft to the right (as viewed from the drive end) and set the injection interval for the remaining cylinders by adjusting shims. See the table below. Adjust the cylinder injection intervals within ±30’

Injection order ...........................

1

—

4

—

2

—

6

—

3

—

5

—

1

Injection interval........................

| | |

60º

| | |

60º

| | |

60º

| | |

60º

| | |

60º

| | |

60º

| | |

Scale plate indication................

0º

—

60º — 120º — 180º — 240º — 300º — 360º

EF-3-26

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

FUEL INJECTION QUANTITY ADJUSTMENT Testing conditions Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is evident. In calibrating a pump, observe the following: Item

Test condition

Nozzle

105780-0000 (BOSCH Type No. DN12SD12T)

Nozzle holder

105780-2080 (BOSCH Type No. EF8511/9)

Nozzle opening pressure

kPa {kgf/cm2, psi}

17,162 {175, 2,489}

Feed pump oil pressure

kPa {kgf/cm2, psi}

157 {1.6, 23}

Injection pipe (OD x ID – L)

mm (in)

6 x 2 – 600 (0.24 x 0.08 – 23.62)

Test oil

IS04113 or SAE standard test oil (SAE J967d)

Test oil temperature

ºC (ºF)

40 - 45 (104 - 113)

Injection quantity standards (“ZEXEL No.” is Inj. Pump ass’y No.) RAD governor z

ZEXEL No. 101607-9351 Adjusting point

Rack position mm (in)

Pump speed rpm

Injection q’ty milliliter (Imp fl oz)/ 1,000 strokes

Max. var. bet. cyl. (%)

Fixed

A

8.2 (0.323)

600

42±1 (1.48±0.04)

±3.5

Lever

B

8.0 (0.315)

1,000

53±1 (1.9±0.04)

±10

Lever

Approx. 7.0 (0.276)

300

9±1.8 (0.32±0.06)

±10

Rack

Adjust max. var. bet. cyl. at R 7.0 mm (0.276 in). Adjust governor as per gov. adj. spec.

—

100

Above 80 (2.8)

—

Lever

After setting excessive fuel for starting

D z

Remarks Basic



Pump speed rpm



Fixed

A

9.8 (0.386)

600

58.9±1 (2.07±0.04)

±3.5

Lever

B

R1 [10.0 (0.394)]

1,500

80.6±1 (2.84±0.04)

±5

Lever

C

Approx. 7.9 (0.311)

300

8.3±1.8 (0.29±0.06)

±10

Rack

D

—

100

Above 80 (2.8)

—

Lever

EF-3-27

Remarks Basic



A, B, T, TA 173 kW {235 PS}

RLD governor z

ZEXEL No. 101607-9270 Rack position mm (in)

Pump speed rpm



Fixed

11.3 (0.445)

600

48.2±1.6 (1.70±0.06)

±3.5

Rack

Basic

Approx. 9.8 (0.386)

300

9±1.8 (0.32±0.06)

±10

Rack


A

R1 [11.3 (0.445)]

600

48.2±1 (1.70±0.04)

—

Lever

B

R1 –0.2 (–0.008)

1,000

[62.0 - 65.2 (2.2 2.3)]

—

Lever

I

—

100

80+10 (2.8+0.4)

—

Lever

Adjusting point

z

Rack limit


Pump speed rpm



Fixed

12.6 (0.496)

1,500

77.5±1.6 (2.73±0.06)

±3.5

Rack

Basic

Approx. 9.7 (0.382)

300

9.5±1.8 (0.33±0.06)

±10

Rack


A

R1 [12.6 (0.496)]

1,500

77.5±1 (2.73±0.04)

—

Lever

Basic

B

R1 –1.65 (–0.0650)

600

[40 - 44 (1.4 - 1.55)]

—

Lever

I

—

150

77.5+20 (2.73+0.7)

—

Lever

Adjusting point

z

Remarks

Remarks

Rack limit


Pump speed rpm



Fixed

11.8 (0.465)

600

66.3±1.6 (2.33±0.06)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [11.8 (0.465)]

600

66.3±1 (2.33±0.04)

—

Lever

B

R1 –0.2 (–0.008)

900

[71.4 - 74.6 (2.51 - 2.63)]

—

Lever

C

R1 [11.8 (0.465)]

1,500

[81.9 - 85.9 (2.88 - 3.02)]

—

Lever

I

—

100

84+10 (3.0+0.4)

—

Lever

Adjusting point

EF-3-28

Remarks Basic

Basic

Rack limit

INJECTION PUMP ASSEMBLY z


Pump speed rpm



Fixed

12.5 (0.492)

1,500

83.7±1.6 (2.95±0.06)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.5 (0.492)]

1,500

83.7±1 (2.95±0.04)

—

Lever

B

R1 –0.55 (–0.0217)

900

68.7±2 (2.42±0.07)

—

Lever

I

—

150

85+20 (3.0+0.7)

—

Lever

Adjusting point

z

Remarks Basic

Basic

Rack limit


Pump speed rpm



Fixed

12.5 (0.492)

1,500

83.7±1.6 (2.95±0.06)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.5 (0.492)]

1,500

83.7±1 (2.95±0.04)

—

Lever

Basic Boost press. kPa {mmHg, inHg} Above 23.3 {175, 6.89}

B

R1 –0.55 (–0.0217)

900

68.7±2 (2.42±0.07)

—

Lever

Boost press. kPa {mmHg, inHg} Above 23.3 {175, 6.89}

I

—

150

85+20 (3.0+0.7)

—

Lever

Boost press. 0 Rack limit

Adjusting point

z

A, B, T, TA 173 kW {235 PS}

Remarks Basic


Pump speed rpm



Fixed

12.4 (0.488)

700

77.5±2 (2.73±0.07)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.4 (0.488)]

700

77.5±1 (2.73±0.04)

—

Lever


B

R1 +0.15 (+0.0059)

1,400

[89.4 - 92.6 (3.15 3.26)]

—

Lever


C

R2 [R1 –0.3 (–0.012)]

550

[66.9 - 70.1 (2.35 2.47)]

—

Lever


D

R2 –0.9 (–0.035)

550

[46.5 - 48.5 (1.64 1.71)]

—

Lever

Boost press. 0

I

—

150

85+20 (3.0+0.7)

—

Lever


Adjusting point

EF-3-29

Remarks Basic



Pump speed rpm



Fixed

12.4 (0.488)

700

77.5±2 (2.73±0.07)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.4 (0.488)]

700

77.5±1 (2.73±0.04)

—

Lever


B

R1 +0.15 (+0.0059)

1,400

[89.4 - 92.6 (3.15 3.26)]

—

Lever


C

R2 [R1 –0.3 (–0.012)]

550

[66.9 - 70.1 (2.35 2.47)]

—

Lever


D

R2 –0.6 (–0.024)

550

[53.5 - 55.5 (1.88 1.95)]

—

Lever

Boost press. 0

I

—

150

84+20 (3.0+0.7)

—

Lever


Adjusting point

z

Remarks Basic


Pump speed rpm



Fixed

12.5 (0.492)

1,500

83.7±1.6 (2.95±0.06)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.5 (0.492)]

1,500

83.7±1 (2.95±0.04)

—

Lever

B

R1 –0.55 (–0.0217)

900

68.7±2 (2.42±0.07)

—

Lever

I

—

150

85+20 (3.0+0.7)

—

Lever

Adjusting point

z

A, B, T, TA 173 kW {235 PS}

Remarks Basic

Basic

Rack limit


Pump speed rpm



Fixed

13.3 (0.524)

700

97.5±2 (3.43±0.07)

±3.5

Rack

Basic

Approx. 10.1 (0.398)

275

10±1.8 (0.35±0.06)

±10

Rack


A

R1 [13.3 (0.524)]

700

97.5±1 (3.43±0.04)

—

Lever


B

R1 +0.1 (+0.004)

1,400

[102.9 - 106.1 (3.62 3.73)]

—

Lever


C

R1 –2.0 (–0.079)

700

[56.5 - 58.5 (1.99 2.06)]

—

Lever

Boost press. 0

I

—

150

85+20 (3.0+0.7)

—

Lever


Adjusting point

EF-3-30

Remarks


A, B, T, TA 173 kW {235 PS}


Pump speed rpm



Fixed

13.3 (0.524)

700

97.5±2 (3.43±0.07)

±3.5

Rack

Basic

Approx. 10.1 (0.398)

275

10±1.8 (0.35±0.06)

±10

Rack


A

R1 [13.3 (0.524)]

700

97.5±1 (3.43±0.04)

—

Lever


B

R1 +0.1 (+0.004)

1,400

[102.9 - 106.1 (3.62 3.73)]

—

Lever


C

R1 –2.0 (–0.079)

700

[56.5 - 58.5 (1.99 2.06)]

—

Lever

Boost press. 0

I

—

150

85+20 (2.8+0.7)

—

Lever


Pump speed rpm



Fixed

Adjusting point

Remarks

RFD governor z



A

8.1 (0.319)

600

42.2±1 (1.49±0.04)

±3.5

Lever

B

7.8 (0.307)

1,000

53.3±1 (1.88±0.04)

±10

Lever

Approx. 7.0 (0.276)

300

9±1.8 (0.32±0.06)

±10

Rack


—

100

Above 80 (2.8)

—

Lever


D z

Remarks Basic



Pump speed rpm



Fixed

A

9.8 (0.386)

600

58.9±1 (2.07±0.04)

±3.5

Lever

B

R1 [10.0 (0.394)]

1,500

80.6±1 (2.84±0.04)

±5

Lever

C

Approx. 7.9 (0.311)

300

8.3±1.8 (0.29±0.06)

±10

Rack

D

—

100

Above 80 (2.8)

—

Lever

EF-3-31

Remarks Basic



A, B, T, TA 173 kW {235 PS}

RLD governor z


Pump speed rpm



Fixed

11.8 (0.465)

600

66.3±1.6 (2.33±0.06)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [11.8 (0.465)]

600

66.3±1 (2.33±0.04)

—

Lever

B

R1 –0.2 (–0.008)

900

[73±1.6 (2.57±0.06)]

—

Lever

C

R1 [11.8 (0.465)]

1,500

[83.9±2 (2.95±0.07)]

—

Lever

I

—

100

84+10 (3.0+0.4)

—

Lever

Adjusting point

z

Remarks Basic

Basic

Rack limit


Pump speed rpm



Fixed

12.4 (0.488)

700

86.4±2 (3.04±0.07)

±3.5

Rack

H

Approx. 9.5 (0.374)

300

9.5±1.8 (0.33±0.06)

±10

Rack

A

R1 [12.4 (0.488)]

700

86.4±1 (3.04±0.04)

—

Lever


B

R1 +0.15 (+0.0059)

1,400

[86.5±1.6 (3.04±0.06)]

—

Lever


C

R2 [R1 –0.3 (–0.012)]

550

[76±1.6 (2.68±0.06)]

—

Lever


D

R2 –0.6 (–0.024)

550

[65±1 (2.29±0.04)]

—

Lever

Boost press. 0

I

—

150

90+20 (3.2+0.7)

—

Lever


Adjusting point

EF-3-32

Remarks Basic



Pump speed rpm



Fixed

13.6 (0.535)

700

92.5±2 (3.26±0.07)

±3.5

Rack

H

Approx. 9.7 (0.382)

275

17±1.8 (0.60±0.06)

±10

Rack

A

R1 [13.6 (0.535)]

700

92.5±1 (3.26±0.04)

—

Lever

B

[R1 +0.3 +0.05 –0.15 (+0.0118 +0.0020 –0.0059 )]

1,400

[99.5±1.6 (3.50±0.06)]

—

Lever

C

R2 [R1 –0.2 (–0.008)]

420

[80±1.6 (2.82±0.06)]

—

Lever


D

R2 –1.8 (–0.071)

420

[46±1 (1.62±0.04)]

—

Lever

Boost press. 0

I

—

150

105+20 (3.7+0.7)

—

Lever


Adjusting point

z

A, B, T, TA 173 kW {235 PS}

Remarks Basic

Basic Boost press. kPa {mmHg, inHg} Above 40.0 {300, 11.81} Boost press. kPa {mmHg, inHg} Above 40.0 {300, 11.81}


Pump speed rpm



Fixed

13.6 (0.535)

700

92.5±2 (3.26±0.07)

±3.5

Rack

H

Approx. 9.7 (0.382)

275

17±1.8 (0.60±0.06)

±10

Rack

A

R1 [13.6 (0.535)]

700

92.5±1 (3.26±0.04)

—

Lever

B

[R1 +0.3 +0.05 –0.15 (+0.0118 +0.0020 –0.0059 )]

1,400

[99.5±1.6 (3.50±0.06)]

—

Lever

C

R2 [R1 –0.2 (–0.008)]

420

[80±1.6 (2.82±0.06)]

—

Lever


D

R2 –1.15 (–0.0453)

420

[56.5±1 (1.99±0.04)]

—

Lever

Boost press. 0

I

—

150

105+20 (3.7+0.7)

—

Lever


Adjusting point

EF-3-33

Remarks Basic

Basic Boost press. kPa {mmHg, inHg} Above 28.7 {215, 8.46} Boost press. kPa {mmHg, inHg} Above 28.7 {215, 8.46}


Injection quantity adjustment procedure 1.

Check the control rack “0” position.

2. 3.

Remove the control rack guide screw. Attach the lock screw instead of the control rack guide screw (to secure the control rack) to the pump housing.

4.

Set the pump speed, control rack position and plunger strokes as specified in the service data. 5. Measure the fuel injection quantity for each cylinder. If the fuel injection quantity is not as specified, adjust as follows. (1) Loosen the control pinion clamp screw.

(2) Rotate the control sleeve clockwise or counterclockwise using an appropriate tool. The control sleeve is rotated toward the governor side to increase fuel injection quantity.

EF-3-34

A, B, T, TA 173 kW {235 PS}


GOVERNOR ADJUSTMENT This section is divided into 3 parts according to the governor type. Each part describes the general adjustment procedure first and then each governor’s performance chart.

RAD type Preparations 1. Mount the injection pump assembly securely on a pump test stand. Then, attach the test nozzle and nozzle holder assembly, test lines and measuring device to measure control rack travel, to the injection pump. 2. Remove the damper spring, cover, torque control spring using a socket wrench (157914-0500) and Idling spring. Loosen adjusting screw.

3.

Fill governor chamber and camshaft chamber with injection pump oil. Cam chamber: 15 milliliter (0.5 Imp fl oz) for every cylinder Governor chamber: 200 milliliter (7.0 Imp fl oz)

4.

Mount a measuring device (105782-6030) to measure the load control lever angle.

5.

With injection pump “off”, ensure that control rack travels smoothly by moving load control lever in both “fuelincrease” and “fuel-decrease” directions.

EF-3-35

A, B, T, TA 173 kW {235 PS}


Setting the control rack zero point 1.

After fixing load control lever in the “idling” position, temporarily set speed adjusting screw so that governor begins to move the control rack in the “fuel-decrease” direction at pump speed of 500 to 600 rpm.

2.

Increase the pump speed so that the control rack travels to the non-injection position. Then, press the control pinion with a screw driver until control rack stops. Make this position the “zero” point of the control rack, and set the measuring device pointer to correspond with “zero” of the scale. NOTE z The operation of the stopping lever will not cause the control rack to travel to “zero” point.

Flyweight lift and full load position The total lift of the flyweight is divided into two categories; one for high-speed control and the other for idling control. Firstly, adjust the flyweight lift for high-speed control. 1. Fix the load control lever at “full” position (control rack position “Rb”), and temporarily set speed setting screw so that governor begins to move the control rack in the “fueldecrease” direction at pump speed of 700 to 800 rpm.

2.

While raising pump speed to “Na”, make adjustments by means of full-load stopper bolt so that control rack position corresponds with “Ra”. NOTE z The control rack position “Ra” equals control rack position “Rb” minus the travel “L”. z If “Ra” is below “zero”, set the control rack to the “Ra plus 2.0 mm (0.079 in)” position. 3.

Next, decrease pump speed to “Nb” and, by means of stroke adjusting screw adjust flyweight lift for high-speed control “L” (control rack position “Rb”). NOTE z If the control rack is set to the “Ra plus 2.0 mm (0.079 in)” position in Step 2, set the stroke adjusting screw to the “Rb plus 2.0 mm (0.079 in)” position.

EF-3-36

A, B, T, TA 173 kW {235 PS}


4.

Readjust the full-load stopper bolt to the “full-load fuel injection quantity” position according to the service data.

Idling 1. 2.

Run injection pump at “Nc” (Nd plus 100 rpm) rpm. Make adjustments by means of idling adjusting screw, so that control rack position corresponds with “Rc”.

3. 4.

Decrease pump speed so as to maintain “Ne” rpm. Incorporate idling spring assembly into tension lever. Screw in the assembly until control rack position corresponds with “Rd”, and then lock it at this point, with a wrench (1579162620). NOTE z At this time, pump speed may sometimes drop. Ascertain that “Ne” rpm is maintained.

EF-3-37

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 5. 6.

7. z

z

A, B, T, TA 173 kW {235 PS}

Make sure control rack position remains above “Re” even when pump speed is decreased to 0 rpm. Next, increase pump speed slowly and ensure that when control rack reaches position “Rc” the corresponding speed is “Nd” rpm.

Measure the load control lever angle at the idling position. When load control lever is depressed toward the “full” position side, replace shifter shim with a thicker one. When load control lever is depressed toward the “idling” position side, replace shifter shim with a thinner one.

Damper spring 1. 2.

Fix the load control lever at “idling” control position. Increase pump speed slowly from “idling” speed (Ne rpm) to the speed where control rack position corresponds with Rf minus 0.2 mm (0.008 in), and maintain this speed.

ZEF109A

3.

Screw in damper spring until control rack position corresponds with Rf minus 0.1 mm (0.004 in) and lock the spring at this point.

EF-3-38


Stopper bolt If idling performance is included in service data, as represented by dotted line, adjust stopper bolt setting. 1. After setting damper spring when pump speed is decreased to 0 rpm, control rack position moves to “Re”.

2.

After loosening stopper bolt, move the load control lever until control rack position is “Rg” and set stopper bolt at this point.

High-speed control starting point and speed droop check 1. 2.

Fix the load control lever at “full” position. Raise pump speed slowly to “Nh” rpm. Make adjustments to setting screw so that control rack starts to travel from position “Rb”.

3.

Ensure by raising pump speed that it remains below “Ni” rpm when control rack position reaches “Rh”. NOTE z When “Ni” rpm exceeds the standard value, the no-load maximum speed of the engine is also increased, which is dangerous. Recheck both “Rb”, (full-load rack position) and “Rf” –0.1 mm (0.004 in), (the set position of damper spring). 4.

Further increase the pump speed to “Nj” rpm and ensure the control rack is positioned at “Ri” mm (in).

Stopping lever 1. 2. 3.

4.

Fix the load control lever at “full” position. Maintain the pump speed at approximately 800 rpm. Move the stopping lever to the “fuel-decrease” position and ensure the control rack reaches the non-injection zone [injection quantity of less than 3 milliliter (0.11 Imp fl oz) per 1,000 strokes]. Check that the control rack moves smoothly to the “fullload” position when releasing the stopping lever.

EF-3-39

A, B, T, TA 173 kW {235 PS}


Smoke limiter 1.

Attach the measuring device (105782-6090) to the plunger spring chamber.

2. 3. 4.

Fix the load control lever at “full” position. Maintain the pump speed at “Nb” rpm. Fix the measuring device scale plate with the indicator at control rack position “Rb” mm (in).

5.

Remove the measuring device (105782-6280) attached to the control rack tip and attach the smoke limiter.

6.

Maintaining the pump speed at “Nk” rpm, adjust and set the control rack in “Rj” mm position [normally “Rb” plus 0.2 mm (0.008 in) with the smoke limiter spring capsule]. Reduce the pump speed to 80 to 100 rpm, then check that the control rack position is “Rk”. Check the fuel injection quantity for “engine start” at point E.

7.

EF-3-40

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Governor adjustment diagram (“ZEXEL No.” is Inj. pump ass’y No.)

EF-3-41


RLD type Preparation Follow the instructions below to prepare for adjustment. 1. Secure the fuel injection pump on the pump test stand and fill both the governor chamber and cam chamber with lubricating oil (injection pump oil 131453-0120 is recommended).

2.

Mounting the adjusting device (105782-6170) 1) Align the mark on the supporting bracket with the matching mark on the scale plate, then tighten the locknut. NOTE z The angle scale plate has three matching marks; use any that is convenient.

2) Move the supporting bracket to position pin A over the center hole of the control lever shaft and bolt the supporting bracket. Then, insert pin B into the rod connecting hole of the control lever.

Setting the control rack’s zero position 1. 2.

Mount the control rack travel measuring device (1057826280) on the end of the control rack. Setting the control rack’s “0” position. 1) Screw in the governor shaft fully, and hold the control lever at the idling position.

2) Raise the pump speed gradually until it reaches point ((06)), where the governor spring stops operating. Then, push the rack fully in the “fuel decrease” direction. The position where it stops moving is the control rack’s “0” position. 3) Set the indicator of the measuring device’s dial gauge to “0”.

EF-3-42

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY NOTE z

The control rack of the RLD type governor-mounted fuel injection pump cannot be set at zero unless the pump is operated at point (06). If the control rack is pushed to the non-injection position while the injection pump is running at less than point (06), the governor links may be damaged.

Cautions on adjustment [Governor performance chart]

EF-3-43

A, B, T, TA 173 kW {235 PS}


2.

3.

Locking the control rack At this time it is necessary to fix the control rack. Normally, injection timing adjustment and fuel injection quantity adjustment are performed before governor adjustment. Fix the control rack according to the following procedure: Increase the pump speed to 500 to 600 rpm with the control lever held at the idling position, then shift the lever to the maximum-speed position. Next, set the control rack 3 mm (0.12 in) beyond the full-speed position using the full-load setting bolt. Various adjustments can now be made with the control rack locked in the specified position. Control lever operation Before shifting the control lever to the maximum-speed position, increase the pump speed to 500 to 600 rpm while the control lever is held at the idling position. The performance of the governor depends on the engine specifications. The performance chart given above is typical of this governor.

Idling adjustment 1.

With the pump speed maintained at 80 to 100 rpm, temporarily set the control lever so that the control rack position is Rs mm (in).

2.

Maintain pump speed at Nb rpm and screw in the idling spring assembly. When the rack position is Rb mm (in), tighten the locknut. : 18 - 22 N·m{1.8 - 2.2 kgf·m, 13 - 16 ft·lbf}

EF-3-44

A, B, T, TA 173 kW {235 PS}


Increase the pump speed until the control rack position is at Ri mm (in) and then check that the pump speed is Ni rpm. NOTE z If the pump speed Ni rpm is not as specified, adjust by altering the shim thickness. Adjusting shims Part No.

Thickness mm (in)

029310-9240 029310-9250 029310-9260 029310-9270

0.10 (0.0039) 0.20 (0.0079) 0.25 (0.0098) 1.00 (0.0394)

Remarks

ZEF119A

4.

Adjustment of the governor springs 1) Maintain pump speed at Nh1 rpm and adjust the amount the governor shaft is screwed in so that the rack position is Rh1 mm (in)].

2) Check that the control rack position is Rh2 mm (in) when the pump speed is Nh2 rpm. If it is not as specified, replace the governor springs with new ones. NOTE z The adjustment sequence may be reversed. [Set to Rh2 mm (in) at Nh2 rpm, check that speed is Nh1 rpm at Rh1 mm (in)].

5.

3) Further increase the pump speed until the control rack reaches position “0” mm (in), and ensure the pump speed is Ne rpm. Idling adjustment 1) Decrease the pump speed to Nb’ rpm and adjust the idling setting bolt so that the control rack will be at position Rc mm (in). Then lock the nut.

EF-3-45

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY 2) Further decrease the pump speed to 80 to 100 rpm, and ensure the control rack is positioned at Ra mm (in). 3) Check that the control lever angle is as specified with the adjusting device (105782-6170).

Full-load rack position adjustment When adjusting the boost compensator-equipped governor, perform the full-load rack position adjustment using the values for a boost-compensator equipped governor, as shown in the service data. 1. With the pump speed maintained at Nf rpm, temporarily set the control lever at the position where the lever contacts the maximum-speed setting bolt.

2.

Adjust the maximum-speed setting bolt so that the control rack begins moving toward the fuel decrease direction at a pump speed of Ng rpm. Then, lock the maximum-speed setting bolt with the nut.

3.

Adjust the full-load setting bolt so that the control rack position is Rf mm (in) when the pump speed is Nf rpm. NOTE z When the full-load setting bolt is turned clockwise, the control rack position value decreases.

EF-3-46

A, B, T, TA 173 kW {235 PS}


Adjusting the torque cam 1) Using wrench (157913-3620), adjust the adjusting nut so that the control rack position is Rf4 mm (in) when the pump speed is Ni rpm. Lock the adjusting nut with a lock screw. NOTE z Torque cam adjustment can be performed at a pump speed of either Nk rpm or Ni rpm, whichever is convenient.

2) Decrease the pump speed to Nj minus approximately 100 rpm, then increase it to Ng rpm to ensure that the torque cam stroke is within the specified range. If the torque cam stroke is not as specified, readjust the fullload setting bolt and torque cam. If this adjustment cannot be performed to obtain the specified control rack position, replace the torque cam. NOTE z Before installing a new torque cam, ensure the stamping mark is the same as the number given in the service data. 3) Next, increase the pump speed from Nj minus approximately 100 rpm to Ng rpm, then ensure the pump speed is as specified for each control rack position. If the pump speed is not as specified, the torque cam has not been adjusted properly. Readjust it. If the torque cam cannot be adjusted to obtain the specified pump speed, replace the torque cam.

5.

Measure the fuel injection quantity at each of the adjusting points (as specified; that is, the fuel injection characteristics for full-load). If the fuel injection quantity is not as specified, adjust the full-load setting bolt and the torque cam adjusting nut carefully. Lock the nut and bolt after adjustments. NOTE z If this adjustment is not executed properly, the specified fuel injection quantity cannot be obtained, there will be decreased engine output and black smoke may be produced. EF-3-47

A, B, T, TA 173 kW {235 PS}


Maximum-speed control adjustment 1. 2.

3. 4.

5.

Lock the control lever when it contacts the maximum-speed setting bolt. With the pump speed maintained at Ng rpm, adjust the maximum-speed setting bolt so that the control rack begins moving from Rf3 mm (in) in the fuel decrease direction. Then, lock the bolt with the nut.

Checking the speed droop Gradually increase the pump speed and ensure the pump speed is Nh rpm when the control rack reaches Rg mm (in). Increase the pump speed further to ensure the control rack reaches 0 mm (0 in).

Check that the control lever angle is as specified with the adjusting device (105782-6170).

Boost compensator adjustment (If so equipped) If the governor does not have a boost compensator, proceed to “confirmation of the excess fuel limit for engine starting”. 1. Install the spacer (1A); refer to the illustration on page EF-349 (EEF3-177) on the governor cover, and ensure the pushrod can move smoothly.

EF-3-48

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Checking pushrod protrusion 1) Fix the control lever in the maximum-speed position. 2) Operate the injection pump at the specified speed, marked BASIC in the injection quantity table of the injection pump calibration data (usually adjusting point A). 3) In this condition, use calipers to measure the protrusion (dimension L) of push rod B from the end face of the spacer. If dimension L is not within the specified range, replace pushrod B so that L is as specified.

Pushrod table Part No.

Length mm (in)

159274-0120 159274-0220 159274-0320 159274-0420 159274-0520 159274-0620 159274-0720 159274-0820 159274-0920 159274-1120 159274-1220 159274-1320 159274-1420 159274-1520

125.0 (4.92) 127.5 (5.02) 128.0 (5.04) 127.0 (5.00) 126.0 (4.96) 129.0 (5.08) 128.5 (5.06) 125.5 (4.94) 126.5 (4.98) 119.5 (4.70) 120.0 (4.72) 120.5 (4.74) 121.0 (4.76) 121.5 (4.78)

Part No.

Length mm (in)

159274-1620 159274-1720 159274-1820 159274-1920 159274-4220 159274-4320 159274-4420 159274-4520 159274-4620 159274-4720 159274-4820 159274-4920 159274-5020

122.0 (4.80) 122.5 (4.82) 123.0 (4.84) 123.5 (4.86) 129.5 (5.10) 130.0 (5.12) 130.5 (5.14) 131.0 (5.16) 131.5 (5.18) 132.0 (5.20) 132.5 (5.22) 133.0 (5.24) 133.5 (5.26)

3.

Install the boost compensator assembly, then attach the compressed-air pipe.

4.

Boost compensator stroke adjustment 1) Confirm that the screw (62) position is the same as that before disassembly. 2) Remove the plug (46) and gasket (45). 3) Maintain the pump speed at N1 rpm. 4) Fully loosen the screw (55) with the wrench (1579133520), and then confirm that the control rack position R2 mm (in) can be obtained. If the control rack position R2 mm (in) is not as specified, readjust the full-load setting bolt and torque cam.

EF-3-49

Remarks


5) Shift the control rack position from R2 mm (in) to R1 mm (in) using the screw (55), and then lock it with the nut (54). NOTE z During boost compensator stroke adjustment, it is not necessary to supply compressed air.

5.

Setting the boost compensator spring force 1) With the pump speed maintained at N1 rpm, gradually increase the boost pressure. 2) Adjust the screw (62) so that the control rack begins moving from R1 mm (in) in the fuel increase direction when the boost pressure reaches P1 kPa {mmHg, inHg}. Lock the screw with the nut (63).

3) Increase the boost pressure, and ensure it reaches P2 kPa {mmHg, inHg} when the control rack is at R2 mm (in). If the boost pressure is not as specified, replace the boost compensator spring (16). 4) Recheck the boost compensator stroke, and if not as specified, readjust the screw (55).

EF-3-50

A, B, T, TA 173 kW {235 PS}


Confirming the excess fuel limit for engine starting 1. 2. 3.

With the pump speed maintained at Ns rpm, lock the control lever when the control rack position is Rc mm (in) (point J). Ensure the control rack moves beyond Ra’ mm (in) when the pump speed is reduced to 0 rpm. Maintaining a pump speed of less than N liter rpm, ensure the control rack moves beyond Rs mm (in) when the control lever is shifted toward the maximum-speed position.

The above confirmation ensures that the sensor lever and torque cam are positioned as shown in the figure when the control rack moves beyond Rs mm (in). NOTE

The control rack must not move to Rs mm (in) if the pump speed is decreased to N liter rpm with the control lever locked at the maximum-speed position. z If control rack positions Ra’ Aa and Rs mm (in) are not indicated in the calibration data, confirmation of the excess fuel limit is unnecessary. z

Confirming the black smoke limit 1.

With the pump speed maintained above N liter (that is, Nb’) rpm, fix the control lever at the idling position. 2. Ensure the control rack does not move beyond Rf5 mm (in) when the control lever is shifted toward the maximumspeed position. 3. Keep the control lever at the maximum-speed position and gradually increase the pump speed. 4. Confirm that the control rack begins moving from Rf5 mm (in) in the fuel decrease direction when the pump speed exceeds Nj rpm. The above confirmation ensures that the sensor lever and torque cam are as shown in the figure when the control lever is shifted toward the maximum-speed position during engine operation.

Control rack limiter adjustment Screw type 1. Using the lock (157976-3100), lock the control rack at the position given with the calibration data, maintaining the pump speed at 0 rpm.

EF-3-51

A, B, T, TA 173 kW {235 PS}


2.

Measure the depth “liter” of the rack cap.

3. 4.

Attach both the bolt and nut to the end of the control rack. Adjust the bolt so that the distance between the end face of the pump housing and the bolt top is “liter”, that is, the rack cap depth. Tighten the nut to lock the bolt.

5.

Install the rack cap.

Installation of plate plugs After adjusting the governor, check that there is no damage to the inside surfaces where the governor cover plates are press fitted. In addition, remove as much oil as possible from inside. 1) Push in new plate plugs with a finger, and drive them securely into place with the rods (157923-5800, -5900, 6000). 2) After press-fitting each plug, thoroughly coat the outside surface with adhesive (THREE BOND No. 1405D).

EF-3-52

A, B, T, TA 173 kW {235 PS}


Sealing All adjusting stoppers (bolts, nuts) that directly affect engine performance are sealed after adjustment. Do not readjust any stopper without using the pump test stand or the engine test bench, as this will adversely effect the engine, which will then be unable to operate at peak performance. In addition, the engine may overrun or overheat, causing damage.

1 On full-load stopper z Sealing cap part No.: 154062-1900 Unit: mm (in) Stopper bolt protrusion

L1 = 21 - 24 (0.83 - 0.94)

2 On maximum-speed stopper z Sealing cap part No.: 154062-1700 Unit: mm (in) Stopper bolt protrusion

L2 = 29 - 36 (1.14 - 1.42)

EF-3-53

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Governor adjustment diagram (“ZEXEL No.” is Inj. pump ass’y No.) z

ZEXEL No. 101607-9270

EF-3-54


ZEXEL No. 101696-9410

EF-3-55

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101607-9260

EF-3-56

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9380

EF-3-57

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY ZEXEL No. 101696-9370

EF-3-58

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY ZEXEL No. 101696-9390

EF-3-59

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9200

EF-3-60

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9360

EF-3-61

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9210

EF-3-62

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9400

EF-3-63

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101608-9030

EF-3-64

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101697-9000

EF-3-65

A, B, T, TA 173 kW {235 PS}


Aneroid compensator kit adjustment 1.

Aneroid compensator adjustment (Before governor installation). Select a suitable push rod so that L is as follows: 10.5 - 11.5 mm (0.413 - 0.453 in) NOTE z As “L” cannot be measured after the spacer is installed, select the push rod 2 before installing the spacer. 2.

Adjustment at governor installation. With the control lever at the full position and Np = 1,400 rpm/min, screw in the aneroid compensator kit body so that push rod 1 contacts push rod 2 and the performance as shown is obtained. NOTE z As there is some hysteresis, measure the injection quantity when the absolute pressure is decreasing. z Screw the aneroid compensator into the spacer and confirm that the performance is as shown (adjust the beginning of operation by adjusting the amount that the aneroid compensator is screwed in). Rack variation characteristics when negative pressure is applied to the inside of the case.

EF-3-66

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9920

EF-3-67

A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101696-9751

EF-3-68

A, B, T, TA 173 kW {235 PS}


RFD type Preparations 1. Remove damper spring, cover, torque control springs and idling spring, and loosen adjusting screws. 2. Mount injection pump assembly securely on a pump test stand. Then, attach the test nozzle and nozzle holder assembly, test lines and measuring device to measure control rod travel, to injection pump. 3.

Fill governor chamber and camshaft chamber with injection pump oil.

4.

Mount measuring device (105782-6030) to measure the angle of load control lever.

5.

With injection pump off, assure by moving load control lever in the directions of both “increase fuel” and “decrease fuel”, that control rack travels smoothly.

Setting the control rack zero point 1.

After fixing load control lever in the idling position, temporarily set speed control lever so that governor begins to move the control rack to the fuel decrease direction at pump speed of 500 to 600 rpm.

EF-3-69

A, B, T, TA 173 kW {235 PS}


Increase pump speed so that control rack travels to the non-injection position. Then, press with a screw driver the tip of control rack or control pinion until it stops. Make this position the “zero” point of control rack, and set the indicating pointer of measuring device to correspond with “zero” of scale. NOTE z The operation of stopping lever will not cause control rack to travel to “zero” point.

Torque control stroke 1. 2.

Fix load control lever in the full load position. Temporarily hold speed control lever in position so that governor begins to move the control rack to the fuel decrease direction at pump speed of approximately 800 rpm.

3.

Using a wrench (157913-3520) make adjustments by means of adjustment screws, while raising and lowering pump speed within the range of 500 to 600 rpm, so that control rack position corresponds with the specified value “liter”.

Flyweight lift and full load position The total lift of flyweight is divided into two categories: one for high speed control and the other for idling control. Firstly, adjust the flyweight lift for high speed control. 1. Fix load control lever at full position (control rack position “Rb”), and temporarily set speed control lever so that governor begins to move the control rack to the fuel decrease direction at pump speed to 700 to 800 rpm.

EF-3-70

A, B, T, TA 173 kW {235 PS}


While raising pump speed to “Na”, make adjustments by means of full load stopper bolt so that control rack position corresponds with “Ra”. NOTE z The control rack position “Ra” is the result of control rack position “Rb” minus the travel “L”. z If “Ra” is below “zero”, set the control rack to “Ra plus 2 mm (0.08 in)” position. 3.

Next, decrease pump speed to “Nb” and by means of stroke adjusting screw adjust flyweight lift for high speed control “L” (control position “Rb”). NOTE z If the control rack is set to the “Ra” plus 2.0 mm (0.079 in)” position in Step 2, set the stroke adjusting screw to the “Rb plus 2.0 mm (0.079 in) position.

EF-3-71

A, B, T, TA 173 kW {235 PS}


Idling 1. 2.

Run injection pump at “Nc” (Nd + 100 rpm) rpm. Make adjustments by means of idling adjusting screw so that control rack position corresponds with “Rc”.

3. 4.

Decrease pump speed so as to maintain “Ne” rpm. Incorporate idling spring assemblies into tension lever. Screw in the assemblies until control rack position corresponds with “Rd”, and then lock them at this point using a wrench (157916-2620). NOTE z At this time, pump speed may sometimes drop. Ascertain that the “Ne” rpm is maintained. 5. 6. 7. z

z

Make sure control rack position remains above “Re” even when pump speed is brought down to 0 rpm. Next, raise pump speed slowly and ensure that when control rack reaches the position “Rc”, the corresponding speed is “Nd” rpm. Measure the load control lever angle. When load control lever is depressed toward the “full” position, replace shifter shim with a thicker one. When load control lever is depressed toward the “idling” position side, replace shifter shim with a thinner one.

Damper spring 1. 2.

Fix load control lever at “idling” control position. Raise pump speed slowly from “idling” speed (Ne rpm) to the speed where control rack position corresponds with “Rf” minus 0.2 mm (0.008 in), and maintain this speed.

EF-3-72

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}

Screw in damper spring until control rack position corresponds with “Rf” minus 0.1 mm (0.004 in) and lock the spring at this point.

Stopper bolt 1.

After setting damper spring, when pump is brought to 0 rpm, control rack position moves to “Re”.

2.

After loosening the stopper bolt, move the load control lever until control rack position is “Rg” and set stopper bolt at this point.

EEF3-222

EF-3-73


High-speed control starting point and speed droop check 1. 2. 3.

Fix load control lever at “full” position. Raise pump speed slowly to “Nk” rpm. Make adjustments to stopper bolt so that control rack starts to travel from the position “Rb”. Ensure by raising pump speed that it remains below “N liter” rpm when control rack position reaches “Ri”.

NOTE z

If “N liter” rpm exceed the standard value, the no-load maximum speed of the engine is also increased, creating dangerous conditions. Recheck both “Rb”, (full-load rack position) and “Rf” 0.1 mm (0.004 in) (the set position of damper spring).

4.

Further increase the pump speed to Nm rpm and ensure the control rack reaches in the non-injection zone [injection quantities are less than 3 milliliter (0.11 Imp fl oz) per 1,000 strokes].

Stopper bolt When used as variable speed governor. 1. After making adjustments as described in the figure, fix load control lever at full-load position. 2. Then, run the injection pump at speed “Ny” rpm which is slightly higher than the idling speed. 3. Return stopper bolt to the low-speed position side and lock it with nut, at control rack position Rd mm (in).

Full-load fuel delivery Readjust the full-load stopper bolt to the full-load fuel injection quantity position according to the service data.

EF-3-74

A, B, T, TA 173 kW {235 PS}


Smoke limiter 1. 2. 3.

Fix load control lever at full position. Maintain pump speed at “Nn” rpm. Screw in spring capsule or screw and lock it at point E, where the specified fuel delivery may be obtained.

EF-3-75

A, B, T, TA 173 kW {235 PS}


A, B, T, TA 173 kW {235 PS}


ZEXEL No. 101607-9361

EF-3-76


ZEXEL No. 101607-9341

EF-3-77

A, B, T, TA 173 kW {235 PS}


TESTING TIMER In general, measurement of the timer advance angle is performed on the pump tester after completing an adjustment of the injection timing, injection quantity and governor.

Timing Advance Specification z

z

z

z

z

z

z

ZEXEL No. 101607-9351, 101607-9270, 101607-9361 Pump speed (rpm)

(1,140)

1,500

Advance angle (º)

Start

Finish 4.0±0.5

ZEXEL No. 101607-9331, 101607-9260, 101607-9341, 101608-9030 Pump speed (rpm)

Below 850

800

1,500

Advance angle (º)

Start

Below 0.5

Finish 4.0±0.5

ZEXEL No. 101696-9410 Pump speed (rpm)

Below 1,250

1,200

1,500

Advance angle (º)

Start

Below 0.5

Finish 1.0±0.5


Below 1,050

1,000

1,500

Advance angle (º)

Start

Below 0.5

Finish 2.0±0.5


1,400

Advance angle (º)

Finish 2.0±0.3

ZEXEL No. 101696-9210, 101696-9400 Pump speed (rpm)

Below 1,170

1,120

1,400

Advance angle (º)

Start

Below 0.5

Finish 2.0±0.5

ZEXEL No. 101696-9920, 101696-9751 Pump speed (rpm)

Below 1,170

1,120

1,400

Advance angle (º)

Start

Below 0.5

Finish 3.0±0.5

EF-3-78

A, B, T, TA 173 kW {235 PS}


Measuring equipment handling precautions 1. 2. 3.

4.

5. 6.

7.

Be sure not to apply any large shock or vibration to the timing checker. Do not use the reflection plate excessively. Carefully store the remaining plate to avoid discoloration. Never use the equipment in any location where inflammable gases or any other explosive atmosphere may exist because very high pulse voltages are generated in the equipment. This equipment has a built-in DC high-tension circuit. Do not use the equipment at any location where it may get wet; otherwise, equipment may be damaged and electric shock to the human body may result. The sensor generates an intense flash of light. Do not look straight at the light source of this equipment; otherwise, eyesight may be harmed. The light source unit is separate from the power supply unit of this equipment. Before disconnecting or connecting the lamp cable, be sure to turn OFF the power switch to avoid electrical shock. This equipment uses high tension current. Be sure to connect the ground terminal of the equipment to the ground by using a proper ground cable.

Installation 1.

Attach the coupling (105784-0510) to the injection pump camshaft. NOTE z At this time, note that both the camshaft and coupling shaft unit key groove must face in the same direction. 2. 3.

Attach the timer to the coupling shaft unit and fix it firmly. Fix the timer to the test stand flywheel firmly. At this time, make sure that there is no eccentricity in the center of the rotating portion.

Reflection plate attaching position 1. 2.

With attaching the reflection plate (157951-1100), avoid the stamped portion and the caution plate on the timer causing. Cut the reflection plate to a 5 x 7 mm (0.20 x 0.28 in) size each time the timer advance characteristics are checked.

EF-3-79

A, B, T, TA 173 kW {235 PS}


Measuring equipment installation 1. 2. 3. 4. 5. 6.

Securely fix the holder (157842-5220) to the groove in the pump tester bed. Temporarily tighten the sensor (157830-3420) to the holder with the sensor light source facing the timer. Connect the sensor cable to the INPUT terminal of the timing checker (157830-3320). Connect the lamp (157830-3520) cable to the LAMP terminal of the checker. With the checker POWER switch set to OFF, connect the power cable to a power outlet (AC 100V 50/60 Hz). The distance between the reflection plate and the sensor must be 10 to 55 mm (0.39 to 2.17 in).

Operating procedure for timing check 1. 2.

3.

4. 5.

Run the injection pump at a low speed and change the selector switch of the timing checker (157830-3320) from the OFF to ON position. Direct the light from the sensor (157830-3420) to the reflection plate (157951-1100) and be sure the angle scale graduation on the pump tester flywheel can be read by use of the lamp (157830-3520). Set the pump at a speed approximately 100 rpm below the beginning rpm of the timer advance. Move the dial plate and determine the zero point at any desired position while directing the lamp light to the pump tester flywheel. Increase the pump speed from low to high, and read the timer advance angle at each representative rpm position. Upon completing measurement, stop the rotation of the injection pump after turning the timing selector switch to the OFF position.

ADJUSTMENT OF TIMING DEVICES Using a timing checker, measure the advance angle characteristics of the timer. The measurement should be taken both when pump speed increases and when it reduces. In any case, its performance must satisfy the specified value. The governor control lever at this time must be at full speed status, unless any special instruction is given. 1. The figure shows the timer performance line. Ensure that the specified advance angle characteristics can be obtained as the pump speed is increased gradually, according to calibration data of the injection pump (including timer). 2. If the specified characteristics cannot be satisfied, adjust the thickness of the shim built into the spring end, or replace the spring. (Refer to Section on Disassembly/Reassembly timer.) After reassembling, perform a verification test once again.

EF-3-80

A, B, T, TA 173 kW {235 PS}

- MEMO -


TA 157 KW {213 PS}

= FE6TA [157 kW {213 PS}] = INJECTION PUMP ASSEMBLY z

For information on disassembly, inspection, reassembly, adjusting and testing of the injection pump, refer to the service manual published by Zexel Co.

CONSTRUCTION INJECTION PUMP ASSEMBLY Type I (for HONG KONG)

EF-4-1


Type II (for NORWAY)

EF-4-2

TA 157 KW {213 PS}


TA 157 KW {213 PS}

INJECTION PUMP PROPER Type I (for HONG KONG)

1. Sleeve 2. Oil seal 3. Bolt 4. Cover 5. Pointer 6. Socket head bolt 7. Shim 8. O-ring 9. Bearing 10. Camshaft 11. Woodruff key 12. Bushing 13. Socket head bolt 14. Connector 15. Bushing 16. Bearing 17. Washer 18. Control rod 19. Plug 20. Gasket 21. Stud

22. Nut 23. Washer 24. Delivery valve holder 25. O-ring 26. Spring 27. Valve assembly 28. O-ring 29. O-ring 30. Stopper 31. Plunger assembly 32. Control sleeve 33. Spring seat 34. Plunger spring 35. Spring seat 36. Shim 37. Guide 38. Snap ring 39. Bushing 40. Plug 41. Pin

42. Roller 43. Screw 44. Gasket 45. Center bearing 46. Stud 47. Gasket 48. Nut 49. Overflow valve 50. Control rack 51. Pin 52. Bushing 53. Bushing 54. Gasket 55. Plug 56. Plug 57. Bearing 58. Ring 59. Shim 60. Eye bolt 61. Eye bolt

NOTE z

Numbers before part names do not indicate the disassembly sequence. EF-4-3


TA 157 KW {213 PS}

Type II (for NORWAY)

1. Sleeve 2. Oil seal 3. Bolt 4. Cover 5. Pointer 6. Socket head bolt 7. Shim 8. O-ring 9. Bearing 10. Camshaft 11. Woodruff key 12. Bushing 13. Socket head bolt 14. Connector 15. Bushing 16. Bearing 17. Washer 18. Control rod 19. Plug 20. Gasket 21. Stud

22. Nut 23. Washer 24. Delivery valve holder 25. O-ring 26. Spring 27. Valve assembly 28. O-ring 29. O-ring 30. Stopper 31. Plunger assembly 32. Control sleeve 33. Spring seat 34. Plunger spring 35. Spring seat 36. Shim 37. Guide 38. Snap ring 39. Bushing 40. Plug 41. Pin

42. Roller 43. Screw 44. Gasket 45. Center bearing 46. Stud 47. Gasket 48. Nut 49. Overflow valve 50. Control rack 51. Pin 52. Bushing 53. Bushing 54. Gasket 55. Plug 56. Plug 57. Bearing 58. Ring 59. Shim 60. Eye bolt 61. Eye bolt

NOTE z

Numbers before part names do not indicate the disassembly sequence. EF-4-4


GOVERNOR

EF-4-5

TA 157 KW {213 PS}


1. Nut 2. Lever 3. Spring 4. Shim 5. O-ring 6. Nut 7. Spring washer 8. Lever 9. Washer 10. Oil seal 11. Bolt 12. Gasket 13. Governor housing 14. Nut 15. Bolt 16. Cover cap 17. Shaft 18. Oil seal 19. Washer 20. Shim 21. Snap ring 22. Lever 23. Snap ring 24. Bolt 25. Lever 26. Plug 27. Nut 28. Shaft 29. Spring 30. Woodruff key 31. Bolt 32. Flyweight assembly 33. Lever 34. Shaft 35. Spring seat 36. Governor spring 37. Governor spring 38. Spring seat 39. Plate 40. Bolt 41. Spring 42. Socket head bolt 43. Link 44. Spring washer 45. Nut

46. Sleeve 47. Shim 48. Shifter 49. Rack sensor assembly 50. Snap ring 51. Washer 52. Shaft 53. Spring 54. Washer 55. Lever 56. Lever 57. Snap ring 58. Lock screw 59. Adjusting nut 60. Guide lever 61. Spring 62. Snap ring 63. Tension lever assembly 64. Plug 65. Snap ring 66. Shaft 67. Snap ring 68. Pin 69. Rod 70. Spring 71. Spring 72. Spring 73. Nut 74. Shifter 75. Screw 76. Snap ring 77. Snap ring 78. Cam plate 79. Snap ring 80. Snap ring 81. Plug 82. Gasket 83. Gasket 84. Bolt 85. Lever 86. Nut 87. Lever 88. Oil seal 89. Snap ring 90. Shim

TA 157 KW {213 PS}

91. Nut 92. Bolt 93. Cover cap 94. Bolt 95. Nut 96. Screw 97. Plug 98. Bracket 99. Bolt 100. Nut 101. Plug 102. Plug 103. Governor cover 104. Bolt 105. Spring 106. Washer 107. Spring assembly 108. Screw 109. Plug 110. Tube 111. Spring 112. Nut 113. Spring washer 114. Disk 115. Plate 116. Bushing 117. Nut 118. Spring 119. Diaphragm 120. Gasket 121. Screw 122. Cover 123. Gasket 124. Eye bolt 125. Bolt 126. Spring washer 127. Bolt 128. Nut 129. Gasket 130. Cap nut 131. Push rod 132. Bolt 133. Guide plate 134. Bolt 135. Lever assembly

NOTE z


EF-4-6


TA 157 KW {213 PS}

COUPLING Type I (for HONG KONG) and Type II (for NORWAY)

1. Bolt 2. Plate 3. Bolt 4. Nut 5. Lock washer 6. Coupling 7. Nut 8. Washer

9. Coupling 10. Bolt 11. Bolt 12. Plate 13. Bolt 14. Cross coupling 15. Sensor

16. Nut 17. Washer 18. Plate 19. Bolt 20. Washer 15 - 20. Type II only

NOTE z


EF-4-7


TA 157 KW {213 PS}

ACTUATOR HOUSING

1. Socket head bolt 2. Spring washer 3. Harness clamp 4. Washer 5. Socket head bolt 6. Spring washer 7. Washer

8. Socket head bolt 9. Spring washer 10. Cover 11. Seal ring 12. Socket head bolt 13. Spring washer 14. Washer

15. Bolt 16. Seal ring 17. Eye bolt 18. Bolt 19. Gasket 20. Seal ring 21. Housing

NOTE z


EF-4-8


FEED PUMP

EF-4-9

TA 157 KW {213 PS}


1. Plug 2. Gasket 3. Check valve spring 4. Check valve 5. Priming pump 6. Gasket

7. Check valve spring 8. Check valve 9. Eye bolt 10. Eye bolt 11. Housing

TA 157 KW {213 PS}

12. Push rod 13. Piston 14. Piston spring 15. Gasket 16. Plug

NOTE z


EF-4-10


REMOVAL 1.

Apply chocks to the front and rear wheels and tilt open the cab. 2. Turn the key switch OFF and disconnect the ground cable from the battery. 3. Remove the left side cover. 4. Disconnect the fuel line. z Disconnect the fuel tube. z Remove the fuel filter assembly and bracket as a unit. z Disconnect the injection nozzle tube. NOTE z Use a container or a clean cloth to catch and wipe oil as required.

5.

Disconnect the accelerator wire and auto-stop solenoid plate.

EF-4-11

TA 157 KW {213 PS}


Disconnect the harness connector of engine speed sensor, rack sensor and pre-stroke sensor of MD-TICS.

7.

Disconnect the inlet and outlet oil tubes from the injection pump.

8.

Remove the bolts which secure the coupling.

9.

Remove the bolts which secure the injection pump. Remove the injection pump assembly from the stay.

FUEL FEED PUMP AND PRIMING PUMP DISASSEMBLY 1. z

Removing the push rod Pull out the push rod.

EF-4-12

TA 157 KW {213 PS}


Place the fuel feed pump in a vise, remove the plug, gasket and pull out the piston spring and piston.

3.

Disassembling the priming pump It is recommended that the priming pump not be disassembled unless the rubber seat in the piston part of the pump has become defective or the piston has seized or is rusty. Apply a wrench to the Hex section at the bottom of the cylinder and remove the priming pump assembly. Remove the check valve spring and check valve.

z

z

INSPECTION Wash all disassembled parts in cleaning solvent. Carefully check for scratches, cracks or damage. Replace faulty parts as necessary.

Housing and push rod clearance Unit: mm (in) Maintenance standard

Service limit

0.003 - 0.018 (0.0001 - 0.0007)

0.1 (0.004)

Housing and piston clearance Unit: mm (in) Maintenance standard

Service limit

0.014 - 0.056 (0.0006 - 0.0022)

0.15 (0.0059)

Gauze filter Check the gauze filter for clogging.

EF-4-13

TA 157 KW {213 PS}


REASSEMBLY Before assembling the feed pump, replace old gaskets and O-rings with new ones. 1. Insert the piston, piston spring and gasket, and tighten the plug. 2. Install the discharge side check valve, check valve spring and gasket, and tighten adapter and priming pump. 3. Install the push rod in the housing. NOTE

Coat the threads of the plug with the adhesive agent.

z

SUPPLY PUMP TEST Suction test 1.

Attach a hose to the supply pump suction port and insert the other end into a fuel oil container. NOTE z Ensure suction head of approx. 1 m (3 ft). 2. 3.

Operate the injection pump at 100 rpm. Fuel oil must be discharged in less than 40 seconds.

Priming pump test 1. 2. 3.

Fully loosen the priming pump’s screw cap. Operate the priming pump using the screw cap, at 60 to 100 strokes per minute. Fuel oil must be discharged in less than 25 strokes.

Capacity test 1. 2.

Place discharge hose in a measuring cylinder (1579700500). Operate the injection pump and check the supply rate, referring to the following table:

Pump speed

Supply rate

100 rpm

More than 60 m liter (2.1 Imp fl oz)/15 seconds

500 rpm


1,000 rpm


1,500 rpm


EF-4-14

TA 157 KW {213 PS}


Feed pressure measurement 1. 2. 3.

Connect the hose (157984-8400) between the supply pump discharge port and the pressure gauge. Operate the injection pump at 600 rpm. Ensure that the supply pump maintains a feed pressure of 333 to 412 kPa {3.4 to 4.2 kgf/cm2, 48 to 60 psi.}

Air tightness test 1. 2. 3.

Plug the supply pump discharge port using the plug (029111-4050). Apply 196 kPa {2 kgf/cm2, 28 psi} air pressure to the suction port. Immerse the supply pump in a container of fuel oil, and check for air leakage. There must be no air leakage.

INSTALLATION 1.

Install the injection pump assembly. (Refer to the “DR” section for procedures.)

2.

Connect the inlet and outlet oil tubes to the injection pump.

3.

Connect the accelerator wire and auto-stop solenoid plate. For adjustment procedures, refer to the instructions under the “ENGINE CONTROL SYSTEM” in this manual.

EF-4-15

TA 157 KW {213 PS}


TA 157 KW {213 PS}

Connect the fuel system parts: Connect the injection nozzle tube. z Install the fuel filter assembly. z Connect the fuel tube. Connect the harness connector of engine speed sensor, rack sensor and pre-stroke sensor of MD-TICS. Bleed air from the fuel system. (Refer to the “MA” section for procedures.) z

5. 6.

FUEL INJECTION QUANTITY ADJUSTMENT Testing conditions Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is evident. In calibrating a pump, observe the following: Item

Test condition

Nozzle & Nozzle holder assembly

105780-8250 (BOSCH Type No. 1 688 901 101)

Pump rotation

Clockwise (Viewed from driver side)

Nozzle

105780-0120 (BOSCH Type No. 1 688 901 990)

Nozzle holder

105780-2190 kPa {kgf/cm2, psi}

Nozzle opening pressure

20,693 {211, 3,000}

2

157 {1.6, 23}

kPa {kgf/cm , psi}

Feed pump oil pressure Injection pipe (OD x ID - L)

mm (in)

8 x 2 - 600 (0.31 x 0.08 - 23.62)

Test oil

IS04113 or SAE standard test oil (SAE J967d)

Test oil temperature

ºC (ºF)

40 - 45 (104 - 113)

Type of selector switch setting

11

Injection quantity standards (“ZEXEL No.” is Inj. pump ass’y No.) RLD governor z ZEXEL No. 107692-0831 Adjusting point


Pump speed rpm

Injection q’ty m liter (lmp fl oz) 1,000 strokes


Fixed

A

13.8 (0.543)

1,400

112±1 (3.94±0.04)

—

Lever

B

12.1 (0.476)

900

105±2 (3.70±0.07)

—

Lever


C

9.85 (0.3878)

350

33±2 (1.16±0.07)

—

Lever

Boost press. 0

I

Approx. 11.45 (0.4508)

100

89 (3.1)

—

Lever

Boost press. 0

EF-4-16

Remarks Basic



TA 157 KW {213 PS}

ZEXEL No. 107692-0832 and 107692-0920

Adjusting point


Pump speed rpm



Fixed

A

R1 [13.8 (0.543)]

1,400

112±1 (3.94±0.04)

—

Lever

B

R1 -1.7 (0.067)

900

105±2 (3.70±0.07)

—

Lever


C

R2 -0.6 (0.024)

350

25±2 (0.88±0.07)

—

Lever

Boost press. 0

I

Approx. R1 -2.0 (0.079)

100

90 (3.17)

—

Lever

Boost press. 0

z

Remarks Basic


ZEXEL No. 107069-1220

Adjusting point


Pump speed rpm



Fixed

A

13.8 (0.543)

1,400

112±1 (3.94±0.04)

—

Lever

B

12.1 (0.476)

900

105±2 (3.70±0.07)

—

Lever


C

9.85 (0.3878)

350

33±2 (1.16±0.07)

—

Lever

Boost press. 0

I

Approx. 11.45 (0.4508)

100

89 (3.1)

—

Lever

Boost press. 0

EF-4-17

Remarks Basic




ZEXEL No. 107692-0831

EF-4-18

TA 157 KW {213 PS}


ZEXEL No. 107692-0832 and 107692-0920

EF-4-19

TA 157 KW {213 PS}


ZEXEL No. 107069-1220

EF-4-20

TA 157 KW {213 PS}


Injection timing Pre-stroke: No. 1 Plunger 5.6±0.03 mm (0.2205±0.0012 in) NOTE 1. Adjust using the shim (1). 2. Adjust with the rack in the full-load position. z

3. Adjust with the connector (2) contacting the stopper pin (3).

4. Plungers are numbered from the drive side. z Injection order:

z

1—4,

1—2,

1—6,

1—3,

1—5,

60º±15′

120º±15′

180º±15′

240º±15′

300º±15′

Tappet clearance: Manually rotate the camshaft 2 to 3 times and confirm that it rotates smoothly.

Pre-stroke actuator adjustment Pre-stroke Actuator type: Retard Power supply voltage: 24±0.5V Ambient temperature: 23±5°C (73±9°F) z ZEXEL No. 107692-0831 Pre-stroke mm (in)

Pre-stroke sensor Output Voltage V

Remarks

2.5±0.05 (0.0984±0.0020)

2.83±0.01

Pre-stroke actuator adjustment

5.6±0.03 (0.2205±0.0012)

V1=1.2±0.2

Confirmation

—

Above 3.05

Confirmation (Pre-stroke actuator operating range)

EF-4-21

TA 157 KW {213 PS}


TA 157 KW {213 PS}

ZEXEL No. 107692-0832, 107069-1220 and 107692-0920 Pre-stroke mm (in)

Pre-stroke sensor Output Voltage V

Remarks

2.5±0.01 (0.0984±0.0004)

2.83±0.01

Pre-stroke actuator adjustment

5.6±0.01 (0.2205±0.0004)

V1=1.2±0.2

Confirmation

—

Above 3.05

Confirmation (Pre-stroke actuator operating range)

NOTE

1. Move the pre-stroke actuator fully counterclockwise (viewed from the drive side), and temporarily secure it to the actuator housing using the bolts. : 1.0 - 1.5 N·m {0.10 - 0.15 kgf·m, 0.7 - 1.1 ft·lbf} 2. Move the pre-stroke actuator clockwise (viewed from the drive side) to adjust it. 3. After pre-stroke actuator adjustment, stamp both the prestroke actuator and the housing with an aligning mark.

Injection quantity variation rate adjustment NOTE z

At adjustment Item

Pre-stroke

Adjustment point “—”

3.6±0.05 mm (0.1417±0.0020 in) (V = 2.25±0.01)

Adjustment point Z

5.5±0.03 mm (0.2165±0.0012 in) (V = [V1+0.05]±0.01)

Adjusting point


Pump speed rpm



Fixed

—

13.8 (0.543)

1,400

112±2 (3.94±0.07)

±4

Rack

Basic

Z

Approx. 8.0 (0.315)

465

10.6±1.8 (0.37±0.06)

±10

Rack

Adjust injection q’ty at N=465. Adjust governor as per gov. adj. spec.

EF-4-22

Remarks


TA 157 KW {213 PS}

Injection quantity adjustment (after governor adjustment) Adjustment the injection quantity at a pre-stroke of 3.6±0.05 mm (0.1417±0.0020 in) (pre-stroke sensor output voltage: 2.25±0.01V). z ZEXEL No. 107692-0831 Adjusting point


Pump speed rpm



Fixed

A

13.8 (0.543)

1,400

112±1 (3.94±0.04)

—

Lever

B

12.1 (0.476)

900

105±2 (3.70±0.07)

—

Lever


C

9.85 (0.3878)

350

[6.9±2 (0.24±0.07)]

—

Lever

Boost press. 0

I

Approx. 11.45 (0.4508)

100

[80 (2.8)]

—

Lever

Boost press. 0

z

Remarks Basic


ZEXEL No. 107692-0832 and 107692-0920

Adjusting point


Pump speed rpm



Fixed

A

R1 [13.8 (0.543)]

1,400

112±1 (3.94±0.04)

—

Lever

B

R1 -1.7 (0.067)

900

105±2 (3.70±0.07)

—

Lever


C

R2 -0.6 (0.024)

350

25±2 (0.88±0.07)

—

Lever

Boost press. 0

I

Approx. R1 -2.0 (0.079)

100

90 (3.17)

—

Lever

Boost press. 0

z

Remarks Basic


ZEXEL No. 107069-1220

Adjusting point


Pump speed rpm



Fixed

A

13.8 (0.543)

1,400

112±1 (3.94±0.04)

—

Lever

B

12.1 (0.476)

900

105±2 (3.70±0.07)

—

Lever


C

9.85 (0.3878)

350

33±2 (1.16±0.07)

—

Lever

Boost press. 0

I

Approx. 11.45 (0.4508)

100

89 (3.1)

—

Lever

Boost press. 0

EF-4-23

Remarks Basic



RACK SENSOR 1.

Do not operate the aneroid compensator if installed. Secure the speed control lever in the full position and set the pump speed at 1,400 rpm. (If equipped with a boost compensator, first apply boost pressure.)

Adjust the rack sensor after determining VR from the control unit part no. VR 2V

Control unit part No. 407912-1742 105782-6320 407910-2901

3V

407910-3032 407910-6010 407910-7210

2. 3.

Adjust the bobbin (1) so that the rack sensor’s output voltage is VR±0.01. After adjustment, mark the area where the joint (2) and the nut (3) contact and the area where the joint (2) and the pump housing contact with red paint.

Injection timing setting 1. 2.

Turn the pre-stroke actuator OFF. Position the camshaft in the No. 1 plunger’s beginning of injection position.

EF-4-24

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY 3. 4. 5.

Confirm that the injection pump pointer aligning mark and the flywheel aligning mark are aligned. If not aligned, remove the incorrect flywheel aligning mark, and remark the flywheel aligning mark. Confirm that the center of the coupling key groove is as specified.

Speed sensor ZEXEL No. 107069-1220 and 107692-0920 Install the speed sensor so that the gap between the sensor and the coupling (flywheel) projection is 0.8 to 1.0 mm (0.031 to 0.039 in), and then secure it using the lock nut (i.e. the position when the speed sensor is returned 1 revolution from the point where it contacts the coupling (flywheel) projection). z

ZEXEL No. 107692-0831 and 107692-0832 Install the speed sensor so that the gap between the sensor and the drive gear (air compressor) projection is 0.7 to 1.3 mm (0.028 to 0.051 in), and then secure it using the lock nut (i.e. the position when the speed sensor is returned 1 revolution from the point where it contacts the drive gear (air compressor) projection). z

EF-4-25

TA 157 KW {213 PS}

NOZZLE AND NOZZLE HOLDER

CONVENTIONAL TYPE

NOZZLE AND NOZZLE HOLDER = CONVENTIONAL TYPE = CONSTRUCTION

REMOVAL 1. 2. 3.

Chock wheels and tilt open the cab. Turn the key switch OFF and disconnect the ground cable from the battery. Disconnect the injection nozzle tube and spill tube, remove the nozzle holder assembly from the cylinder head.

EF-5-1


CONVENTIONAL TYPE

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) + 1. Cap nut 2. Gasket 3. Adjusting screw 4. Nozzle spring

5. Push rod 6. Inlet connector 7. Gasket + 8. Retaining nut

9. Nozzle 10. Pin 11. Nozzle holder


Key point of disassembly 1 Cap nut 1. Clamp the nozzle holder into a vise with holder plate (157944-9520). 2. Set the nozzle holder in the plate and remove the cap nut. Loosen the adjusting screw until the nozzle spring no longer has tension on it. 3. Remove the adjusting screw and separate the nozzle spring and push rod. 8 Retaining nut 1. Reverse the nozzle holder position by facing the nozzleside up, and remove the retaining nut with a appropriate wrench. 2. Remove the nozzle from the nozzle holder. Do not drop the nozzle needle.

EF-5-2


INSPECTION Clean all disassembled parts in cleaning solvent. Check for scratches, cracks or damage and replace faulty parts. z If measurement indicates that the service limit has exceeded, repair or replace faulty parts. NOTE z Remove carbon from around nozzle jets using a wire brush. z

1.

Remove carbon from around nozzle jets using the pin vice (99727 Z5005). Unit: mm (in)

Nozzle identification mark

Number of injection nozzle holes

Z, D3 D2, A5, A6 C1, F4

5


Wire diameter

0.29 (0.0114)

0.26 (0.0102)

0.30 (0.0118)

0.29 (0.0114)

0.245 (0.0096)

0.23 (0.0091)

NOTE

Do not extend tip of the holder more than 2 to 2.5 mm (0.079 to 0.098 in). Otherwise, it may bend inside the nozzle body so that it cannot be removed. z Carefully push the holder into the inside of the nozzle to remove carbon. z Use an oil stone to grind the wire tip of the holder until it is shaped as shown in the figure. z

2.

Clean remaining carbon off the back of the nozzle jet using the nozzle cleaner (99726 Z5000). NOTE z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle. Do not use compressed air to remove carbon because this may introduce foreign matter into the jet. 3.

Install the needle on the nozzle body while immersing both in clean diesel fuel.

4.

Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation. Position the nozzle body vertically. Pull out the needle so that it protrudes approximately 1/3 its total length beyond the top of the nozzle body. Then release it to ensure that it drops to the valve seat under its own weight.

5.

EF-5-3

CONVENTIONAL TYPE


REASSEMBLY To reassemble, reverse the order of the above removal procedures. Observe the following: NOTE

Clean the mating surfaces of the nozzle and nozzle holder and the retaining nut in clean diesel fuel before installation. z Use new gaskets. z

ADJUSTMENT 1. 2.

Loosen the adjusting screw and install the nozzle on a nozzle tester (105785-0960). Operate the hand lever forcefully two or three times to remove foreign matter. Adjust fuel valve opening pressure using the adjusting screw. Unit: kPa {kgf/cm2, psi} Maintenance standard

Service limit

Z, D2, A5, A6, C1, F4

20,104 - 20,595 {205 - 210, 2,915 - 2,986}

—

D3, F4

22,066 - 22,556 {225 - 230, 3,200 - 3,271}

—

Item Valve opening pressure (Regulated pressure)

WARNING WARNING z

Be extremely careful not to direct fuel spray to hand while adjusting fuel injection. It may penetrate into blood vein to the skin and cause toxic symptoms.

3.

After adjusting injection pressure to specifications, install the cap nut. Recheck injection pressure. Z, D2, D3, A5 and A6 : 39 - 49 N·m {4.0 - 5.0 kgf·m, 29 - 36 ft·lbf} C1 and F4 : 29 - 39 N·m {3.0 - 4.0 kgf·m, 22 - 29 ft·lbf}

4.

While adjusting injection pressure, check the spray pattern. Also check for signs of fuel leakage or obstruction. If inspection reveals slight wear on the seating surfaces of the nozzle body and needle, lap both using lapping compound. If either part requires replacement, replace both parts as a unit. 1.

Equal, symmetrical fuel spray pattern

4.

Lean fuel spray pattern

2.

Asymmetrical fuel spray pattern

5.

Stepped fuel spray pattern

3.

Incorrect fuel spray pattern

6.

Equal fuel spray (from 5 jets)

EF-5-4

CONVENTIONAL TYPE


INSTALLATION 1. 2. 3. 4.

Install the nozzle holder assembly on the cylinder head. : 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf} Connect the spill tube and injection nozzle tube. Bleed air from the fuel system. (Refer to the “MA” section for procedures.) Connect the ground cable to the battery.

EF-5-5

CONVENTIONAL TYPE


= TWO-SPRING TYPE = CONSTRUCTION

REMOVAL 1. 2. 3.

Chock wheels and tilt open the cab. Turn the key switch OFF and disconnect the ground cable from the battery. Disconnect the injection nozzle tube and spill tube, remove the nozzle holder assembly from the cylinder head.

EF-5-6

TWO-SPRING TYPE


TWO-SPRING TYPE

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cap nut 2. Gasket 3. Nut 4. Adjusting screw 5. No. 2 spring 6. No. 2 push rod 7. Shim (for pre-lift adjustment)

8. Setscrew 9. Spacer 10. Shim (for valve opening pressure adjustment) 11. No. 1 spring 12. No. 1 push rod

Key point of disassembly Nozzle and nozzle holder assembly 1. Secure nozzle in vice by holding nozzle holder portion with nozzle holes facing down. 2. Loosen cap nut and remove gasket. 3. Loosen nut, and remove adjusting nut, and then take out No. 2 spring, No. 2 push rod and pre-lift adjusting shim. 4. Remove set screw, and take out spacer, valve opening pressure adjusting shim, No. 1 spring and No. 1 push rod. 5. Secure nozzle by holding nozzle holder in vice with nozzle hole facing up, and loosen retaining nut, then remove nozzle assembly and pin. 6. Remove nozzle needle from nozzle body. NOTE z Be sure to keep nozzle needle and nozzle body as a matched set.

EF-5-7

13. Retaining nut 14. Nozzle assembly 15. Pin 16. Connector 17. Gasket 18. Nozzle holder


INSPECTION Clean all disassembled parts in cleaning solvent. Check for scratches, cracks or damage and replace faulty parts. z If measurement indicates that the service limit has exceeded, repair or replace faulty parts. NOTE z Remove carbon from around injection hole using wire brush. z

1.

Using pin vise (99727 Z5005), remove carbon from nozzle hole. Unit: mm (in)

Nozzle identification mark A3

Number of injection nozzle holes


Wire diameter

2

0.30 (0.0118)

0.29 (0.0114)

NOTE

Do not extend tip of the holder more than 2 to 2.5 mm (0.079 to 0.098 in). Otherwise, it may bend inside the nozzle body so that it cannot be removed. z Carefully push the holder into the inside of the nozzle to remove carbon. z Use an oil stone to grind the wire tip of the holder until it is shaped as shown in the figure. z

2.

Clean remaining carbon off the back of the nozzle jet using the nozzle cleaner (99726 Z5000). NOTE z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle. Do not use compressed air to remove carbon because this may introduce foreign matter into the jet. 3.

Install the needle on the nozzle body while immersing both in clean diesel fuel.

4.

Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation. Position the nozzle body vertically. Pull out the needle so that it protrudes approximately 1/3 its total length beyond the top of the nozzle body. Then release it to ensure that it drops to the valve seat under its own weight.

5.

EF-5-8

TWO-SPRING TYPE


REASSEMBLY To reassemble, reverse the sequence of disassembly, paying attention to the following points. NOTE

When assembling nozzle to nozzle holder, be sure to clean each contacting surface and retaining nut with clean light oil. z Replace gasket with a new one each time nozzle is disassembled. See section “Adjustment” when reassembling. z

Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Cap nut

39 - 49{ 4.0 - 5.0, 29 - 36}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Nut

20 - 25 {2.0 - 2.5, 14 - 18}

Set screw

49 - 59 {5.0 - 6.0, 36 - 43}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

ADJUSTMENT OVERHAULING TYPE Adjusting nozzle opening pressure 1.

Using retaining nut (157892-2020), fix nozzle assembly on nozzle holder. : 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf} NOTE z Tighten retaining nut after confirming that dowel pin is entered fully into nozzle. 2.

Remove screw from end of retaining nut (157892-2020).

3.

Install No. 1 push rod, No. 1 spring, opening pressure adjusting shim and spacer to nozzle holder, and tighten with set screw. : 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}

EF-5-9

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER 4.

Using nozzle tester (105785-1010) [with 49,035 kPa {500 kgf/cm2, 7,110 psi} gauge], measure valve opening pressure (regulated pressure) of nozzle. Unit: kPa {kgf/cm2, psi} Maintenance standard

Service limit

17,162 - 17,947 {175 - 183, 2,489 - 2,602}

—

5.

If the valve opening pressure is out of standard, change thickness of valve opening pressure adjusting shim so that specified pressure is obtained. NOTE z Before installing a shim, be sure to measure its thickness with a micrometer. z If necessary, use a set of two shims. z Select proper shims, noting that a 0.02 mm (0.0008 in) thick shim changes the valve opening pressure by 235 kPa {2.4 kgf/cm2, 34 psi}. 0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118), Adjusting shim 0.40 (0.0157), 0.50 (0.0197), 0.52 (0.0205), thickness 0.54 (0.0213), 0.56 (0.0220), 0.58 (0.0228), mm (in) 0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315), 0.90 (0.0354), 1.00 (0.0394)

Pre-lift adjustment 1.

Install a 60.5 mm (2.382 in) pin (157892-1100) to the dial gauge (157954-3800) and connect it to the adjusting device (157892-0220).

2.

Secure base (157892-1800) in vise, assemble No. 2 push rod, and set adjusting device (157892-0220), then align dial gauge needle with “0”. 3. Assemble push rod into nozzle holder. NOTE z Do not assemble No. 2 spring and pre-lift adjusting shim.

EF-5-10

TWO-SPRING TYPE


Fit adjusting device to nozzle holder set screw, secure with intermediate screw, and move dial gauge holder up and down to check for smooth dial gauge movement. 5. Push down by holding dial gauge holder, and read dial gauge needle deflection (lift: h). NOTE z Read dial gauge indication in units of 1/100 mm. 6.

Select proper thickness of pre-lift adjusting shim. t = (l + h) t: Thickness of shim (measured value) l: Pre-lift (standard value) h: Lift (measured value in step 5) above) Thickness of shim to be selected must be T = t±0.015 mm. 0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118), 0.40 (0.0157), Adjusting shim 0.50 (0.0197), 0.52 (0.0205), 0.54 (0.0213), 0.56 (0.0220), thickness 0.58 (0.0228), 0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315), mm (in) 0.90 (0.0354), 1.00 (0.0394)

7.

Remove adjusting device from nozzle holder.

Adjustment of No. 2 spring 1.

Assemble No. 2 spring adjusting screw and nut on nozzle holder. NOTE z Do not assemble pre-lift adjusting shim at this stage. Accordingly, No. 1 and No. 2 push rods are in contact. 2.

Using nozzle tester, adjust No. 2 spring by turning adjusting screw, and lock with nut. : 20 - 25 N·m {2.0 - 2.5 kgf·m, 14 - 18 ft·lbf} NOTE z Reconfirm the valve opening pressure after adjustment; it changes by securing with the lock nut. Unit: kPa {kgf/cm2, psi} Item Valve opening pressure (Regulated pressure)


Service limit

Remarks

24,321 - 24,910 {248 - 254, 3,527 - 3,612}

—

Push rod contacting method

NOTE z

Push rod contacting method means that the plug at the tip of the special tool’s retaining nut has been removed.

EF-5-11

TWO-SPRING TYPE


Checking total lift of nozzle (needle valve) 1. 2.

Install screw on retaining nut (157892-2020). Install connector (157892-1320) on nozzle holder set screw. : 39 - 49 N·m {4.0 - 5.0 kgf·m, 29 - 36 ft·lbf}

3.

Install a 50.0 mm (1.969 in) pin (157892-1200) to the dial gauge (157954-3800) and connect it to the connector. NOTE z Secure the dial gauge so that it can measure a stroke of about 1.2 mm (0.047 in). z Be careful not to tighten the nut excessively as the dial gauge shaft may seize causing malfunction. 4. Set dial gauge to “0” point. 5. Using nozzle tester, bleed air from retaining nut, and also check for fuel leaks. 6. Operate nozzle tester (105785-1010), pressurize up to 34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi}, and read total lift “L” of nozzle needle indicated on dial gauge. NOTE z Dimension “L” indicated at this time is pre-lift plus prelift adjusting shim thickness. 7.

Remove connector (with dial gauge) from nozzle holder.

Assembling pre-lift adjusting shim 1.

Remove set screw assembly (consisting of set screw, adjusting screw and nut) and No. 2 push rod from nozzle holder. NOTE z Never attempt to loosen nut, otherwise, No. 2 spring adjusting pressure will change.

EF-5-12

TWO-SPRING TYPE


Insert pre-lift adjusting shim selected in step 6 (under “Prelift adjustment”) between spacer and No. 2 push rod, and assemble spacer and rod onto nozzle holder, and fit No. 2 spring; then tighten with set screw assembly. : 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf} NOTE z At this stage, No. 1 and No. 2 push rods are separated by space equivalent to pre-lift. 3.

4.

Install connector (157892-1320) on nozzle holder set screw, install dial gauge, and set dial gauge needle to “0” point. : 39 - 49 N·m {4.0 - 5.0 kgf·m, 29 - 36 ft·lbf} Using nozzle tester, bleed air from within retaining nut.

5.

Operate nozzle tester (105785-1010), pressurize up to 34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi}, and read total lift “S” of nozzle needle on dial gauge. NOTE z Dimension S is total lift of needle valve minus pre-lift.

Checking pre-lift 1.

2. 3.

Confirm amount of pre-lift from dimension L measured in step 4 (under “Checking total lift of nozzle”) and dimension S measured in step 5 (under “Assembling pre-lift adjusting shim”). Uliter = L - S mm (in) Uliter: Pre-lift (measured value) L: Total lift of needle valve (measured value) S: Needle valve lift after subtracting pre-lift (measured value) Confirm that dimension Uliter is within pre-lift range of 0.12±0.02 mm (0.0047±0.0008 in). If dimension Uliter is not within range of specified dimension 0.12±0.02 mm (0.0047±0.0008 in), replace pre-lift adjusting shim, and perform operations 4 and 5 (under “Assembling pre-lift adjusting shim”). Select thickness (t’) of shim, proceeding as follows: t’ = t + (liter - Uliter) t’: Shim thickness t: Thickness of shim assembled. T = t’±0.015 T: Thickness of shim to be used

Checking No. 2 spring adjusting pressure 1.

After checking for pre-lift, pressurize up to 34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi} to fully stroke (total lift) nozzle needle valve. EF-5-13

TWO-SPRING TYPE


After needle valve is lifted up fully, release nozzle tester handle to allow pipe pressure to lower spontaneously. When 0.05 mm (0.0020 in) drop in needle valve lift is indicated on dial gauge, read pressure on pressure gauge. Unit: kPa {kgf/cm2, psi} Item

Valve opening pressure (Regulated pressure)


Service limit

23,046 - 23,537 {235 - 240, 3,342 - 3,413}

—

Remarks Nozzle cover method

NOTE z

Nozzle cover method means that the special tool’s retaining nut and the plug at the tip are attached.

3.

If No. 2 spring adjusting pressure is not within specified value, perform adjustment as explained in step Adjustment of No. 2 spring “Push rod contacting method”, then check No. 2 spring adjusting pressure again. 4. Remove connector (157892-1320) together with dial gauge. Finish inspection 1. Remove retaining nut (157892-2020), and install standard retaining nut. : 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf} NOTE z Before tightening retaining nut, confirm that dowel pin is completely fitted into nozzle. 2.

Install cap nut. : 39 - 49 N·m {4.0 - 5.0 kgf·m, 29 - 36 ft·lbf}

3.

Install nozzle on nozzle tester (105785-1010), and check injection opening pressure. Unit: kPa {kgf/cm2, psi} Item

Injection opening pressure (1st stage)


Service limit

16,672 {170, 2,417}

—

NOTE z

Never spray injected fuel on hand: otherwise, fuel spray under high pressure will penetrate deeply into the skin, causing blood poisoning.

EF-5-14

TWO-SPRING TYPE


Check spray pattern, injection holes for clogging, and for oil tightness. If nozzle body seat face and nozzle needle are scratched or worn by chips or carbon in fuel, repair by lapping with compound, provided damage is very small. If replacement is needed, be sure to replace nozzle needle and body as a matched set. 1.

Even and symmetrical

4.

Too thin

2.

Asymmetrical

5.

Stepped

3.

Branching

6.

Uniform injection from five nozzle holes

SIMPLIFIED INSPECTION Checking injection beginning pressure and spray pattern 1.

Install nozzle on nozzle tester, and check injection opening pressure. Unit: kPa {kgf/cm2, psi} Item

Injection opening pressure (1st stage)


Service limit

16,672 {170, 2,417}

—

NOTE z

Never spray injected fuel on hand: otherwise, fuel spray under high pressure will penetrate deeply into the skin, causing blood poisoning.

2.

Check spray pattern, injection holes for clogging, and oil tightness.

3.

1.

Even and symmetrical

4.

Too thin

2.

Asymmetrical

5.

Stepped

3.

Branching

6.

Uniform injection from five nozzle holes

If nozzle is found to be faulty, replace or overhaul nozzle, and perform adjustment according to step 1 above.

EF-5-15

TWO-SPRING TYPE


Checking No. 2 spring adjusting pressure 1.

Remove retaining nut, and install retaining nut (1578922020) for adjustment. : 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf} NOTE z Be sure to tighten retaining nut after making sure that dowel pin is fitted completely into nozzle. 2.

3.

4.

Remove cap nut, and install connector (157892-1320) together with dial gauge. Use dial gauge pin of 50.0 mm (1.969 in) in length. : 39 - 49 N·m {4.0 - 5.0 kgf·m, 29 - 36 ft·lbf} Install nozzle holder on nozzle tester, and purge air from inside of retaining nut, then raise pressure in pipe to 34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi} to move nozzle needle valve to maximum lift position.

After moving needle valve to maximum lift position, leave nozzle tester handle as it is to allow pressure to lower. As pressure drops, needle valve lift will decrease. Read pressure gauge indication when dial gauge indicates a needle valve drop of 0.05 mm (0.0020 in). Unit: kPa {kgf/cm2, psi} Item

Valve opening pressure (Regulated pressure)

5.


Service limit

23,046 - 23,537 {235 - 240, 3,342 - 3,413}

—

Remarks Nozzle cover method

If adjusting pressure of No. 2 spring is not within specified range, perform adjustment according to step 1 above.

Finish inspection Check injection beginning pressure, spray condition and oil tightness according to steps 1 and 2 (under “Checking injection beginning pressure and spray pattern”).

INSTALLATION 1. 2. 3. 4.

Install the nozzle holder assembly on the cylinder head. : 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf} Connect the spill tube and injection nozzle tube. Bleed air from the fuel system. (Refer to the “MA” section for procedures.) Connect the ground cable to the battery. EF-5-16

TWO-SPRING TYPE

FUEL FILTER

FUEL FILTER CONSTRUCTION Cartridge type

Center bolt type

EF-6-1

FUEL FILTER

Primary fuel filter

EF-6-2

FUEL FILTER

Fuel strainer

REPLACING FUEL FILTER ELEMENT Refer to the “MA” section for replacement of the fuel filter.

Cartridge type Disassembly sequence (Reassembly sequence is the reverse order of disassembly.) 1.

Cartridge assembly

2.

Cover

EF-6-3

FUEL FILTER

Center bolt type Disassembly sequence (Reassembly sequence is the reverse order of disassembly.) 1.

Drain plug

6.

Seat spring

2.

Packing

7.

Retainer

3.

Center bolt

8.

Element

4.

Packing

9.

Packing

5.

Filter case

10.

Filter cover

Primary fuel filter Disassembly sequence (Reassembly sequence is the reverse order of disassembly.) 1.

Plug

7.

Set spring

2.

Packing

8.

Retainer

3.

Drain cock

9.

Element

4.

Center bolt

10.

Packing

5.

Packing

11.

Filter cover

6.

Filter case

EF-6-4

FUEL FILTER Disassembly sequence (Reassembly sequence is the reverse order of disassembly.) 1.

Drain plug

7.

Seat

2.

Packing

8.

Element

3.

Center bolt

9.

Packing

4.

Packing

10.

Filter cover

5.

Filter case

11.

Filter plug

6.

Spring

12.

O-ring

Fuel strainer Disassembly sequence (Reassembly sequence is the reverse order of disassembly.) 1.

Drain plug

6.

Set spring

2.

Center bolt

7.

Baffle

3.

Packing

8.

Screen

4.

Strainer case

9.

Packing

5.

Spring retainer

10.

Strainer cover

EF-6-5

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM = FE6A, FE6B, FE6T AND FE6TA [173 kW {235 PS}] = CONSTRUCTION

ADJUSTMENT ENGINE CONTROL WIRE Turn the engine control knob fully counterclockwise and connect the engine control wire to lever. Securely fit the clips (2 places on the wire end) in the bracket. Dimension L: 78.0 - 80.0 mm (3.071 - 3.150 in)

EF-7-1


ACCELERATOR WIRE 1.

Connect one end of the accelerator wire to lever. Securely fit the clip on the wire in the panel. NOTE z Be careful not to break the boot.

2.

Connect the other end of the accelerator wire to the engine side. Check that the control lever of the injection pump touches the stopper bolt and that there is no free play at the wire connection. Then, tighten the nut.

3.

Depress the accelerator pedal until the control lever of the injection pump contacts the stopper bolt. While holding the control lever in that position, adjust the clearance between the pedal and stopper to “H” and secure the stopper bolt. Clearance H: 0 - 4.0 mm (0 - 0.157 in)

ENGINE STOP LINKAGE Manual stop type Connect the engine stop wire on the fuel injection pump side. The knob should be positioned at “load” position. Before securing the threaded section of the wire, ensure that the adjusting section of the wire has no slack, and that dimension L is maintained. Item

Dimension L mm (in)

Except vacuum brake vehicle

118.0 (4.646)

Vacuum brake vehicle only

128.0 (5.039)

Auto stop type 1. Turn the ignition switch OFF and stop the motor. NOTE z Make sure the wire inner cable is retracted on the motor side. Stroke A: 35.0 mm (1.378 in) Set length B: 90.0 mm (3.543 in)

EF-7-2

ENGINE CONTROL SYSTEM 2.

Connect the clevis of the cable tip to the stop lever of the injection pump. Pull the stop lever to the stop position and temporarily install the wire adjusting nut on the support.

3.

Turn the wire adjusting nut in the wire tensioning direction, approximately one turn additionally from the condition under which there is no slack in the wire.

EF-7-3


= FE6TA [157 kW {213 PS}] = CONSTRUCTION

ADJUSTMENT ENGINE CONTROL WIRE Turn the engine control knob fully counterclockwise and connect the engine control wire to lever. Securely fit the clips (2 places on the wire end) in the bracket. L length: 78.0 - 81.0 mm (3.071 - 3.189 in)

EF-7-4


ACCELERATOR WIRE 1.

Connect one end of the accelerator wire to lever. Securely fit the clip on the wire in the panel. NOTE z Be careful not to break the boot.

2.

Connect the other end of the accelerator wire to the engine side. Check that the control lever of the injection pump touches the stopper bolt and that there is no free play at the wire connection. Then, tighten the nut.

3.

Depress the accelerator pedal until the control lever of the injection pump contacts the stopper bolt. While holding the control lever in that position, adjust the clearance between the pedal and stopper to “H” and secure the stopper bolt. Clearance H: 0 - 4.0 mm (0 - 0.157 in)

EF-7-5


ENGINE STOP LINKAGE To install and adjust the engine auto-stop system, proceed as follow: 1. Temporarily install the solenoid assembly on bracket and connect wiring. 2. Install the rod between the stop lever on the injection pump and on the solenoid on the injection pump side. Tighten the lock nuts.

3.

Turn the key switch ON. Current flows so that the solenoid retracts. NOTE z Ensure that solenoid retracts completely.

4. 5.

Turn the swivel one more turn in the direction of the arrow, and move the stop lever approximately 3.0 mm (0.118 in) towards the stop side. After stop lever adjustment, tighten the lock nut and solenoid mounting bolts.

EF-7-6

- MEMO -

“MD-TICS” SYSTEM

“MD-TICS” SYSTEM CONTENTS SYSTEM OVERVIEW ................................................................................................. EF-8-2 SYSTEM DIAGRAM ............................................................................................................................. EF-8-2 LOCATION OF EQUIPMENT .............................................................................................................. EF-8-4 FUNCTION OF EQUIPMENT ............................................................................................................. EF-8-5

FUNCTION AND CONSTRUCTION .......................................................................... EF-8-7 OUTLINE ............................................................................................................................................. FUEL INJECTION RATE CONTROL .................................................................................................. PRE-STROKE CONTROL MECHANISM ........................................................................................... FUEL INJECTION TIMING CONTROL ............................................................................................... SELF-DIAGNOSIS AND “BACK UP” FUNCTION ............................................................................... Trouble Display and “Back-up” ....................................................................................................... Trouble Diagnosis ..........................................................................................................................

EF-8-7 EF-8-8 EF-8-9 EF-8-13 EF-8-14 EF-8-14 EF-8-14

TROUBLE DIAGNOSIS AND TROUBLE-SHOOTING ............................................. EF-8-16 [1] TROUBLE DISPLAY ...................................................................................................................... [2] TROUBLE DIAGNOSIS ................................................................................................................. [3] TROUBLE-SHOOTING .................................................................................................................. (1) Checking Diagnosis Light System ............................................................................................ (2) Checking Control Unit Power Supply System .......................................................................... (3) Checking Rack Sensor System ................................................................................................ (4) Checking Engine Speed Sensor System ................................................................................. (5) Checking Engine Coolant Temperature Sensor System .......................................................... (6) Checking Pre-stroke Sensor System ....................................................................................... (7) Checking Pre-stroke Servo System ......................................................................................... (8) Checking Pre-stroke Power Supply System ............................................................................ [4] CLEARING DIAGNOSTIC MEMORY ............................................................................................

EF-8-17 EF-8-18 EF-8-21 EF-8-29 EF-8-33 EF-8-36 EF-8-43 EF-8-49 EF-8-54 EF-8-58 EF-8-62 EF-8-64

APPENDIX ................................................................................................................. EF-8-65 Table 1 Failure Judgement Conditions For “MD-TICS” System .................................................... Table 2 “BACK-UP” Operations For “MD-TICS” System ............................................................... Terminal Connection Drawing ....................................................................................................... Wiring Diagram ..............................................................................................................................

EF-8-65 EF-8-66 EF-8-67 EF-8-70

NOTE z

There are two types of “MD-TICS SYSTEM”; one is destined for HONG KONG and the other for NORWAY. On the following pages, “Type I” refers to HONG KONG specifications and “Type II” refers to NORWAY specifications.

EF-8-1


SYSTEM OVERVIEW The “MD-TICS” system is a system that optimizes the fuel injection rate and fuel injection timing by using electronic control. MD - TICS Code

Timing & Injection rate Control System

The MD-TICS system consists of the control unit, the pre-stroke actuator that is actuated by the signal from the control unit, the sensors (engine speed sensor, rack sensor, engine coolant temperature sensor, and prestroke sensor) that read the operating condition of the engine and give signals to the control unit, the switches and lights, and the electrical wiring. This is an electronic control system in which the action of these units is used to compare the ideal values programmed beforehand into the microcomputer (control unit) with the actual values. In this way, the injection timing and fuel feed rate are controlled, the exhaust gas is cleaned, and the output is improved.

SYSTEM DIAGRAM

EF-8-2


EF-8-3


LOCATION OF EQUIPMENT

EF-8-4


FUNCTION OF EQUIPMENT Control Unit Main function z Fuel injection rate control z Fuel injection timing control Supplementary function z Self-diagnosis function z “Back up” function

Pre-stroke Actuator/Sensor The pre-stroke actuator is installed at the front of the injection pump. It consists of the pre-stroke sensor and pre-stroke servo that is actuated by signals from the control unit. The pre-stroke sensor is inside the pre-stroke actuator. It compares the target position instructed from the pre-stroke control unit with the actual position to detect if the position is correct, and feeds this information back to the control unit.

Engine Speed Sensor The engine speed sensor is installed to the gear case and detects the engine speed with a magnetic pick-up. The engine speed sensor detects the potential difference generated when gear teeth traverse the tip of the engine speed sensor and sends the potential difference to the control unit (25 pulses by one rotation of the engine).

The engine speed sensor is installed to the injection pump and detects the engine speed with a magnetic pick-up. It detects the potential difference generated when the protrusions (12 places at equal distances) on the coupling (flywheel) of the injection pump pass the tip of the engine speed sensor and sends this to the control unit.

Engine Coolant Temperature Sensor The engine coolant temperature sensor is a variable resistor (thermistor type) in which the resistor changes according to the change in the temperature of the engine cooling water. It reads the engine coolant temperature as the change in the resistance, and inputs an electrical signal to the control unit. The engine coolant temperature sensor is installed at the water manifold.

EF-8-5


Rack Sensor The rack sensor is a non-contact displacement meter that acts to send the movement of the control rack of the injection pump to the control unit. The rack sensor sends out an alternating wave current (sine wave) from the OSC terminal (oscillation terminal) of the control unit. It detects the position of the rack from the MDL (middle) signal generated by the change in the impedance (self-induction) between the two coils, and sends this to the control unit.

Diagnostic Switch The diagnostic switch is the switch used to carry out trouble-shooting of the electronic control system. The diagnostic switch consists of one pair of male and female terminals. These are normally connected; they are disconnected only when carrying out trouble-shooting. The diagnostic switch is installed behind the electrical unit board and labeled with a “DIAGNOSIS” tag.

Memory Reset Switch This switch is used to delete the control unit trouble data from memory. To delete the data, short circuit the connector terminals for about ten seconds. The memory reset switch is installed behind the electrical unit board and labeled with a “MEMORY” tag.

EF-8-6


FUNCTION AND CONSTRUCTION OUTLINE The “MD-TICS” system is a system that optimizes the fuel injection rate and fuel injection timing by using electronic control. In more concrete terms, it controls the pre-stroke of the injection pump, and changes the injection timing and injection rate. The concept of the pre-stroke control is shown in the diagram below. Pre-stroke Characteristic

EF-8-7


FUEL INJECTION RATE CONTROL With the present type of injection pump, the pre-stroke is fixed. However, with the variable injection rate injection pump, the operating condition of the engine and control condition of the driver are detected by various sensors, and the information signal is processed by the control unit. Based on the control signal from the control unit, the control sleeve installed in the fuel chamber of the barrel portion is moved up and down by the pre-stroke actuator to change the pre-stroke and control the fuel injection rate. NOTE z

Hereafter in this text, from the point of explaining the action with the operation diagrams, the expression “fuel injection rate” is not used. The term “fuel feed rate” is used instead.

When supplying a fixed amount of fuel, if the feed timing is long, a smaller amount of fuel is supplied per unit time, and this gives a low fuel feed rate. On the other hand, if the feed timing is short, a larger amount of fuel is supplied per unit time, and this gives a high fuel feed rate.

The amount of cam lift when the injection pump cam rotates and moves from the plunger lift starting point a to the fuel feed starting point A is called the pre-stroke.

EF-8-8


PRE-STROKE CONTROL MECHANISM The operation of the fuel feed for the variable fuel feed rate injection pump is as follows.

1.

Before fuel feed Until the plunger rises and the suction port is blocked by the control sleeve, the fuel in the pressure chamber passes through the suction port and flows out to the fuel chamber. Therefore, the pressure in the pressure chamber does not rise.

2.

Start of fuel feed When the plunger rises further and the suction port is blocked by the bottom end of the control sleeve, the fuel feed operation starts.

3.

During fuel feed While the suction port is between the bottom of the control sleeve and the spill port, the fuel continues to be fed.

4.

Completion of fuel feed When the suction port and the notched groove (lead) of the plunger are connected with the spill port of the control sleeve, the high pressure fuel in the pressure chamber is drained through the spill port to the fuel chamber, and this completes the fuel feed.

EF-8-9


Change in fuel feed rate for same fuel feed amount When the control sleeve is at the top, the pre-stroke is at its maximum, and as the plunger lift speed is fast, the fuel feed time can be made shorter. This means that the amount of fuel fed per unit time is larger and the fuel feed rate is higher. On the other hand, when the control sleeve is at the bottom, the pre-stroke is at its minimum, and as the plunger lift speed is slow, the fuel feed time is longer. This means that the amount of fuel fed per unit time is smaller and the fuel feed rate is lower. Under normal operating conditions, for low speed, the control sleeve is at the top to give a high fuel feed rate, and at high speed, the control sleeve is moved to the bottom to prevent the fuel feed rate from becoming too high.

The pre-stroke control mechanism consists of the following. (1) The control sleeve that is moved up and down by the control rod inside the barrel (2) The control rod that rotates and moves the control sleeve with a pin (3) The rotary solenoid that rotates the control rod

(4) The pre-stroke sensor that always feeds back the movement of the rotary solenoid to the control unit When the control sleeve goes up, the pre-stroke becomes larger, and when it goes down, the pre-stroke becomes smaller.

EF-8-10


The pre-stroke actuator has a shape that forms three sides of a square, and consists of an iron core with a coil wound around it. A rotor is placed between the jaws of the actuator, and a magnetic force proportional to the control signal (current) from the control unit is generated by the rotary solenoid. The action of this magnetic force then causes the rotor to rotate. The control sleeve is interconnected, so it moves up or down.

EF-8-11


The power source for the pre-stroke actuator has a separate circuit. If there is any abnormality in the pre-stroke servo system, this circuit functions to stop the control, and at the same time it opens the pre-stroke cut relay to cut the power for the pre-stroke actuator. At the same time, the boost compensator cut 3-way magnetic valve is switched OFF, and the maximum injection amount is limited to prevent any secondary damage being caused when the control of the injection pump is stopped.

EF-8-12


The pre-stroke sensor compares the target position sent from the control unit and detects if the pre-stroke actuator is actually in the correct position. Like the rack sensor, it is a non-contact displacement meter, and sends out an alternating wave current (sine wave) from the OSC terminal (oscillation terminal) of the control unit. It detects the position of the pre-stroke actuator (control sleeve) from the MDL (middle) signal generated by the change in the impedance (selfinduction) between the two coils, and sends this to the control unit. The pre-stroke sensor harness is equipped with a shielding wire to prevent noise. The shielding wire acts to prevent the influence of any outside interference, thereby protecting the signal detected by the sensor; it also acts to set the measurement standard. If there is improper connection of the shielding wire (particularly at the connector), or there is improper grounding of the control unit case, this may cause disconnections or resistance (increased or reduced) which will cause abnormalities in the pre-stroke control. To prevent this, please be sure to carry out the grounding connection of the control unit and the pre-stroke sensor wiring harness properly.

FUEL INJECTION TIMING CONTROL The timing for the start of fuel injection from the variable fuel feed rate injection pump is interconnected with the control of the pre-stroke. If the fuel feed rate is made high, the pre-stroke will become larger, so this well result in retarding the timing for the start of fuel injection; if the fuel feed rate is made low, the pre-stroke will become smaller, so this will result in advancing the timing for the start of fuel injection. Under actual operating conditions, the fuel feed rate is set high when the engine is rotating at low speed, such as during warming-up operations, and is set low when the engine is rotating at high speed. Therefore, the timing for the start of fuel injection is also delayed when the engine speed is low and is advanced when the engine speed is high, which is more or less the same action as with the present timer. In addition, when the weather is cold, to prevent white smoke, control is carried out by the control unit in accordance with the operating condition of the engine to give the optimum fuel feed rate and timing for the start of injection.

EF-8-13


SELF-DIAGNOSIS AND “BACK-UP” FUNCTION The control unit always uses the signals input from each sensor to diagnose whether there is any abnormality inside the system. If it judges that there is an abnormality, it lights up the Engine Control warning light inside the cluster meter to warn the drive of the abnormality. At the same time, it carries out a back-up function to move the system to a safe zone where there is no excessive load on the engine. By using the diagnostic switch, the Diagnosis Display Code is displayed on the diagnosis light (Engine Control warning light and Overheat warning light), and trouble-shooting is carries out.

Trouble display and “back-up” If a failure occurs in the MD-TICS system (refer to Table 1 “Failure Judgement Conditions” at the end of the chapter), the Engine Control warning light comes on and displays the occurrence of a failure. [User mode] At the same time, the back-up system is actuated to keep the system in the safety zone so that there is no excessive load on the engine, while making it possible to continue to travel. Table 2 at the end of the chapter gives details of the back-up operation.

Trouble diagnosis Trouble diagnosis can be carried out by releasing the diagnostic switch. The results of the diagnosis are displayed by the diagnosis light (Engine Control warning light and Overheat warning light) (flashing light: Diagnosis Display Code). [Dealer mode] When the Overheat warning light flashes, the buzzer also sounds at the same time.

EF-8-14

“MD-TICS” SYSTEM Engine Control warning light: displays present trouble

Overheat warning light: displays the past trouble (*)

NOTE (*) z To carry out analysis of past troubles, the system is equipped with a diagnostic memory function. This function stores in the memory any failure signals for abnormality that occurred during travel. It acts to replay these signals when carrying out analysis of the trouble. The signals stored in the memory are retained even when the ignition key switch is turned OFF. z Normally, the Overheat warning light lights up when the engine overheats or when the coolant level becomes too low. However, when the diagnostic switch is released, it displays the result of the diagnosis of past troubles in the MD-TICS system. The overheat warning function is not incorporated in the control unit.

EF-8-15


TROUBLE DIAGNOSIS AND TROUBLE-SHOOTING The “MD-TICS” system always uses the signals input from each sensor to diagnose whether there is any abnormality inside the system. If it judges that there is an abnormality (for judgement standards, refer to Table 1 at the end of the chapter), it lights up the Engine Control warning light inside the cluster meter to warn the driver of the abnormality. The abnormality is displayed by the lighting up of the Engine Control warning light in the cluster meter. If any abnormality occurs, the back-up function is automatically carried out to move the system to a safe zone where there is no excessive load on the engine. (For details of the back-up operation, refer to Table 2 at the end of the chapter.) When the Engine Control warning light lights up to display an abnormality, carry out trouble diagnosis and trouble-shooting using the procedure given below.

EF-8-16


[1] TROUBLE DISPLAY If it is judged that there is an abnormality in the MD-TICS system, the Engine Control warning light comes on to display trouble. NOTE z

This is called the “User mode”. The user mode is displayed when the diagnostics switch is ON (connected).

Item MD-TICS Normal Abnormal

Ignition key switch “ON”

Remarks

Engine stopped

Engine running

Light “ON”

Light “OFF”

Lights come ON to check for blown bulbs

Light “ON”

Light “ON”

Abnormality in MD-TICS

Light “OFF”

Light “OFF”

Light bulb blown or other abnormality

EF-8-17


[2] TROUBLE DIAGNOSIS If the trouble display shows that there is an abnormality in the MD-TICS system, carry out trouble diagnosis according to the following procedure. 1) TURN THE DIAGNOSTIC SWITCH OFF. 2) IGNITION KEY SWITCH 1. OFF → ON: Do not run the engine. 2. After cranking, stop the engine. With the ignition key switch ON. 3. Run the engine. Carry out diagnosis under the above three conditions. NOTE z

The reason for using these three positions of the ignition key switch is to allow diagnosis to be carries out under all three conditions so that all troubles can be located. Refer to Diagnosis Display Code and Trouble Location table.

3)

DISPLAY OF RESULT OF TROUBLE DIAGNOSIS The result of the trouble diagnosis is displayed by the flashing (Diagnosis Display Code) of the diagnosis light (Engine Control warning light and Overheat warning light) NOTE z This is called the “Dealer mode”. The dealer mode is displayed when the diagnostic switch is OFF (released).

Diagnosis light

Engine control warning light

Overheat warning light & buzzer

Displays present trouble

Displays past trouble (*)

Normal

Displays Diagnosis Display Code <0-1>

Key ON: Light ON, Buzzer shows <0-1> code Eng. ON: Light & Buzzer show Diagnosis Code

Abnormal

Displays Diagnosis Display Code

Displays Diagnosis Display Code

MD-TICS

NOTE (*) z The diagnostic memory of the control unit has a memory that stores the past trouble conditions, and displays them. When the diagnostic switch is released, it does not show the engine overheating condition; instead of this, it displays the results of diagnosis of past troubles. z If the trouble that occurred in the past is the same as the trouble that is occurring at the present, only the present condition (Engine Control warning light) is displayed.

EF-8-18


Dealer mode

OFF → ON

ON (after cranking, stop engine)

ON (engine running)

Diagnosis light (Engine control warning light Overheat warning light)

0—1

O

O

O

OFF

—

—

—

Light bulb blown, etc.

(1)

ON

—

—

—

C.U. power supply system

(2)

1—3

X

O

O

Rack sensor system

(3)

1—5

O

O

O

Engine speed sensor system (disconnection)

User mode [MD-TICS normal or abnormal]

Diagnosis display code

Normal

OFF

Location of trouble (trouble-shooting item number)

Position of ignition key switch (*)

Lighting pattern

—

—

(4) 1—6

X

O

X

Engine speed sensor system (no pulse)

2—1

O

O

O

Engine coolant temperature sensor system

(5)

2—3

O

O

O

Pre-stroke sensor system

(6)

1—2

O

O

O

Pre-stroke servo system

(7)

2—2

O

O

O

Pre-stroke power supply system

(8)

2—4

O

X

X

Pre-stroke learning function

(6)

Abnormal ON

Note (*) “O”: Displayed “X”: Not displayed

EF-8-19


Meaning of Diagnosis Display Code

Actual Display Method for Diagnosis Display Code The diagnosis light displays the diagnosis continuously as follows.

Example: Compound trouble (1-2 and 1-3 occur together) After displaying 1-2 three times, 1-3 is displayed three times. After this, 1-2 and 1-3 are displayed three times each in turn.

EF-8-20


[3] TROUBLE-SHOOTING If the trouble diagnosis makes the condition of the trouble clear, go on to trouble-shooting. The explanation below gives the procedure for trouble-shooting for each trouble location (this forms a pair with the diagnosis display code).

[Precautions when carrying out trouble-shooting] (1) Precautions when checking the wiring harness There is a high probability that problems with the wiring harnesses, such as disconnections, short circuits, and improper contact, will occur at the connector. It is rare for disconnections or short circuits to occur in the wiring inside the wiring harness, but these problems can occur if there is interference between the wiring harness and other parts, causing it to ground with the body. When checking for abnormalities in the wiring harness, be particularly careful to check the following. 1) Is the connector properly connected? 2) Are any pins deformed? 3) Is there any dirt or dust stuck in the terminal, or is there any corrosion? 4) Is there any disconnection or short circuit at the joint of the connector. 5) Has the grounding been carries out properly? 6) Is there any interference between the wiring harness and other parts, or any improper insulation? (2) Precautions when measuring resistance at connector and checking continuity 1) When checking the resistance at the connector terminal and checking the continuity, the terminal hole is small, so strip the lead wire, insert two or three copper wires, and make sure that the terminal and lead wire are properly in contact. (For female terminals)

2) Do not insert the test lead of the tester directly into the connector terminal. If it is pushed in by force, the terminal inside the connector will be expanded and this will cause improper contact.

3) After completing this operation, check the connection of the connectors. Be particularly careful with the Z connectors for the engine because these can easily remain incompletely connected.

EF-8-21


[Preparation] Parts name and parts number

Use

Memory clear connector (24004 00Z09)

To clear diagnostic memory

Circuit tester (Commercially available; use tester with digital display)

Inspecting MD-TICS component and circuit

Lead wire x 2 (make yourself)

Connecting tester lead

EF-8-22

Shape


[How to read wiring diagram]

C.U. U CF M C

: Control Unit : Unit Harness : Cab Front Harness : Main Harness : Chassis Harness

EF-8-23


z

All connector symbols are shown from the terminal side. The number inside the box shows the number of the pins.

For single lines, a connector is indicated in the midway of the line. For plural lines, a connector and connector terminal position are shown in the midway of the lines. In this vicinity, connector shapes are shown and terminal positions are indicated by numbers.

EF-8-24


Wire size: sectional area (mm2)

Color code: Unicolor Alphabetical symbol

Color

W

White

B

Black

R

Red

Y

Yellow

G

Green

L

Blue

P

Pink

BR

Brown

LG

Light green

OR

Orange

PU

Purple

GR

Gray

SB

Sky Blue

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe

EF-8-25


[Position of harnesses and connectors]

A. Under the passenger seat Pull out the control unit from under the front passenger seat.

Locations for inspection 1. Control unit proper 2. Unit harness connector U-12 (18 pin, black) 3. Unit harness connector U-13 (12 pin, black)

EF-8-26


B. Inside of glove compartment Remove the lid and front cover of the glove compartment. Locations for inspection 1. Fuse block

C. Under the cab Tilt the cab and remove the cover. Locations for inspection 1. Unit harness connector U-4 (6, 12 pin) 2. Unit harness connector U-5 (5, 12 pin) 3. Unit harness connector U-1 (4, 16 pin) 4. Chassis harness connector C-3 (6, 12 pin) 5. Chassis harness connector C-4 (5, 12 pin) 6. Cab front harness connector CF-18 (4, 16 pin) 1. Unit harness connector U-18 (6, 12 pin) 2. Unit harness connector U-17 (5, 8 pin) 3. Unit harness connector U-16 (4, 12 pin) 4. Chassis harness connector C-82 (6, 12 pin) 5. Chassis harness connector C-81 (5, 8 pin) 6. Cab front harness connector CF-23 (4, 12 pin)

D. Front of engine Location for inspection 1. Engine coolant temperature sensor harness connector C27 (2 pin) NOTE z

There are two engine coolant temperature sensors of the same type beside each other. The one for the MD-TICS is distinguished by the wiring at the engine harness end (blue/red, blue/black).

EF-8-27

“MD-TICS” SYSTEM 2. 3. 4.

Pre-stroke actuator harness connector C-85 (8 pin) Rack sensor harness connector C-24 (4 pin) Engine speed sensor harness connector C-22 (3 pin)

E. Inside of electric unit board Locations for inspection 1. Rack sensor harness connector M-83 (2 pin)

[Service data] Item

Terminals to measure


Control unit power voltage

V

U-12 (3) - (12) U-12

20 - 28

Rack sensor resistance

Ω

C-24 (3) - (2) C-24 C-24 (2) - (1) C-24 C-24 (3) - (1) C-24

92.5 - 101.5 92.5 - 101.5 186

Pre-stroke sensor resistance

Ω

C-85 (2) - (5) C-85 C-85 (2) - (4) C-85 C-85 (5) - (4) C-85

5-7 5-7 10 - 14

Resistance

Ω

C-85 (7) - (6) C-85

2.5 - 2.9

Power source voltage

V

U-12 (2) - Body ground

20 - 28

Pre-stroke actuator

Engine speed sensor

Type I Type II

Gap from protrusion Resistance Gap from protrusion Resistance

Engine coolant temperature sensor resistance

mm (in) Ω

0.7 - 1.3 (0.028 - 0.051) C-22 (2) - (1) C-22

mm (in) Ω Ω

C-22 (3) - (2) C-22

2.1 - 2.5

C-27 (1) - (2) C-27

Refer to EF-8-51. [Engine coolant temperature and resistance of engine coolant temperature sensor]

Alignment of lines (B.T.D.C.) Rack sensor output voltage (Rack out voltage) — when idling (630 - 670 rpm) —

867 - 1,073 0.8 - 1.0 (0.031 - 0.039)

3º V

EF-8-28

M-83 (2) - (1) M-83

MTM 1.77


(1) Checking Diagnosis Light System (light do not light up) Stays OFF

CHECK

NG

FUSE 1 OK

CHECK LIGHT

NG

2 OK CHECK Check continuity between terminal (4) - light - fuse OK 4 NG CHECK Check continuity between terminal (12) and body ground

NG

3 OK

Replace fuse

Replace C.U.

Repair or replace C.U. GND line harness

Repair or replace wiring harness for light system, or replace blown light bulb

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

CHECK (1) Check fuses 1. 2.

Check if the other lights on the cluster meter light up. Judgement z If it lights up → fuse is normal → go to CHECK (2). z If it does not light up → replace fuse

EF-8-29


CHECK (2) Check lights 1. 2. 3.

Turn the ignition key switch OFF, then remove control unit harness connector U-12. Turn the ignition switch ON, then use the lead wire to ground terminal (4) of connector U-12, and check if the light lights up. Judgement z If it lights up → lamp is normal → go to CHECK (3). z If it does not light up → go to CHECK (4).

CHECK (3) Check continuity between control unit and body ground 1. 2.

Check the continuity between the body and terminal (12) of control unit harness U-12. Judgement z Continuity → abnormality in control unit → replace control unit z No continuity → abnormality in harness → repair or replace harness

EF-8-30


CHECK (4) Check continuity between control unit — light — fuse

1.

Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness connector U-12. 2. Judgement z Continuity → check again from CHECK (2). z No continuity → light bulb blown or disconnection in harness → replace light, or repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.

EF-8-31


CHECK (4) Check continuity between control unit — lamp — fuse

1.

Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness connector U-12. 2. Judgement z Continuity → check again from CHECK (2). z No continuity → lamp bulb blown or disconnection in harness → replace lamp, or repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.

EF-8-32


(2) Checking Control Unit Power Supply System (lights do not go out) Lights stay lighted up

CHECK FUSE

NG

1 OK

NG

Replace fuse. Locate cause of blown fuse

CHECK Check power circuit (+end) 4 OK

CHECK Does light go out? 2

NO

YES CHECK Check power circuit

NG

Check continuity of unit harness 2 NG

3 OK

Repair or replace harness for diagnostic light system

CHECK

C.U. abnormal, replace

Repair or replace unit harness


EF-8-33

OK


CHECK (1) Check fuse 1.

Check that the fuse for the control unit power is not blown. When doing this, measure the voltage at the fuse also. Voltage values Unit: V

2.

Place of measurement

Standard value

Fuse for control unit power

20 - 28

Judgement Fuse is blown → replace fuse (voltage is normal)

z z z

Fuse is normal → go to CHECK (2). Voltage is not as specified → disconnection in harness between battery and fuse, abnormality in battery → repair harness or inspect battery

CHECK (2) Check that lights go out 1. 2. 3.

Remove connector U-12 from control unit. Turn the ignition key switch ON. Judgement z Lamp stays ON → abnormality in wiring harness of diagnostic light system → repair or replace harness z Lamp goes out → go to CHECK (3).

CHECK (3) Check power circuit 1. 2.

Turn the ignition key switch ON. Measure voltage between terminal (3) (+end) and terminal (12) (–end) of control unit harness connector U-12. Values for voltage of control unit power Unit: V

3. z z

Measurement location

Standard value

Connector U-12, (3) (+end) - (12) (–end)

20 - 28

Judgement Voltage normal → replace control unit Voltage abnormal → go to CHECK (4).

EF-8-34


CHECK (4) Check power circuit (+end) 1. 2.

Turn the ignition key switch ON. Measure voltage between terminal (3) (+end) of control unit harness connector U-12 and body ground (–end). Voltage of control unit power Unit: V

3.


Standard value

Connector U-12, (3) (+end) - body (–end)

20 - 28

Judgement Voltage normal → go to CHECK (5) z Voltage abnormal → harness abnormal → repair or replace z

CHECK (5) Check continuity of unit harness 1.

Check the continuity between the body and terminal (12) of control unit harness connector U-12. 2. Judgement z Continuity → check again from CHECK (3). z No continuity→ harness abnormal → repair of replace NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.

EF-8-35


(3) Checking Rack Sensor System DIAGNOSIS DISPLAY CODE 1-3

CHECK Check harness of C.U. portion

NG

1 OK NG

CHECK

CHECK Check resistance of rack sensor 3 OK

NG

Check rack sensor output voltage

2 OK or NG

C.U. abnormal, replace

Replace injection pump

CHECK Check each harness 4 OK

Repair or replace harness


EF-8-36


CHECK (1) Check harness at control unit end 1. 2.

Turn the ignition key switch OFF. Measure the resistance between terminals (22) and (21), (21) and (27), (22) and (27) of connector U-13. 3. Check the insulation of each terminal and the rack sensor body. Resistance and insulation of rack sensor Unit: Ω Measurement location

Connector U-13

4.

Standard value

(22) - (21)

92.5 - 101.5

(21) - (27)

92.5 - 101.5

(22) - (27)

186

(21), (22), (27) Injection pump body

Min. MΩ

Judgement Resistance value normal → rack sensor harness normal → go to CHECK (2). z Resistance value abnormal → check resistance of rack sensor body → go to CHECK (3). z

CHECK (2) Check output voltage of rack sensor 1. 2.

Start the engine and run the engine at idling speed. Measure the voltage between terminal (2) (–end) and terminal (1) (+end) of rack out connector M-83 inside the control unit cover. Rack out voltage (when idling) Unit: V

3.


Standard reference value

Connector M-83, (2) (–end) - (1) (+end)

MTM 1.77 (630 - 670 rpm)

Judgement Output voltage normal → rack sensor position normal → carry out CHECK (1) again or replace C.U. z Output voltage abnormal → replace injection pump assembly z

EF-8-37


CHECK (3) Check rack sensor body 1.

Measure the resistance between terminals (3) and (2), (2) and (1), (3) and (1) of connector C-24. 2. Check the insulation of each terminal and the rack sensor body. Resistance and insulation of rack sensor Unit: Ω Measurement location

Connector C-24

3.

Standard value

(3) - (2)

92.5 - 101.5

(2) - (1)

92.5 - 101.5

(3) - (1)

186

(2), (3), (1) - Injection pump body

Min. MΩ

Judgement Resistance value is as specified → go to CHECK (4). z Disconnection, short circuit, or resistance value is not as specified → rack sensor abnormal → replace injection pump z

EF-8-38


CHECK (4) Check harness

1. 2.

Turn the ignition key switch OFF. Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-24 of the rack sensor and harness connector U-13 of the control unit. Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-3

U-4

U-13

Check 1

(1)

(6)

(6)

(27)

Check 2

(2)

(5)

(5)

(21)

Check 3

(3)

(4)

(4)

(22)

Check 4

Shield

(7)

(7)

(27)

EF-8-39

“MD-TICS” SYSTEM 3.

Judgement If the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harness z If the harness is not abnormal → improper output voltage of rack sensor or abnormality in control unit → contact ZEXEL sales for repair NOTE z If there is no abnormality in the harness or resistance value of the rack sensor, the rack sensor output voltage may be defective or the may be an abnormality in the control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine, so it is difficult to check. z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality. z

EF-8-40


CHECK (4) Check harness

1. 2.

Turn the ignition key switch OFF. Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-24 of the rack sensor and harness connector U-13 of the control unit. Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-82

U-18

U-13

Check 1

(1)

(6)

(6)

(27)

Check 2

(2)

(5)

(5)

(21)

Check 3

(3)

(4)

(4)

(22)

Check 4

Shield

(7)

(7)

(27)

EF-8-41


Judgement If the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harness z If the harness is not abnormal → improper output voltage of rack sensor or abnormality in control unit → contact ZEXEL sales for repair NOTE z If there is no abnormality in the harness or resistance value of the rack sensor, the rack sensor output voltage may be defective or the may be an abnormality in the control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine, so it is difficult to check. z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality. z

EF-8-42


(4) Checking Engine Speed Sensor System DIAGNOSIS DISPLAY CODE 1 - 5, 1 - 6

CHECK Check harness of C.U. portion

NG

1 OK NG

CHECK Check resistance of engine speed sensor body 2

CHECK Check engine speed sensor gap

OK NG

4 OK or

NG


Replace C.U.

Adjust gap

Replace engine speed sensor



Reference If the Diagnosis Display Code is 1-5, it can be taken that there is a disconnection, and if it is 1-6, the problem is something other than disconnection (short circuit, improper adjustment of gap, etc.).

EF-8-43


CHECK (1) Check harness at control unit end 1. 2.

Turn the ignition key switch OFF and remove connector U12. Measure the resistance between terminal (9) and terminal (18) of unit harness connector U-12.

3.

Check the insulation between terminal (9) of connector U12 and the body. 4. Check the insulation between terminal (18) of connector U12 and the body. Resistance of engine speed sensor Unit: kΩ Measurement location (9) - (18) Connector U-12

(9) - Body (18) - Body

5.

Standard value 2.1 - 2.5 ∝

Judgement Resistance value is as specified → sensor normal → go to CHECK (4). z Disconnection, short circuit, defective insulation, or resistance value is not as specified → go to CHECK (2). z

CHECK (2) Check engine speed sensor body 1.

Measure the resistance between terminal (1) and terminal (2) of harness connector C-22 of engine speed sensor. 2. Check the insulation between the body and terminals (3), (2), and (1) of connector C-22. Resistance of engine speed sensor Unit: Ω Measurement location (2) - (1) Connector C-22

Standard value 867 - 1,073

(3) - Body (2) - Body

∝

(1) - Body

EF-8-44


Judgement Resistance value is as specified → sensor normal → go to CHECK (3). z Disconnection, short circuit, defective insulation, or resistance value is not as specified → replace sensor → go to CHECK (4). z

CHECK (2) Check engine speed sensor body 1.

Measure the resistance between terminal (3) and terminal (2) of harness connector C-22 of engine speed sensor. 2. Check the insulation between the body and terminals (3), (2), and (1) of connector C-22. Resistance of engine speed sensor Unit: kΩ Measurement location (3) - (2) Connector C-22

Standard value 2.1 - 2.5

(3) - Body (2) - Body

∝

(1) - Body

3.

Judgement Resistance value is as specified → sensor normal → go to CHECK (3). z Disconnection, short circuit, defective insulation, or resistance value is not as specified → replace sensor → go to CHECK (4). z

EF-8-45


CHECK (3) Check for abnormality in harness

1.

Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit. Harness

Chassis harness

Connector No. Terminal

2.

Unit harness

C-22

C-3

U-4

U-12

Check 1

(2)

(2)

(2)

(18)

Check 2

(3)

(1)

(1)

(9)

Check 3

(1)

(3)

(3)

(18)

Judgement z If the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harness z If the harness is not abnormal → abnormality in control unit → replace control unit

EF-8-46



1.

Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit. Harness

Chassis harness


z

Unit harness

C-22

C-82

U-18

U-12

Check 1

(2)

(2)

(2)

(18)

Check 2

(3)

(1)

(1)

(9)

Check 3

(1)

(3)

(3)

(18)

Judgement z If the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harness z If the harness is not abnormal → abnormality in control unit → replace control unit

EF-8-47


CHECK (4) Check engine speed sensor gap 1.

Check the gap between the engine speed sensor and the drive gear (Air compressor). Standard value for engine speed sensor gap Unit: mm (in) 0.7 - 1.3 (0.028 - 0.051)

2.

Judgement Gap normal → check again from CHECK (1), or replace C.U. z Gap defective → adjust as follows 1) Align the centers of the engine speed sensor and the protrusions on the drive gear (Air compressor). 2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut. NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality. z

CHECK (4) Check engine speed sensor gap 1.

Check the gap between the engine speed sensor and the protrusions on the coupling (flywheel) of the injection pump. Standard value for engine speed sensor gap Unit: mm (in) 0.8 - 1.0 (0.031 - 0.039)

2.

Judgement z Gap normal → check again from CHECK (1), or replace C.U. z Gap defective → adjust as follows 1) Align the centers of the engine speed sensor and the protrusions on the coupling (flywheel) of the injection pump. 2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut. NOTE z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.

EF-8-48


(5) Checking Engine Coolant Temperature Sensor System DIAGNOSIS DISPLAY CODE 2-1

CHECK Check harness at C.U. portion

NG

1 OK CHECK NG

or

Check engine coolant temperature sensor 2 OK

NG

Replace C.U.

Replace engine coolant temperature sensor




EF-8-49


CHECK (1) Check harness between engine coolant temperature sensors at control unit 1. 2. 3.

Turn the ignition key switch ON. Remove control unit harness connectors U-12 and U-13. Measure the resistance between terminal (14) of connector U-12 and terminal (19) of connector U-13.

4.

Check for insulation and short circuit between the body and terminal (14) of connector U-12 and terminal (19) of connector U-13. Resistance of engine coolant temperature sensor Sensor resistance (x102Ω)

∝

454

270

55

Engine coolant temperature ºC (ºF)

Sensor error

–40 (–40)

–39 (–38)

–1 (30)

3.2

1.8

0.9

0

111 (232)

130 (266)

Sensor error

24 20 (68)

5.

12

6

40 (104) 62 (144) 86 (187)

Judgement z Resistance corresponds to engine coolant temperature → sensor normal z Disconnection, short circuit, or defective insulation, or resistance does not correspond to engine coolant temperature → go to CHECK (2).

EF-8-50


CHECK (2) Check engine coolant temperature sensor body 1.

2.

Measure the resistance between terminals (1) and (2) of engine coolant temperature sensor harness connector C27. For details of the resistance value of the engine coolant temperature sensor, see the table for CHECK (1).

Judgement Resistance corresponds to engine coolant temperature → engine coolant temperature sensor normal → go to CHECK (3). z Disconnection, short circuit, or defective insulation, or resistance does not correspond to engine coolant temperature → engine coolant temperature sensor abnormal → replace engine coolant temperature sensor z

EF-8-51



1.

Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and U-13 and harness connector C-27 of the engine coolant temperature sensor. Harness

Chassis harness


Unit harness

C-27

C-4

U-5

Check 1

(1)

(5)

(5)

Check 2

(2)

(4)

(4)

2.

U-13

U-12 (14)

(19)

Judgement If harness is abnormal (disconnection, short circuit) → repair or replace harness z If there is no abnormality in the harness → carry out CHECK (1) again → if it is normal, the control unit is abnormal → replace unit NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality. z

EF-8-52



1.

Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and U-13 and harness connector C-27 of the engine coolant temperature sensor. Harness

Chassis harness


Unit harness

C-27

C-81

U-17

Check 1

(1)

(5)

(5)

Check 2

(2)

(4)

(4)

2.

U-13

U-12 (14)

(19)

Judgement If harness is abnormal (disconnection, short circuit) → repair or replace harness z If there is no abnormality in the harness → carry out CHECK (1) again → if it is normal, the control unit is abnormal → replace unit NOTE z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality. z

EF-8-53


(6) Checking Pre-stroke Sensor System DIAGNOSIS DISPLAY CODE 2 - 3 or 2 - 4

CHECK Check wiring harness at C.U. portion

NG

1 OK

If error is 1-2, check pre-stroke actuator

CHECK

NG

Check pre-stroke sensor 2 OK

NG

Check each harness 3 OK

or

CHECK

If abnormality is 1-2 or 2-4, operation of pre-stroke actuator is probably defective

Replace C.U.




EF-8-54


CHECK (1) Check harness between pre-stroke sensors at control unit 1. 2.

Turn the ignition key switch OFF. Measure the resistance between terminals (23) and (24), (23) and (29), and (24) and (29) of control unit harness connector U-13. Resistance value for pre-stroke sensor Unit: Ω Measurement location Connector U-13

3.

Standard value

(23) - (24)

5-7

(23) - (29)

5-7

(24) - (29)

10 - 14

Judgement z Resistance is as specified → pre-stroke sensor normal → check pre-stroke actuator (refer to (7) Check prestroke servo system) z Resistance value is not as specified → disconnection, short circuit, or pre-stroke sensor abnormal → go to CHECK (2).

CHECK (2) Check pre-stroke sensor body 1. 2.

Turn the ignition key switch OFF. Measure the resistance between terminals (2) and (5), (2) and (4), and (5) and (4) of pre-stroke sensor harness connector C-85. Resistance value for pre-stroke sensor Unit: Ω Measurement location Connector C-85

3.

Standard value

(2) - (5)

5-7

(2) - (4)

5-7

(5) - (4)

10 - 14

Judgement z Resistance is as specified → pre-stroke sensor normal → check harness → go to CHECK (3). z Resistance value is not as specified → pre-stroke sensor abnormal → replace pre-stroke sensor (injection pump assembly)

EF-8-55



1. 2.

Turn the ignition key switch OFF. Check continuity between pre-stroke sensor harness connector C-85 and control unit harness connector U-13. Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-82

U-4

U-13

Check 1

(1)

(12)

(12)

(30)

Check 2

(2)

(11)

(11)

(23)

Check 3

(3)

(10)

(10)

(29)

Check 4

(4)

(9)

(9)

(29)

Check 5

(5)

(8)

(8)

(24)

3.

Judgement Continuity is as specified → control unit abnormal → replace control unit z Continuity is not as specified → harness abnormal → repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality. z

EF-8-56



1. 2.

Turn the ignition key switch OFF. Check continuity between pre-stroke sensor harness connector C-85 and control unit harness connector U-13. Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-85

C-82

U-18

U-13

Check 1

(1)

(12)

(12)

(30)

Check 2

(2)

(11)

(11)

(23)

Check 3

(3)

(10)

(10)

(29)

Check 4

(4)

(9)

(9)

(29)

Check 5

(5)

(8)

(8)

(24)

3.

Judgement Continuity is as specified → control unit abnormal → replace control unit z Continuity is not as specified → harness abnormal → repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality. z

EF-8-57


(7) Checking Pre-stroke Servo System DIAGNOSIS DISPLAY CODE 1-2

CHECK Check wiring harness at C.U. portion

NG

1 OK

NG

Check pre-stroke actuator also

CHECK Check resistance of pre-stroke actuator 2 OK

or

CHECK NG

Operation of pre-stroke actuator is probably defective

Replace C.U.


Check each harness 3 OK



EF-8-58


CHECK (1) Check harness between pre-stroke actuator at control unit end 1.

Turn the ignition key switch OFF, then remove control unit harness connector U-12. 2. Measure the resistance between terminals (1) and (10) of harness connector U-12. Resistance value for pre-stroke sensor Unit: Ω Measurement location Connector U-12

3.

(1) - (10)


Judgement Resistance is as specified → check pre-stroke sensor z Resistance value is not as specified → pre-stroke actuator or harness abnormal → go to CHECK (2). z

CHECK (2) Check pre-stroke actuator body 1.

Turn the ignition key switch OFF, then remove the harness connector of the pre-stroke actuator. 2. Measure the resistance between terminals (7) and (6) of connector C-85 at the pre-stroke actuator end. Resistance value for pre-stroke sensor Unit: Ω Measurement location Connector U-85

3.

(7) - (6)


Judgement Resistance is as specified → pre-stroke actuator normal → check harness → go to CHECK (3). z Resistance value is not as specified → replace injection pump z

EF-8-59



1. 2.

Turn the ignition key switch OFF. Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12. Harness

Chassis harness


Unit harness

C-85

C-4

U-5

U-12

Check 1

(6)

(7)

(7)

(10)

Check 2

(7)

(6)

(6)

(1)

3.

Judgement Continuity is normal → check for CHECK (1) again → replace control unit or replace injection pump z Continuity is not normal → harness abnormal → repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality. z

EF-8-60



1. 2.

Turn the ignition key switch OFF. Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12. Harness

Chassis harness


Unit harness

C-85

C-81

U-17

U-12

Check 1

(6)

(7)

(7)

(10)

Check 2

(7)

(6)

(6)

(1)

3.

Judgement Continuity is normal → check for CHECK (1) again → replace control unit or replace injection pump z Continuity is not normal → harness abnormal → repair or replace harness NOTE z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality. z

EF-8-61


(8) Checking Pre-stroke Power Supply System DIAGNOSIS DISPLAY CODE 2-2

NG

CHECK FUSE 1

or

OK

CHECK Check continuity between fuse and connector

NG

2 OK or

Replace fuse

Replace C.U.

Repair or replace harness or pre-stroke cut relay


EF-8-62


CHECK (1) Check fuse 1.

Check that the power fuse for the pre-stroke actuator is not blown. 2. Measure the voltage at the fuse portion. Value for power source voltage Unit: V

3.


Standard value

Power source fuse for pre-stroke actuator

20 - 28

Judgement Fuse is blown (voltage is normal) → after finding cause, replace fuse z Fuse is normal → go to CHECK (2). z Voltage is not as specified → disconnection in harness between battery and fuse, battery abnormal → repair harness or check battery z

CHECK (2) Check harness between unit and power source for pre-stroke actuator system 1.

Remove all harness connectors from the control unit, turn the ignition key switch ON, then measure the voltage the body(–end) and between terminal (2) (+end) of connector U-12. Value for power source voltage Unit: V

2.


Standard value

Connector U-12, (2) (+end) - body (–end)

20 - 28

Judgement Voltage is as specified → control unit abnormal → replace control unit z Voltage is not as specified → abnormality in power harness between power harness connectors, or pre-stroke cut relay abnormal → repair or replace harness, or replace pre-stroke cut relay z

EF-8-63


[4] CLEARING DIAGNOSTIC MEMORY To clear the diagnostic memory, short circuit the memory reset switch at the behind the electrical unit board.

1. 2. 3.

Release the diagnostic switch. Turn the ignition key switch ON. Check that the Overheat warning light is displaying the Diagnosis Display Code. 4. Connect the harness or memory clear connector (24004 00Z09) to the memory reset switch terminal, and short circuit the switch. NOTE z When connecting the harness, the battery voltage is applied to the Y/R cord side, so be careful not to short circuit any other part. 5.

Check that the Overheat warning light and buzzer display shows the normal Diagnosis Display Code (0-1). The memory will be erased in about ten seconds. 6. Remove the special connector or harness from the memory reset switch terminal. 7. Connect the diagnostic switch. 8. Turn the ignition key switch OFF, then turn the ignition key switch ON again and check that the Overheat warning buzzer shows code <0-1>. NOTE z If the ignition key switch is turned ON with the sensor terminals still disconnected, a trouble signal will be recorded in the memory.

EF-8-64


APPENDIX Table 1 Failure Judgement Conditions For “MD-TICS” System Trouble system

Failure judgement conditions

Judgement time (sec)

C.U. power voltage system

When voltage at C.U. power terminal (3) is less than approx. 0V

Immediate

When control unit power source voltage recovers

1

When the detected voltage has become normal, or when the engine speed is no longer under judgement conditions.

1

Reset when pulse is input

Rack sensor system

Engine speed sensor system

1) When detected voltage is 3.5V or more at all speed ranges 2) When detected voltage is less than 0.2V at 300 - 1,600 rpm 1) When resistance for all engine speed sensors (including harness) is more than 50 kΩ (disconnection) 2) When the pulse cannot be recognized with the ignition key switch at the START position

Immediate

Reset condition

Reset when pulse is input After error judgement is reset, and ignition key switch is turned again to START, then start again


When detected voltage (resistance) is 0.1V (30Ω) or less, or 4.9V (73.5Ω) or more

3

When the detected voltage has become normal


When detected voltage is 0.9V or less, or 3.4V or more

1

When the detected voltage has become normal


When difference between target value and detected value is more than 3.9º at pre-stroke actuator angle

20

Do not reset while power remains ON

Pre-stroke power voltage system

When detected voltage at pre-stroke actuator power terminal (2) is 1.5V or less

1

When power voltage is reset

When electricity is not passing through Pre-stroke learning func- pre-stroke actuator, detected voltage of tion system pre-stroke sensor is 1.0V or less or 1.4V or more

EF-8-65

2.4

Do not reset while power remains ON

“MD-TICS” SYSTEM Table 2 ”BACK-UP” Operations For “MD-TICS” System Back-up operation Trouble system

Diagnosis display code

Pre-stroke control

Max. injection limit by boost compensator cut (Yes: O, No: X)

Expected result

Control stopped (pre-stroke: injection timing fixed at most retarded angle)

O

Lack of power, excessive white smoke

Pre-stroke control characteristic fixed at characteristic for full load

X

No abnormality is felt

1-5 or 1-6

Fixed at a constant pre-stroke value

X

Slight lack of power


2-1

Control is carried out assuming engine coolant temperature of 80ºC (176ºF)

X

Excessive white smoke when cold.


2-3

Control stopped (pre-stroke: injection timing fixed at most retarded angle)

O

Lack of power, excessive white smoke


1-2

Same as above

O

Same as above

Pre-stroke power voltage system

2-2

Same as above

O

Same as above

Pre-stroke learning function system

2-4

Controlled with learning compensation at 0

X

Engine performance changes slightly but no abnormality is felt

C.U. power voltage system

Stays lighted up

Rack sensor system

1-3

Engine speed sensor system

EF-8-66


Terminal Connection Drawing

EF-8-67


Terminal Connection Drawing

EF-8-68


- MEMO -

EF-8-69


Wiring Diagram

EF-8-70


EF-8-71


Wiring Diagram

EF-8-72


EF-8-73

- MEMO -

AIR INTAKE AND EXHAUST SYSTEM

CONTENTS SERVICE DATA ...................................... IE-1-1 SPECIFICATIONS............................................ SERVICE DATA ............................................... TIGHTENING TORQUE ................................... INTAKE AND EXHAUST SYSTEM ..................

IE-1-1 IE-1-3 IE-1-4 IE-1-6 TOOLS .................................................... IE-2-1 AIR CLEANER ........................................ IE-3-1 CONSTRUCTION............................................. IE-3-1 REPLACING AIR CLEANER ELEMENT .......... IE-3-3 TURBOCHARGER.................................. IE-4-1

= MODELS T04B AND T04E = CONSTRUCTION............................................. REMOVAL ........................................................ DISASSEMBLY ................................................ INSPECTION.................................................... REASSEMBLY ................................................. INSTALLATION ................................................

IE-4-1 IE-4-1 IE-4-2 IE-4-6 IE-4-9 IE-4-13

= MODELS RHC62E AND RHC6V = CONSTRUCTION............................................. REMOVAL ........................................................ DISASSEMBLY ................................................ INSPECTION.................................................... REASSEMBLY .................................................

IE-4-14 IE-4-15 IE-4-16 IE-4-20 IE-4-22

INSTALLATION ................................................ IE-4-24

EXHAUST SYSTEM ................................ IE-5-1 REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... INSTALLATION ................................................ INSPECTION AFTER INSTALLATION.............

EXHAUST BRAKE .................................. = CHAMBER TYPE = CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY.................................................. INSTALLATION ................................................

IE-5-1 IE-5-2 IE-5-2 IE-5-3 IE-5-4 IE-6-1 IE-6-1 IE-6-1 IE-6-2 IE-6-4 IE-6-4 IE-6-5

= CYLINDER TYPE = CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY.................................................. INSTALLATION ................................................

IE-6-6 IE-6-8 IE-6-9 IE-6-14 IE-6-15 IE-6-16

IE

SERVICE DATA

SERVICE DATA SPECIFICATIONS AIR CLEANER Engine model Max. gross output

FE6A kW {PS/rpm}

FE6B

118 {160}/3,000

119 {162}/3,000

132 {180}/3,000

Paper element (Dry type) Type I (Single) or Type II (Dual)

Type —

Type III (Single) or Type IV (Dual)

135 {183}/3,000

151 {205}/2,800

Engine model Max. gross output

—

FE6T kW {PS/rpm}

162 {220}/2,800

Paper element (Dry type) Type I (Single) or Type II (Dual) Type

Type III (Single) or Type IV (Dual)

— —

—

Type V (Single) or Type VI (Dual)


—

FE6TA kW {PS}/rpm

173 {235}/2,800

157 {213}/2,800

Paper element (Dry type) Type I (Single) or Type II (Dual)

Type

Type III (Single) or Type IV (Dual) —

Type VII (Single)

T04B

T04E

External dimensions (Length x Width x Height) mm (in)

220 x 190 x 160 (8.66 x 7.48 x 6.30)

230 x 195 x 265 (9.06 x 7.68 x 10.43)

Max. permissible continuous speed rpm

138,000

125,000

TURBOCHARGER Models T04B and T04E Model

Direction of rotation Air volume Compression ratio

Counterclockwise as viewed from the exhaust turbine side kg (lb)/min

21 (46)

20 (44)

3.2

3.0

IE-1-1

SERVICE DATA

Models RHC62E and RHC6V Model External dimensions (Length x Width x Height) mm (in)

RHC62E

RHC6V

218 x 238 x 145 (8.58 x 9.37 x 5.71)

246 x 214 x 196 (9.69 x 8.43 x 7.72)

Max. permissible continuous speed rpm Direction of rotation Air volume

140,000 Counterclockwise as viewed from the exhaust turbine side

kg (lb)/min

18.8 (41.5)

19.4 (42.8)

Compression ratio

3.2

EXHAUST BRAKE Engine model Max. gross output

FE6A kW {PS}/rpm

FE6B

118 {160}/3,000

119 {162}/3,000

132 {180}/3,000

Type

Chamber type

Cylinder type

Operating method

Vacuum type

Air type

286-04505

*286-04446 (286-04442)

Model


FE6T kW {PS}/rpm

135 {183}/3,000

151 {05}/2,800

Type

Cylinder type

Operating method

Air type *286-04446 (286-04442) *286-04453 (286-04441) 286-06109

Model

*286-04446 (286-04442)


286-06109

FE6TA kW {PS}/rpm

157 {213}/2,800

Type

173 {235}/2,800 Cylinder type

Operating method

Air type *286-04446 (286-04442) *286-04453 (286-04441)

Model

NOTE z

162 {220}/2,800

*286-04446 (New) ← 286-04442 (Former) *286-04453 (New) ← 286-04441 (Former)

IE-1-2

SERVICE DATA

SERVICE DATA TURBOCHARGER Models T04B and T04E Unit: mm (in) Maintenance standard

Service limit

Play in shaft axial direction

Item

0.025 - 0.080 (0.0010 - 0.0031)

—

Play in shaft radial direction

0.08 - 0.15 (0.0031 - 0.0059)

—

0.011 (0.0004)

—

Journal part

10.16 (0.4000)

—

Piston ring part

17.34 (0.6827)

—

Inside diameter of back plate

12.71 (0.5004)

—

Distance between contact surface of thrust collar and end of plate

11.66 (0.4591)

—

Bearing part

15.81 (0.6224)

—

Piston ring part

18.06 (0.7110)

—

4.36 (0.1717)

—

Runout of shaft Outside diameter of shaft

Inside diameter of center housing Thrust bearing thickness

Remarks

Models RHC62E and RHC6V Unit: mm (in) Item Turbine wheel shaft

Thrust bushing, Oil thrower, Thrust bearing


Service limit

Outside diameter of journal

—

10.39 (0.4091)

Outside diameter of seal ring groove

—

1.33 (0.0524)

Runout

—

0.011 (0.0004)

Distance between thrust bushing grooves

—

4.08 (0.1606)

—

1.25 (0.0492)

Seal ring groove width

Small diameter

—

1.46 (0.0575)

Thrust bearing width

—

3.98 (0.1567)

Inside diameter

—

10.44 (0.4110)

Outside diameter

—

14.98 (0.5898)

Inside diameter

—

15.10 (0.5945)

Seal ring insertion hole

—

17.03 (0.6705)

Small diameter

—

12.45 (0.4902)

Large diameter

—

14.05 (0.5531)

Play in shaft axial direction

0.05 - 0.08 (0.0020 - 0.0031)

0.10 (0.0039)

Play in shaft radial direction

0.08 - 0.12 (0.0031 - 0.0047)

0.17 (0.0067)

Floating bearing Center housing Seal plate

Seal ring insertion hole

Large diameter

IE-1-3

Remarks

SERVICE DATA

EXHAUST BRAKE Chamber type Unit: mm (in) Item Clearance between valve and body

Only one side Both total


Service limit

Remarks

0.80 - 1.05 (0.0315 - 0.0413)

—

1.6 - 2.1 (0.063 - 0.083)

—

When 86.6 - 93.3 kPa {650 - 700 mmHg, 25.59 - 27.56 inHg} Vacuum pressure is applied to power chamber

Cylinder type Unit: mm (in) Item


Service limit

Spindle O.D.

286-04446 (286-04442) 286-04453 (286-04441)

16.50 (0.6496)

16.43 (0.6468)

Clearance between spindle and bushing

286-04446 (286-04442) 286-04453 (286-04441)

0.3 - 0.4 (0.012 - 0.016)

—

Clearance between bushing and body

286-04446 (286-04442) 286-04453 (286-04441)

0.015 - 0.090 (0.0006 - 0.0035)

—

0.80 - 1.05 (0.0315 - 0.0413)

—

1.6 - 2.1 (0.063 - 0.083)

—

Free length

151.5 (5.965)

—


134.4 - 161.2 {13.70 - 16.44, 30.2 - 36.3}

—

Clearance between valve and body

286-04446 (286-04442) 286-04453 (286-04441)

Air cylinder spring

286-04446 (286-04442) 286-04453 (286-04441) 286-06109


Remarks

When an air pressure of 637 kPa {6.5 kgf/cm2, 92 psi} is applied to the air cylinder and the valve is fully closed


TIGHTENING TORQUE TURBOCHARGER Models T04B and T04E Unit: N·m{kgf·cm, in·lbf} Item Compressor wheel lock nut Back plate and center housing mounting bolt

Tightening torque 2.1 - 2.3 {21 - 23, 18 - 20} → Tighten (110º) 8.4 - 10.2 {86 - 104, 75 - 90}

Turbine housing and center housing mounting bolt

18.0 - 21.5 {184 - 219, 160 - 190}

Compressor housing and back plate mounting bolt

11.3 - 14.7 {115 - 150, 100 - 130}

IE-1-4

Remarks

SERVICE DATA

Models RHC62E and RHC6V Unit: N·m {kgf·cm, ft·lbf} Item

Tightening torque

Turbine housing mounting bolt

Remarks

27.0 - 28.9 {275 - 295, 239 - 256}

Compressor housing mounting bolt

7.4 - 8.3 {75 - 85, 65 - 74}

Thrust bearing mounting screw

1.2 - 1.4 {12 - 14, 10 - 12}

Seal plate mounting screw

3.4 - 4.0 {35 - 41, 30 - 36}

Compressor impeller mounting nut

5.1 - 5.9 {52 - 60, 45 - 52}

With Torx driver

EXHAUST BRAKE Chamber type Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Stopper bolt lock nut

5 - 7 {0.5 - 0.7, 3.6 - 5.1}

Cover mounting bolt (at body)

10 - 16 {1.0 - 1.6, 7 - 12}

Body-to-bracket mounting bolt

10 - 16 {1.0 - 1.6, 7 - 12}

Lever mounting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Clevis adjusting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Power chamber mounting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Cover mounting bolt

5 - 7 {0.5 - 0.7, 3.6 - 5.1}

Cylinder type Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Stopper bolt lock nut

286-04446 (286-04442) 286-04453 (286-04441)

10 - 16 {1.0 - 1.6, 7 - 12}

Cover mounting bolt (at body)

286-04446 (286-04442) 286-04453 (286-04441)

21 - 26 {2.1 - 2.7, 15 - 20}

Body-to-plate mounting bolt

286-04446 (286-04442) 286-04453 (286-04441)

21 - 26 {2.1 - 2.7, 15 - 20}

Lever mounting nut

286-04446 (286-04442) 286-04453 (286-04441)

10 - 16 {1.0 - 1.6, 7 - 12}

Cylinder shaft nut

286-04446 (286-04442) 286-04453 (286-04441) 286-06109

10 - 16 {1.0 - 1.6, 7 - 12}

Air cylinder cover mounting bolt

286-04446 (286-04442) 286-04453 (286-04441) 286-06109

10 - 16 {1.0 - 1.6, 7 - 12}

Insulator (air cylinder) to shield plate bolt and nut

286-04446 (286-04442) 286-04453 (286-04441) 286-06109

21 - 25 {2.1 - 2.6, 15 - 19}

IE-1-5

SERVICE DATA

INTAKE AND EXHAUST SYSTEM INTAKE SYSTEM FE6A, FE6B and FE6T For suction under the cab

For suction behind the cab

IE-1-6

SERVICE DATA

FE6TA

EXHAUST SYSTEM (EXAMPLE)

IE-1-7

TOOLS

TOOLS TURBOCHARGER Models T04B and T04E Tool name and number

Description

Turbocharger tool kit 99760 Z5500

Used when disassembling and reassembling the turbocharger.

Radial play measuring tool 99764 96000

Used to measure play in the radial direction of the turbine wheel.

Radial play adapter 99765 96000

Adapter mounted to the end of the dial gauge when measuring radial play.

End play measuring tool 99766 96000

Used when measuring axial play of the turbine wheel.

End play adapter 99765 96001

Adapter mounted to the end of the dial gauge when measuring end play

Pick 99767 96003

Used when fitting the piston ring of the shaft to the center housing

IE-2-1

Shape

TOOLS


Description

T-handle 99773 96000

Used to remove and install the compressor wheel lock nut.

Torque wrench 99537 96001

Used to tighten and disassemble the center housing and back plate. Torque 9.3 N·m {95 kgf·cm, 82 in·lbf}

Piston ring guide 99763 Z5500

Used when inserting the piston ring to the turbine wheel.

Retaining ring plier 99546 Z5500

Used when removing the retaining ring at the center housing.

Holding fixture 99768 Z5500

Used when disassembling and assembling the rotating assembly.

Torque wrench 99537 Z5500

Used to tighten and remove the turbine housing and center housing. Torque 16.7 N·m {170 kgf·cm, 148 in·lbf}

IE-2-2

Shape

TOOLS


Description


Used to tighten and remove the turbine housing and center housing. Torque 16.7 N·m {170 kgf·cm, 148 in·lbf}


Used to tighten and remove the compressor housing and back plate. Torque 12.7 N·m {130 kgf·cm, 113 in·lbf}

Hex socket head bolt 14220 Z9001

Used when mounting the radial play measuring tool.

Shape

Models RHC62E and RHC6V Tool name

Description

Bar

Used to remove the thrust bearing and bushing

Measuring needle

Attached to the dial gauge for measurement of free play in both axial and radial directions.

IE-2-3

Shape

TOOLS

Tool name

Description

Plier

Used to remove or install the retaining ring

Plier

Used to remove or install the seal ring.

Torx driver

Used to install the thrust bearing and seal plate.

Torque wrench

Used to tighten bolts and nuts. M8 ... 13 mm (0.51 in) – 27.9 N·m {285 kgf·cm, 247 in·lbf} M6 ... 10 mm (0.39 in) – 7.8 N·m {80 kgf·cm, 69 in·lbf} M6 ... 10 mm (0.39 in) – 5.3 N·m {54 kgf·cm, 47 in·lbf}

Box spanner

Used to prevent turbine wheel from turning during installation. 11 mm (0.43 in) x 12 angular type

Measuring needle

Used to measure free play in both axial and radial direction.

IE-2-4

Shape

AIR CLEANER

AIR CLEANER CONSTRUCTION Type I

Type II

IE-3-1

AIR CLEANER

Type III and Type IV

Type V, Type VI and Type VII

IE-3-2

AIR CLEANER

REPLACING AIR CLEANER ELEMENT For inspection and maintenance procedures, refer to the “MA” section.

Type I and Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Clip 2. Cover 3. Packing

4. Inner element (Type II only) 5. Outer element

IE-3-3

6. Evacuator valve 7. Body assembly

AIR CLEANER

Type III and Type IV

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Clip 2. Cover 3. Packing

4. Inner element (Type IV only) 5. Outer element

6. Evacuator valve 7. Body assembly

Type V, Type VI and Type VII

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Wing nut 2. Packing 3. Cover 4. Packing

5. Wing nut 6. Packing 7. Outer element 8. Wing nut

IE-3-4

9. Packing 10. Inner element 11. Evacuator valve 12. Body assembly

TURBOCHARGER

TURBOCHARGER = MODELS T04B AND T04E = CONSTRUCTION

REMOVAL Key point of removal WARNING WARNING z

To avoid being burned, do not touch the exhaust pipe, turbocharger and muffler while the engine is running or immediately thereafter. Check that the engine has cooled before starting work.

IE-4-1

T04B, T04E

TURBOCHARGER

T04B, T04E

DISASSEMBLY


+ + , + + ,+ +

1. Retaining ring 2. Actuator 3. Lock plate 4. Clamp 5. Turbine housing 6. Lock plate 7. Clamp 8. Compressor housing 9. Rotating assembly

10. Lock nut ,+ 11. Compressor wheel , 12. Turbine wheel ,+ 13. Piston ring 14. Shroud wheel 15. Lock plate ,+ 16. Back plate + 17. Thrust collar + 18. Thrust bearing

+ 19. Piston ring 20. Seal ring 21. Retaining ring ,+ 22. Journal bearing 23. Retaining ring 24. Retaining ring ,+ 25. Journal bearing 26. Retaining ring 27. Center housing


IE-4-2

TURBOCHARGER

OPERATIONS BEFORE DISASSEMBLY When disassembling or reassembling the turbocharger, use special tool kits (99760 Z5500) designed for that purpose.

INSPECTION BEFORE DISASSEMBLY Place the turbocharger on a level surface, and turn the compressor wheel with finger tip to determine whether it operates smoothly, then use the following procedure to measure both axial and radial play.

Measuring play in the axial direction 1. 2. 3.

Set the dial gauge to the end play measuring tool (99766 96000). Replace the dial gauge adapter with the end play adapter (99765 96001). Set the end play measuring tool so that the end of the adapter is contacting the compressor wheel end of the shaft. Measure the play in the axial direction. Unit: mm (in) Maintenance standard

Service limit

0.025 - 0.080 (0.0010 - 0.0031)

—

Measuring play in the radial direction 1. 2. 3.

Set the dial gauge to the radial play measuring tool (99764 96000) and replace the dial gauge adapter with the radial play adapter (99765 96000). Tighten the measuring tool with hex socket head bolt (14220 Z9001). Make sure the measuring element contacts the center of the shaft. Measure the play in the radial direction. Unit: mm (in) Maintenance standard

Service limit

0.08 - 0.15 (0.0031 - 0.0059)

—

IE-4-3

T04B, T04E

TURBOCHARGER

Key point of disassembly Before disassembly, spread a piece of clean oil paper or cardboard on the work bench and make matching marks at the connection sections of the turbine housing, center housing, and compressor housing so that there will be no mistakes during reassembly. Since the turbocharger is a precision device, disassemble it with the utmost care.

3 Lock plate, 4 Clamp Unbend the lock plate, remove the lock plate, clamp, bolt and turbine housing. NOTE z If the bolt has seized, apply “thread-release” oil to the bolt, then remove it, being careful not to damage the turbine wheel. If necessary, tap the turbine housing with a wooden hammer.

6 Lock plate, 7 Clamp Unbend the lock plate, and remove the lock plate, clamp and bolt. NOTE z

Make a matching mark on the compressor housing and back plate.

8 Compressor housing Remove the compressor housing being careful not to damage the compressor wheel. NOTE z

The compressor wheel and turbine wheel are precisely dynamically balanced and cannot be repaired. Therefore, they must be handled with extra special care.

9 Rotating assembly Place holding fixture (99768 Z5500) in a vise, and set the turbine wheel on it with the compressor wheel on it with the turbine wheel side facing downward.

IE-4-4

T04B, T04E

TURBOCHARGER 11 Compressor wheel Remove the compressor wheel. z Using a T-handle (99773 96000), remove the lock nut, and then remove the compressor wheel by hand. NOTE Since bending of the shaft is also related to the life of the turbocharger, be careful not to bend it. z Support the turbine wheel by hand while loosening the lock nuts. z

13 Piston ring Remove the piston ring. NOTE z

Once removed, the piston ring must always be replaced with a new ring when reassembling. However, since the turbine wheel can be reused, be careful not to damaged it.

16 Back plate Unbend the lock plate and remove the back plate. NOTE z

When the back plate cannot be removed by hand, tap the center housing lightly with a wooden mallet and then remove it.

17 Thrust collar, 18 Thrust bearing,19 Piston ring Pull out the thrust collar and thrust bearing from the center of the back plate and remove the piston ring from the thrust collar. The piston ring can be removed by hand.

22, 25 Journal bearing NOTE z Be careful not to damage the center housing when removing the retaining ring. 1.

Using retaining ring pliers (99546 Z5500), remove the compressor wheel side retaining ring and journal bearing.

IE-4-5

T04B, T04E

TURBOCHARGER 2. 3.

T04B, T04E

Using retaining ring pliers (99546 Z5500), remove the turbine side retaining ring and journal bearing. Remove the two retaining rings located in the rear of the center housing.

EIE3048A

INSPECTION INSPECTION BEFORE CLEANING Turbocharger failure may sometimes be due to faulty engine parts. It is, therefore advisable to closely inspect parts for accumulation of carbon, presence of dirt or dust, obstruction of oil passages, etc. prior to cleaning, so that the cause of problems may be located easily.

CLEANING After soaking all the parts in clean detergent for about 20 to 30 minutes, remove dirt and grime with a rough brush and then blow dry with compressed air. NOTE z

Be extremely careful not to damage parts. Avoid filing any rotating parts. Also be sure to clean parts completely. Failure to observe these points may cause the parts to become imbalanced. Contents of inspection

Inspection point

Carbon accumulation (check whether parts are jammed)

z z z z z

Lubrication (wear, burning, discoloration etc.)

z z z z z

Oil leakage

z z z z z z

Foreign matter (Also check for obstruction while cleaning parts.)

z z z

Clogging

z z z z

IE-4-6

Turbine wheel journal parts. Outside periphery of center housing. Inside periphery of heat shroud. Inside wall of center housing. Surface of blades of turbine wheel. Turbine wheel journal parts. Journal bearing. Center housing bore part. Thrust collar. Thrust bearing. Inside and outside periphery of turbine housing. Inside periphery of heat shroud. Inside of compressor housing. Surface of back plate. Surface of blades of turbine wheel. Rear surface of compressor wheel. Inside of center housing. Inside of turbine case. Inside of compressor case. Center housing of oil hole. Oil inlet adapter. Oil outlet adapter. Thrust bearing of oil hole.

TURBOCHARGER

T04B, T04E

INSPECTION Inspect parts visually, replacing as necessary. Inspection position

Inspection item

Compressor housing

z

Scratches caused by interference with compressor wheel. Scratches on contact surfaces with back plate. Cracks and dents.

Clamp

z

Corrosion, deterioration and damage.

Turbine housing

z

Scratches caused by interference with turbine wheel. Burrs caused by rust formation. Thermal deformity and cracks.

z z

z z

Compressor wheel

z z z z

Turbine wheel

z z z z z z

Back plate

z z z

Thrust collar

z z

Thrust bearing

z z

Center housing

z z

Heat shroud

z z

Corrosion. Scratches caused by interference with housing. Blade breakage and deformity. Clogging in shaft holes. Scratches from interference with turbine housing. Blade breakage, deformity and cracks. Shaft bent. Discolored journals and blades. Worn and scratched journals. Worn and damaged piston rings. Worn bore. Wear and damage on contact surface of thrust collar. Scratches on rear face of compressor wheel. Wear and scratches on contact surface. Worn and damaged piston ring groove. Thermal discoloration. Wear and scratches on contact surface. Wear and scratches on journal bores and inner surfaces of piston rings. Obstruction in oil hole Scratches caused by contact. Thermal discoloration and corrosion.

Runout of shaft NOTE z

Since the turbine side is heavy and the front end of the shaft will lift when the shaft is supported by V-block, use a magnet V-block or place another V-block to keep the journal part in place. Unit: mm (in) Maintenance standard

Service limit

0.011 (0.0004)

—

IE-4-7

TURBOCHARGER

Inside diameter of back plate (A) Unit: mm (in) Maintenance standard

Service limit

12.71 (0.5004)

—

Outside diameter of shaft Unit: mm (in) Item


Service limit

Journal part

10.16 (0.4000)

—

Piston ring part

17.34 (0.6827)

—

Distance between contact surface of thrust collar and end of plate (B) Unit: mm (in) Maintenance standard

Service limit

11.66 (0.4591)

—

Inside diameter of center housing Unit: mm (in) Item


Service limit

Bearing part (1)

15.81 (0.6224)

—

Piston ring part (2)

18.06 (0.7110)

—

Thrust bearing thickness Unit: mm (in) Maintenance standard

Service limit

4.36 (0.1717)

—

IE-4-8

T04B, T04E

TURBOCHARGER

REASSEMBLY PREPARATIONS BEFORE REASSEMBLY Repair light damage by polishing. Aluminum parts must be polished with a polishing cloth, using silicon carbide. Moreover, steel parts must be polished with a polishing cloth, using polishing powder.

Key point of reassembly 25, 22 Journal bearing Using retaining ring pliers (99546 Z5500), install the retaining rings in the rear of the center housing, then install the journal bearing and the outer retaining ring. NOTE z Ensure that the open end of the retaining ring faces the oil outlet and the round portion faces the journal bearing. z Be careful not to damage the center housing when installing the retaining ring. z Coat the inner and outer periphery of journal bearing with engine oil.

16 Back plate 1. Install the back plate. z Install the piston ring to the thrust collar. z Coat the thrust bearing with engine oil and then install the thrust bearing and thrust collar.

2.

Fit the thrust collar into the groove pin of the center housing, and fit the seal ring to the peripheral groove of the center housing. NOTE z When installing the thrust collar, align the portions indicated by dotted lines in the figure at right.

IE-4-9

T04B, T04E

TURBOCHARGER 3.

Use bolt and lock plate to install the back plate to the center housing and bend the lock plate. : 8.4 - 10.2 N·m {86 - 104 kgf·cm, 75 - 90 in·lbf} NOTE z Ensure that the bosses are ready to be detached from the flanged portions of the inlet and outlet.

13 Piston ring Install the piston ring to the turbine wheel using the piston ring guide (99763 Z5500).

12 Turbine wheel Apply a coat of engine oil to the turbine wheel journal, and carefully insert the turbine wheel into the bore in the center housing. Use pick (99767 96003) to compress the piston ring and install it while rotating the wheel shaft. NOTE z Be careful not to scratch or break the piston ring.

11 Compressor wheel NOTE z Before installing the compressor wheel, clean the parts and check carefully the tightening surface for dust or foreign matter. z When tightening the nut, be careful not to give the bending force to the shaft. z Keep the rated tightening torque and tightening angle.

1. 2. 3.

Coat the compressor wheel mounting and screw section of the turbine wheel and the surface of the lock nut seat with a thin coat of seizure preventative. Fit the compressor wheel into the turbine wheel and tighten the lock nut temporarily. Attach the rotating assembly to a holding fixture (99768 Z5500) which has been placed in a vise.

IE-4-10

T04B, T04E

TURBOCHARGER 4.

Using a torque wrench, tighten the lock nut temporarily. : 2.1 - 2.3 N·m {21 - 23 kgf·cm, 18 - 20 in·lbf}

5.

Tighten the lock nut completely with T-handle (99773 96000) by turning nut 110º further than the temporary position.

Measuring play in shaft axial direction and radial direction 1. Seat the dial gauge to the radial play measuring tool (99764 96000) and replace the dial gauge adapter with the radial play adapter (99765 96000).

2.

Attach the measuring element to the center bearing, and measure its radial play. Unit: mm (in)

3.


Service limit

0.08 - 0.15 (0.0031 - 0.0059)

—

Seat the dial gauge to the end play measuring tool (99766 96000). At this time, replace the dial gauge adapter with the end play adapter (99765 96001).

IE-4-11

T04B, T04E

TURBOCHARGER 4.

Temporarily install the compressor housing. Attach the measuring element to the compressor housing and measure the end play of the shaft. Unit: mm (in) Maintenance standard

Service limit

0.025 - 0.080 (0.0010 - 0.0031)

—

8 Compressor housing 1. Attach the compressor housing to the back plate by properly aligning their marks, then tighten the bolts with the clamps and lock plates in place. : 11.3 - 14.7 N·m {115 - 150 kgf·cm, 100 - 130 in·lbf}

2.

Compressor housing assembly angle (View from the air intake side) T04B β = 292º T04E β = 170º

5 Turbine housing 1. Align the marks on the turbine housing and center housing, attach the turbine housing to the rotating assembly, then tighten bolts with a clamp and lock plate in place. : 18.0 - 21.5 N·m {184 - 219 kgf·cm, 160 - 190 in·lbf} NOTE z Apply a “gauge-preventive” compound to bolts. Do not confuse these bolts (designed especially for high temperature use) with other conventional bolts. 2.

Turbine housing assembly angle (View from exhaust outlet side)

IE-4-12

T04B, T04E

TURBOCHARGER

INSTALLATION Key point of installation 1.

Install the turbocharger assembly on the exhaust manifold using a gasket. NOTE z Mounting nuts are heat-resistant types. Do not confuse them with conventional nuts. 2.

Install the exhaust connector using a gasket and spacer to the turbocharger assembly. NOTE z Mounting nuts are heat-resistant types. Do not confuse them with conventional nuts. 3.

After installing the turbocharger assembly, crank the engine using the sub-starter switch. Crank for approximately 10 to 20 seconds while pulling the engine stop lever. Crank the engine until the oil pressure gauge activates, since oil is not distributed to the oil line. NOTE z Do not crank the engine for more than 20 seconds at a time; otherwise, the starter motor may be damaged. Repeat cranking several times. 4.

Start the engine. Check that no oil leaks.

IE-4-13

T04B, T04E

TURBOCHARGER

= MODELS RHC62E AND RHC6V = CONSTRUCTION Model RHC62E

IE-4-14

RHC62E, RHC6V

TURBOCHARGER

Model RHC6V

REMOVAL Key point of removal WARNING WARNING z

To avoid being burned, do not touch the exhaust pipe, turbocharger and muffler while the engine is running or immediately thereafter. Check that the engine has cooled before starting work.

IE-4-15

RHC62E, RHC6V

TURBOCHARGER

RHC62E, RHC6V

DISASSEMBLY Model RHC62E

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Holder plate ,+ 2. Compressor housing 3. Holder plate + 4. Turbine housing ,+ 5. Nut 6. Compressor impeller , 7. Seal ring (large) 8. Turbine shaft

9. Sealed wheel ,+ 10. Snap ring 11. Floating metal ,+ 12. Center housing ,+ 13. Torx screw 14. Seal plate , 15. Oil thrower 16. Thrust bearing

,+ 17. Torx screw 18. Thrust bearing 19. Seal ring (small) 20. Seal ring 21. Snap ring 22. Actuator 23. Clip 24. Hose


IE-4-16

TURBOCHARGER

RHC62E, RHC6V

Model RHC6V

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Holder plate ,+ 2. Compressor housing 3. Holder plate + 4. Turbine housing ,+ 5. Nut 6. Compressor impeller , 7. Seal ring

8.Turbine shaft 9. Sealed wheel ,+ 10. Snap ring 11. Floating metal ,+ 12. enter housing ,+ 13. Torx screw 14. Seal plate

15. Oil thrower 16. Thrust bushing ,+ 17. Torx screw 18. Thrust bearing 19. Seal ring 20. Seal ring ,


IE-4-17

TURBOCHARGER

INSPECTION BEFORE DISASSEMBLY On-board inspection Turbine shaft rotation Check for abnormal noise from the turbine shaft while rotating the turbocharger. 1. If a sound-detecting rod is used, firmly attach the tip of the rod to the turbocharger case, then increase engine speed. 2. If a high-pitch sound is heard every 2 to 3 seconds during turbocharger rotation, the metal and/or turbine shaft may be damaged. Disassemble and repair the turbocharger or replace it as required.

Turbocharger assembly 1. Cover the oil inlet and outlet using masking tape. 2. Check if the turbine vane is in contact with the compressor impeller or if there is evidence of leaking oil. 3. Check the actuator for improper movement or wear. 4. Check that the impeller spins smoothly by hand. 5. Measure the turbine shaft axial play. z Fix the dial gauge to the turbocharger by the magnetic base. z Move the tip of the turbine shaft by hand in the axial direction so that the dial gauge registers the maximum deflection. Unit: mm (in)

6. z

z

z


Service limit

0.05 - 0.08 (0.0020 - 0.0031)

0.10 (0.0039)

Measure the turbine shaft radial play. Fix the dial gauge to the turbocharger assembly by the magnetic base. Replace the dial gauge measuring probe with a measuring needle. While holding both ends of the turbine shaft in both hands, move the turbine shaft in the radial direction. Read the maximum dial gauge deflection. Unit: mm (in) Maintenance standard

Service limit

0.08 - 0.12 (0.0031 - 0.0047)

0.17 (0.0067)

IE-4-18

RHC62E, RHC6V

TURBOCHARGER

Key point of disassembly CAUTION

The VNT actuator is set to the specified boost pressure before shipment. Do not attempt to remove the actuator in the field. z The variable exhaust nozzle mechanism is complex in design since it slides without lubrication under high temperature conditions. Never attempt to disassemble the nozzle mechanism in the field. z

2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Center housing 1. Before disassembling, place an alignment mark on the joining surfaces of the compressor housing, center housing and turbine housing so that they can be installed in their original positions during reassembly. 2. Liquid gasket is applied to the mating surfaces of the compressor housing and center housing. When removing these parts, be careful not to damage impeller. 4 (RHC62E) 4 (RHC6V) Turbine housing Before removing the turbine housing, place it parallel with the center housing.

5 (RHC62E) 5 (RHC6V) Nut Using a 17-mm (0.67-in) box wrench, remove the nut from the end (turbine side) of the turbine shaft. NOTE z The nut is a left-hand thread type.

10 (RHC62E) 10 (RHC6V) Snap ring Use snap ring pliers when removing or installing snap rings. 13 (RHC62E) 13 (RHC6V) Torx screw Use a Torx driver when removing the Torx T type screws which secure the seal plate. NOTE z

The seal plate can be driven out by equally and firmly tightening the two screws by hand.

IE-4-19

RHC62E, RHC6V

TURBOCHARGER

RHC62E, RHC6V

17 (RHC62E) 17 (RHC6V) Torx screw Use a Torx driver when removing the Torx T type screws which secure the thrust bearing.

INSPECTION Check all parts for scratches (frictional), scratches (on the joining surfaces), cracks, corrosion, bends, wear, thermal deformation, pitting, discoloration, breakage, oil clogging, etc. Replace faulty parts with new ones.

INSPECTION BEFORE CLEANING Before cleaning, visually check various parts for seizure, wear or foreign particles (including carbon) to determine if they are suitable for further use.

Cleaning procedure Turbine shaft

Turbine housing and center housing

Compressor housing and compressor impeller

Pour cleaning liquid (decarbonizing agent) into the cleaning basket. Immerse parts in the liquid, then heat them. NOTE z Protect the turbine shaft journal surface and seal ring groove from damage in advance.

Wait until foreign particles are loose.

Using a scraper or hard brush, clean the parts. NOTE z Do not use a wire brush.

Check all parts as specified under the topic “INSPECTION”.

NOTE

Clean all other parts in kerosene. z Clean the oil passage using dry compressed air. z After cleaning, check all parts as specified under the topic “INSPECTION”. z

IE-4-20

TURBOCHARGER

TURBINE WHEEL SHAFT Outside diameter of journal (A) and outside diameter of seal ring groove (E) Unit: mm (in) Item


Service limit

Outside diameter of journal (A)

—

1.33 (0.0524)

Outside diameter of seal ring groove (E)

—

10.39 (0.4091)

Runout Unit: mm (in) Maintenance standard

Service limit

—

0.011 (0.0004)

THRUST BUSHING, OIL THROWER AND THRUST BEARING Distance between thrust bushing grooves (K) Unit: mm (in) Maintenance standard

Service limit

—

4.08 (0.1606)

Oil thrower seal ring groove widths (G1 and G2) Unit: mm (in) Item


Service limit

Small diameter (G2)

—

1.25 (0.0492)

Large diameter (G1)

—

1.46 (0.0575)

Thrust bearing width (J) Unit: mm (in) Maintenance standard

Service limit

—

3.98 (0.1567)

IE-4-21

RHC62E, RHC6V

TURBOCHARGER

FLOATING BEARING Inside diameter (C) and outside diameter (D) Unit: mm (in) Item


Service limit

Inside diameter (C)

—

10.44 (0.4110)

Outside diameter (D)

—

14.98 (0.5898)

CENTER HOUSING Inside diameter (B) and seal ring insertion hole (F) (on turbine side) Unit: mm (in) Maintenance standard

Service limit

Inside diameter (B)

Item

—

15.10 (0.5945)

Seal ring insertion hole (F)

—

17.03 (0.6705)

SEAL PLATE Seal ring insertion hole (H1 and H2) (on impeller side) Unit: mm (in) Item


Service limit

Small diameter (H1)

—

12.45 (0.4902)

Large diameter (H2)

—

14.05 (0.5531)

REASSEMBLY Key point of reassembly NOTE z

After reassembling the turbocharger, measure the axial and radial play of the turbine shaft.

17 (RHC62E) 17 (RHC6V) Torx screw Use a Torx driver when installing the Torx T type screws which secure the thrust bearing. 15 (RHC62E) 15 (RHC6V) Oil thrower Fit the two seal rings to their grooves on the oil thrower, as shown in the figure.

IE-4-22

RHC62E, RHC6V

TURBOCHARGER 13 (RHC62E) 13 (RHC6V) Torx screw Use a Torx driver when installing the Torx T type screws which secure the seal plate. 7 (RHC62E) 7 (RHC6V) Seal ring Fit the seal ring to the groove on the turbine shaft, as shown in the figure.

10 (RHC62E) 10 (RHC6V) Snap ring Note the direction of the snap ring gap during installation. Refer to the figure. NOTE z Face the tapered side of the snap ring toward the bearing.

5 (RHC62E) 5 (RHC6V) Nut Using a 17 mm (0.67 in) box wrench, tighten the nut on the end (turbine side) of the turbine shaft. NOTE z The nut is a left-hand thread type. z Align the alignment marks on the turbine shaft, compressor impeller and nut (on the end of the turbine shaft) during reassembly. 2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Center housing 1. Before installation, apply 0.1 to 0.2 mm (0.004 to 0.008 in) thick liquid gasket (THREE BOND #1215 or equivalent) to the mating surfaces of the compressor housing and center housing. 2. Align the alignment marks on the joining surfaces of the compressor housing, center housing and turbine housing during reassembly.

IE-4-23

RHC62E, RHC6V

TURBOCHARGER

INSTALLATION Key point of installation 1.

Install the turbocharger assembly on the exhaust manifold using a gasket. NOTE z Mounting nuts are heat-resistant types. Do not confuse them with conventional nuts. 2.

Install the exhaust connector, connector support and seal plate. NOTE z Mounting nuts or bolts are heat-resistant types. Do not confuse them with conventional nuts or bolts. 3.

After installing the turbocharger assembly, crank the engine using the sub-starter switch. Crank for approximately 10 to 20 seconds while pulling the engine stop lever out. Crank the engine until the oil pressure gauge activates, since oil is not distributed to the oil line. NOTE z Do not crank the engine for more than 20 seconds at a time; otherwise, the starter motor may be damaged. Repeat cranking several times. 4.

Start the engine. Check that no oil leaks.

IE-4-24

RHC62E, RHC6V

EXHAUST SYSTEM

EXHAUST SYSTEM REMOVAL Key point of removal WARNING WARNING z

Before removing the exhaust system, ensure that the engine is cool. If it is hot, wait until it cools off to prevent scalding yourself.

Tail pipe 1. 2.

Disconnect the tail pipe clamp and hanger. Remove the tail pipe by loosening the bolts which secure the rear pipe of the muffler to the tail pipe.

Muffler 1. 2.

Remove the bolt from the exhaust shutter, and separate the exhaust brake from the muffler. Separate the hanger from the bracket which secures the rear pipe of the muffler. Remove the muffler.

Exhaust pipe 1. 2. 3.

Disconnect the pipes from the exhaust manifold. Disconnect the exhaust pipe bracket from the hanger. Remove the hanger and clamp from the exhaust pipe.

IE-5-1

EXHAUST SYSTEM

DISASSEMBLY (Example)

1. Gasket 2. Exhaust tube assembly 3. Hanger 4. Rubber

5. Sleeper exhaust tube assembly 6. Gasket 7. Exhaust shutter assembly

8. Muffler 9. Hanger 10. Tail tube assembly

NOTE z

Numbers before part name do not indicate the disassembly sequence.

INSPECTION Carefully check all disassembled parts for scratches, cracks or damage. Repair or replace faulty parts if necessary.

IE-5-2

EXHAUST SYSTEM

INSTALLATION 1.

Replace all gaskets with new ones.

2. Install the hanger and rubber pad on the tail pipe bracket. NOTE z Always install the hanger using the hole at the outer end of the bracket. z Make sure that the convex end of the rubber pad faces down and that the bolt is inserted from the lower side. z Make sure that the nut which secures the rubber pad makes contact with the graded portion of the bolt when tightened. 3.

Install the exhaust pipe on the exhaust manifold using a gasket. Fasten it with the clamp. Install the assembled unit on the hanger.

4.

Temporarily install the clamp, sleeper and rubber pad on the bracket which secures the rear of the muffler.

5.

Insert the rear pipe of the muffler into the clamp. Connect the front pipe to the exhaust pipe by using the exhaust brake assembly and gasket. NOTE z Install the muffler so that the bent part is 30 degrees towards the vehicle from the bottom of the muffler. 6. 7.

Insert the tail pipe between the clamp (which was installed temporarily in step 4 above) and the rear pipe of the muffler. Secure the tail pipe hanger to the tail pipe clamp.

IE-5-3

EXHAUST SYSTEM 8. Adjust the position of the tail pipe and tighten the clamp. NOTE z Make sure that the tail pipe clamp is tightened at a point approximately 5 mm (0.20 in) from the end of the tail pipe.

INSPECTION AFTER INSTALLATION 1.

2.

Check that the exhaust pipe, muffler and tail pipe are sufficiently clear of adjacent parts for safety. Also check that there is sufficient clearance between the exhaust pipes and the seats and ropes. Start the engine. Check the muffler for proper function and connections for signs of air leakage.

IE-5-4

EXHAUST BRAKE

EXHAUST BRAKE = CHAMBER TYPE = CONSTRUCTION

REMOVAL Position the vehicle on a flat surface and apply chocks to the front and rear wheels. WARNING WARNING z

Do not remove the exhaust brake parts while the engine is hot to prevent scalding yourself.

IE-6-1

CHAMBER TYPE

EXHAUST BRAKE

CHAMBER TYPE

DISASSEMBLY EXHAUST SHUTTER AND POWER CHAMBER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cover 2. Pin 3. Clevis pin

, 4. Clevis 5. Power chamber assembly 6. Bearing

7. Gasket 8. Insulator 9. Exhaust shutter assembly


IE-6-2

EXHAUST BRAKE

CHAMBER TYPE

EXHAUST SHUTTER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Lever , 2. Seal ring , 3. Seal ring

4. Cover 5. Gasket

6. Body 7. Bracket assembly


IE-6-3

EXHAUST BRAKE

INSPECTION z

z


REASSEMBLY EXHAUST SHUTTER Key point of reassembly 3, 2 Seal ring Position the spindle, valve and bushing in the body. Install the seal rings on the spindle. NOTE z Make sure that the different seal rings are installed alternately. Adjustment of clearance between the valve and body Apply a vacuum pressure of 86.6 to 93.3 kPa {650 to 700 mmHg, 25.59 to 27.56 inHg} to the power chamber with the valve fully closed. Check to ensure that the clearance between the body and valve is in the specified range indicated in the table below. If it is not, adjust the stopper bolt and tighten the lock nut. : 5 - 7 N·m {0.5 - 0.7 kgf·m, 3.6 - 5.1 ft·lbf} Unit: mm (in) Item Clearance between valve and body



Service limit

0.80 - 1.05 (0.0315 - 0.0413)

—

1.6 - 2.1 (0.063 - 0.083)

—

EXHAUST SHUTTER AND POWER CHAMBER ASSEMBLY Key point of reassembly 4 Clevis Install the clevis on the push rod, and connect the lever using a pin. Adjust the position of the clevis so that the push rod can be set in position when pushed 2 mm (0.08 in) against the power chamber. Check that clearances A and B between the valve and body are equal and that the push rod makes contact with the stopper bolt on the “full-open” side. If no contact is made, adjust it as outlined in “Adjustment of clearance between the valve and body”.

IE-6-4

CHAMBER TYPE

EXHAUST BRAKE : Clevis adjusting nut 10 - 16 N·m {1.0 - 1.6 kgf·m, 7 - 12 ft·lbf} : Stopper bolt lock nut 5 - 7 N·m {0.5 - 0.7 kgf·m, 3.6 - 5.1 ft·lbf}

INSTALLATION Key point of installation 1. Connect the vacuum hoses. NOTE z Be careful not to twist the hoses. 2.

Start the engine. When vacuum pressure reaches the specified value, turn the exhaust brake switch “ON” to ensure that the exhaust brake operates properly. Also check to be sure there is no air leakage.

IE-6-5

CHAMBER TYPE

EXHAUST BRAKE

= CYLINDER TYPE = CONSTRUCTION EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY Models 286-04442 and 286-04441

IE-6-6

CYLINDER TYPE

EXHAUST BRAKE Models 286-04446 and 286-04453

IE-6-7

CYLINDER TYPE

EXHAUST BRAKE Model 286-06109

REMOVAL Key point of removal Position the vehicle on a flat surface and apply chocks to the front and rear wheels. WARNING WARNING z

Do not remove the exhaust brake parts while the engine is hot to prevent scalding yourself.

IE-6-8

CYLINDER TYPE

EXHAUST BRAKE

CYLINDER TYPE

Remove the exhaust shutter assembly. Separate the exhaust brake air-hose connection, and remove the hose. When removing, hold the hose stationary and loosen the nut. NOTE z Be careful not to twist the hose when removing. z

DISASSEMBLY EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY Models 286-04442 and 286-04441

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Pin 2. Clevis pin , 3. Clevis

4. Shield plate 5. Air cylinder assembly

6. Insulator 7. Exhaust shutter assembly


IE-6-9

EXHAUST BRAKE

CYLINDER TYPE

Models 286-04446, 286-04453 and 286-06109

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Pin 2. Clevis pin , 3. Clevis

4. Shield plate 5. Air cylinder assembly

6. Insulator 7. Exhaust shutter assembly


IE-6-10

EXHAUST BRAKE

CYLINDER TYPE

EXHAUST SHUTTER Models 286-04442, 286-04441, 286-04446 and 286-04453

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cover 2. Gasket 3. Lever

4. Plate , 5. Seal ring

, 6. Seal ring 7. Exhaust shutter

Marks “+” and “,” indicate that the key points of operation are explained in the text. CAUTION z

Do not disassemble the exhaust shutter in model 286-06109. Never loosen the stopper bolt.

IE-6-11

EXHAUST BRAKE

CYLINDER TYPE

AIR CYLINDER ASSEMBLY Models 286-04442 and 286-04441

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cover 2. O-ring 3. Nut 4. Washer 5. Retainer

6. Packing 7. Plate 8. Wear ring 9. Protector + 10. Spring

11. Shaft 12. Guide 13. Cover 14. Dust seal 15. Cylinder


IE-6-12

EXHAUST BRAKE

CYLINDER TYPE

Models 286-04446, 286-04453 and 286-06109

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cover 2. O-ring 3. Nut 4. Washer 5. Retainer 6. Packing

7. Plate 8. Wear ring 9. Protector + 10. Spring 11. Shaft 12. Guide

13. Washer 14. Cover 15. Dust seal 16. Retaining ring 17. Filter 18. Cylinder


Key point of disassembly 10 Spring Remove the cover and detach the spring and shaft assembly from the cylinder. NOTE z Be careful not to allow the shaft assembly to jump out because the cover is spring-loaded.

IE-6-13

EXHAUST BRAKE

INSPECTION z

z


Spindle O.D. Unit: mm (in) Maintenance standard

Service limit

16.50 (0.6496)

16.43 (0.6468)

Clearance between spindle and bushing Unit: mm (in) Maintenance standard

Service limit

0.3 - 0.4 (0.012 - 0.016)

—

Clearance between bushing and body Unit: mm (in) Maintenance standard

Service limit

0.015 - 0.090 (0.0006 - 0.0035)

—

Spring Unit: mm (in) Item


Service limit

Free length

151.5 (5.965)

—

134.4 - 161.2 {13.70 - 16.44, 30.2 - 36.3}

—


Remarks


IE-6-14

CYLINDER TYPE

EXHAUST BRAKE

REASSEMBLY EXHAUST SHUTTER Key point of reassembly 6, 5 Seal ring Position the spindle, valve and bushing in the body and attach the seal rings on the spindle. NOTE z Alternately install different types of seal rings. Adjustment of clearance between the valve and body Move the lever toward the full-open side. When the lever contacts the stopper bolt, adjust the stopper bolt so that clearances A and B are equal. Move the lever toward the full-close side. When the lever contacts the stopper bolt, adjust the stopper bolt so that the clearance between the valve and body is within specifications. After adjusting the clearance, tighten the stopper bolt with the lock nut. : 10 - 16 N·m {1.0 - 1.6 kgf·m, 7 - 12 ft·lbf}

Unit: mm (in) Item


0.80 - 1.05 One side Clearance (0.0315 - 0.0413) between valve 1.6 - 2.1 and body Both total (0.063 - 0.083)

Service limit

Remarks

— (*) —

(*) When an air pressure of 637 kPa {6.5 kgf/cm2, 92 psi} is applied to the air cylinder and the valve is fully closed

EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY Key point of reassembly 3 Clevis Connect the shaft of the cylinder assembly and clevis using a pin. Move the lever toward the full-open side until it contacts the stopper bolt. From that position, pull out the shaft less than 1 mm (0.04 in) to ensure that the hole in the shaft is aligned with the clevis hole. Stopper bolt lock nut (at spindle) : 10 - 16 N·m {1.0 - 1.6 kgf·m, 7 - 12 ft·lbf}

IE-6-15

CYLINDER TYPE

EXHAUST BRAKE

INSTALLATION Key point of installation Install the connector so that its hose mounting hole faces upward. NOTE z

Wind two turns of sealing on the threads of the connector in the opposite direction of the threads.

IE-6-16

CYLINDER TYPE

- MEMO -

- MEMO -

ELECTRICAL SYSTEM

CONTENTS SERVICE DATA ...................................... EE-1-1 SPECIFICATIONS............................................ EE-1-1 SERVICE DATA ............................................... EE-1-1 TIGHTENING TORQUE ................................... EE-1-2 STARTING MOTOR ................................ EE-2-1 CONSTRUCTION............................................. EE-2-1 DISASSEMBLY ................................................ EE-2-3 INSPECTION.................................................... EE-2-4 ADJUSTMENT ................................................. EE-2-7

PERFORMANCE CHECK ................................ EE-2-8

ALTERNATOR ........................................ EE-3-1 CONSTRUCTION ............................................. DISASSEMBLY................................................ INSPECTION .................................................... PERFORMANCE CHECK ................................

EE-3-1 EE-3-5 EE-3-7 EE-3-8 AIR HEATER ........................................... EE-4-1 CONSTRUCTION ............................................. EE-4-1 INSPECTION .................................................... EE-4-1

EE

SERVICE DATA

SERVICE DATA SPECIFICATIONS STARTING MOTOR Model

0350 502 0310

0350 502 0321

Type

Shift

Output

V-kW

24-4.5

ALTERNATOR 0202 152 Model

0201 152

0202 152 0310 0202 152 0311 0202 152 0220 0202 152 0221 0201 152 0420 0201 152 0421 0201 222 0273 With vacuum pump

Output

0201 222

Without vacuum pump

V-A

24-50

Type of regulator

24-80

IC transistor (Built-in)

Vacuum pump model

1290 011 00 (VD-120)

1290 009 00 (VD-30)

—

AIR HEATER Type

Ribbon

Rated current

V-A

Rated time

Second

22-85 Less than 50

SERVICE DATA STARTING MOTOR Models 0350 502 0310 and 0350 502 0321 Unit: mm (in) Item

Service limit

36.0 (1.417)

34.0 (1.339)

Runout

Less than 0.09 (0.0035)

More than 0.10 (0.0039)

0.5 - 0.8 (0.020 - 0.031)

0.2 (0.008)

18.0 (0.709)

13.0 (0.512)

29.4 {3.0, 6.6}

20.6 {2.1, 4.6}

Magnetic Brush switch

Undercut depth Brush height

Gear shaft

Commutator


Outside diameter

Shaft runout

Brush spring tension Continuity test

N {kgf, lbf}

Pull coil resistance

Ω

0.70 - 0.86

—

Hold coil resistance

Ω

0.85 - 1.05

—

Less than 0.09 (0.0035)

More than 0.10 (0.0039)

0.1 - 0.5 (0.004 - 0.020)

—

Thrust gap

Armature, field coil

Insulation resistance MΩ

More than 1.0

0.5

Brush holder

Insulation resistance MΩ

More than 1.0

0.5

EE-1-1

Remarks

When spring is set

SERVICE DATA Unit: mm (in)

Performance Adjustment check

Bracket

Item


Service limit

Front bearing (metal) inside diameter

15.0 (0.591)

15.2 (0.598)

Commutator bearing fit section inside diameter

28.0 (1.102)

28.1 (1.106)

Gear bearing fit section inside diameter

35.0 (1.378)

35.1 (1.382)

0.5 - 3.0 (0.020 - 0.118)

—

Less than 100

—

Terminal voltage 24V

More than 4,000

—

Terminal voltage 24V

Less than 16

—

Clearance between pinion gear and pinion stopper (Dimension L) Current

A

Number of rotations

rpm

Measure minimum voltage which is necessary for pinion to pop out V

Remarks

ALTERNATOR

Performance check

Field coil Starter coil

Item Ω

Resistance

Service limit

0.18 - 0.22

—

0201 222

0.14 - 0.18

—

5.6 - 6.8

—

5.0 - 7.0

—

Less than 950

—

Less than 900

—

28 - 29

—

Less than 50

—

Less than 80

—

0202 152 Ω 0201 152 0201 222

Resistance

No-load speed

Maintenance standard 0202 152 0201 152

0202 152 rpm 0201 152 0201 222

Regulating voltage

V 0202 152 A 0201 152 0201 222

Output current

Remarks Between two phases at 20ºC (68ºF)

At 20ºC (68ºF)

TIGHTENING TORQUE STARTING MOTOR Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

C terminal

1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}

B terminal

8 - 11 {0.8 - 1.1, 5.8 - 8.0}

M terminal

6 - 11 {0.6 - 1.1, 4.3 - 8.0}

Magnetic switch mounting bolt

16 - 18 {1.6 - 1.8, 12 - 13}

Through bolt

16 - 18 {1.6 - 1.8, 12 - 13}

Brush holder mounting screw

3.6 - 4.9 {0.37 - 0.50, 2.7 - 3.6}

Gear case mounting bolt

16 - 18 {1.6 - 1.8, 12 - 13}

EE-1-2

SERVICE DATA

ALTERNATOR Unit: N·m {kgf·m, ft·lbf} Item Pulley mounting nut

Tightening torque 0202 152 0201 152

127 - 157 {13.0 - 16.0, 94 - 116}

0201 222

113 - 147 {11.5 - 15.0, 83 - 108}

EE-1-3

STARTING MOTOR

STARTING MOTOR CONSTRUCTION

EE-2-1

0350 502

No

EE-2-2

Starting motor does not stop when key switch is turned off.

Check ignition system and fuel system.

O.K.

N.G. (Turns Does starting motor slowly) turn normally?

Yes

Does engine turn by cranking?

Engine does not start.

Yes

Check inside of engine.

No

Does engine turn by replacing starting motor with a new one?

O.K.

Check engine oil viscosity.

O.K.

Repair or replace starting motor.

Replace engine oil.

*A

Check pinion roller clutch for damage. Replace if necessary.

Repair or replace key switch, block relay or magnetic switch.

Yes

N.G.

Check battery for charging N.G. condition and battery terminals for connections and corrosion.

Check reduction gear parts (armature, gear shaft). Replace if necessary.

No

Does gear shaft turn?

Yes

Does starting motor turn?

No

No

N.G.

No

No

: Problem or corrective action

Replace motor (field coil or armature).

tion, weak return spring and pinion for sliding condition. z Correct meshing condition of pinion and ring gear. Replace if necessary.

z Check lever assembly for deforma-

z Repair or replace magnetic switch.

netic switch.

z Check and repair wiring up to mag-

Check and repair wiring system of block relay. z Key switch. z Starter relay. z Connections.

battery terminals.

z Charge or replace battery. z Repair connections and corrosion of

*A

If any abnormality is found, immediately disconnect battery negative terminal.

: Check item

Check magnetic switch contacts. Replace if necessary.

Yes

Remove starting motor from engine. Does starting motor turn under no load by connecting battery (+) terminal to M terminal of starting motor and battery (–) terminal to starting motor body?

O.K.

Is meshing condition of pinion and ring gear normal?

Yes

Can you hear magnetic switch operating sound?

Yes

Can you hear starter relay operating? (Block relay equipped model only)

O.K.

Check battery for charging condition and battery terminals for connections and corrosion.

N.G.

STARTING MOTOR 0350 502

TROUBLESHOOTING

STARTING MOTOR

0350 502

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Magnetic switch assembly 2. Rear bracket + 3. Brush holder assembly 4. O-ring 5. Yoke assembly 6. Armature assembly 7. O-ring 8. Gear case

9. Packing 10. Retaining ring 11. Hook + 12. Pinion stopper 13. Holder 14. Shaft 15. Lever assembly

16. Center holder 17. Shim washer 18. Pinion assembly 19. Pinion case 20. Felt 21. Cover 22. Metal


EE-2-3

STARTING MOTOR

Key point of disassembly 3 Brush holder assembly Contact the negative side of the brush spring to the side of the brush. Lift the brush from the armature commutator surface. Extract the positive side of the brush from the brush holder. Then, remove the brush holder assembly.

12 Pinion stopper Move the pinion stopper toward the pinion. Using a screwdriver, pry off the pinion stopper clip. Then, extract the pinion assembly and center plate.

INSPECTION z

z


COMMUTATOR Outside diameter Unit: mm (in) Maintenance standard

Service limit

36.0 (1.417)

34.0 (1.339)

NOTE z

If the commutator surface is rough, grind with No. 500 to 600 sandpaper and then measure the outside diameter.

Runout Unit: mm (in) Maintenance standard

Service limit

Less than 0.09 (0.0035)

More than 0.10 (0.0039)

EE-2-4

0350 502

STARTING MOTOR

Undercut depth Unit: mm (in) Maintenance standard

Service limit

0.5 - 0.8 (0.020 - 0.031)

0.2 (0.008)

BRUSH Brush height Unit: mm (in) Maintenance standard

Service limit

18.0 (0.709)

13.0 (0.512)

Brush spring tension Unit: N {kgf, lbf} Maintenance standard

Service limit

29.4 {3.0, 6.6}

20.6 {2.1, 4.6}

Remarks When spring is set

MAGNETIC SWITCH Continuity test (Pull coil resistance) Perform the continuity test between the M and C terminals. Unit: Ω Maintenance standard

Service limit

0.70 - 0.86

—

Continuity test (Hold coil resistance) Check the continuity between the C terminal and coil case. Unit: Ω Maintenance standard

Service limit

0.85 - 1.05

—

EE-2-5

0350 502

STARTING MOTOR

GEAR SHAFT Shaft runout Unit: mm (in) Maintenance standard

Service limit

Less than 0.09 (0.035)

More than 0.10 (0.0039)

Thrust gap Unit: mm (in) Maintenance standard

Service limit

0.1 - 0.5 (0.004 - 0.020)

—

ARMATURE COIL Continuity test Make sure there is no continuity between the commutator and armature assembly.

Insulation resistance Unit: MΩ Maintenance standard

Service limit

More than 1.0

0.5

FIELD COIL Continuity test Make sure there is continuity between the field coil terminals.

EE-2-6

0350 502

STARTING MOTOR

Insulation resistance Unit: MΩ Maintenance standard

Service limit

More than 1.0

0.5

BRUSH HOLDER Insulation resistance Unit: MΩ Maintenance standard

Service limit

More than 1.0

0.5

BRACKET Front bearing (metal) inside diameter Unit: mm (in) Maintenance standard

Service limit

15.0 (0.591)

15.2 (0.598)

Commutator bearing fit section inside diameter Unit: mm (in) Maintenance standard

Service limit

28.0 (1.102)

28.1 (1.106)

Gear bearing fit section inside diameter Unit: mm (in) Maintenance standard

Service limit

35.0 (1.378)

35.1 (1.382)

ADJUSTMENT Measure dimension L moved towards the thrust direction of the pinion when the magnetic switch pushes out the pinion. 1. Connect the S terminal to the battery positive terminal through the magnetic switch. Ground the M terminal midway and then connect it to the battery negative terminal.

EE-2-7

0350 502

STARTING MOTOR 2.

Turn on the switch and make sure the magnetic switch pushes out the pinion. Then, push back the pinion lightly and measure dimension L. Unit: mm (in) Item

Dimension L

3.


Service limit

0.5 - 3.0 (0.020 - 0.118)

—

If dimension L exceeds the maintenance standard, replace the starting motor assembly with a new one.

PERFORMANCE CHECK 1.

Connect as shown in the illustration. Turn off the key switch and turn the starting motor. Under these conditions, measure the current and the number of rotations. (Terminal voltage: 24 volts) Item

Current


Service limit

Less than 100

—

More than 4,000

—

A

Number of rotations rpm

2.

Check that the pinion gear pops smoothly out and in when the switch is turned on and off.

3.

Measure the minimum voltage which is necessary for the pinion to pop out. Prepare a variable resistor and battery voltmeter as testing equipment. Set the resistance higher at first so that a lower voltage applies to the starting motor. Then, slowly lower the resistance and measure the voltage when the pinion pops out. Unit: V Maintenance standard

Service limit

Less than 16

—

EE-2-8

0350 502

- MEMO -

ALTERNATOR

ALTERNATOR CONSTRUCTION Models 0202 152 0310 and 0202 152 0311

Models 0201 152 0420 and 0201 152 0421

EE-3-1

0202 152, 0201 152, 0201 222

ALTERNATOR Models 0202 152 0220 and 0202 152 0221

Model 0201 222 0273

EE-3-2

0202 152, 0201 152, 0201 222

EE-3-3

(Check the battery and its related parts.)

Normal alternator

Yes

Measure the alternator charging current at B terminal. Is it over 35A? (Engine speed: 2,000 rpm)

Yes

Is the voltage across alternator terminals B and E over 27V? (Engine speed: 1,000 rpm)

*B

Yes

Does voltage exist across alternator terminals IG and E? (Key switch is ON)

*A

Yes

Is the voltage across alternator terminals B and E above 22V? (When the key switch is ON and engine is stopped.)

The battery runs down.

No

No

No

No

No

Normal

Yes

Increase the electrical load (Turn on all the lights.) Is the charging current over 35A?

Faulty alternator

Normal

Normal

Is the key switch normal?

To *A

Is the belt broken? Is the belt slipping?

Yes

Does voltage exist?

Check the battery relay.

No

Normal

Faulty alternator

To *B

Is the fuse blown?

Abnormal

To *A

Normal

Abnormal

Abnormal

To *A Abnormal

O Is the fuse blown? O Is the wiring between the alternator and battery normal?

Abnormal

No

Check the wiring.

Abnormal

O Repair the alternator. (Replace the diode, stator or regulator.)

O Replace the fuse.

O Replace the key switch

O Change the belt. O Adjust the belt tension.

O Replace the fuse. O Repair the wiring.

Repair the wiring.

Replace the battery relay.

ALTERNATOR 0202 152, 0201 152, 0201 222

TROUBLESHOOTING

(Check the battery and its related parts.)

Normal alternator

No

Is the voltage across alternator terminals B and E over 29V? (Engine speed: 1,000 rpm)

The battery becomes overcharged. (The battery fluid decreases.).

Yes Faulty alternator (Regulator)

(Battery fluid decreases)

: Check item

: Problem or corrective action

O Repair the alternator (Faulty regulator) (Broken internal wiring)

ALTERNATOR

EE-3-4

0202 152, 0201 152, 0201 222

ALTERNATOR

0202 152, 0201 152, 0201 222

DISASSEMBLY Models 0202 152 and 0201 152

1. Nut 2. Lock washer 3. Washer + 4. Pulley assembly 5. Spacer + 6. Front cover 7. Oil seal 8. Washer

9. Ball bearing 10. Washer 11. Oil seal 12. Cover 13. Rotor assembly 14. Stator assembly 15. Field coil assembly 16. Housing

17. Rubber cap 18. Heat sink 19. Terminal 20. Through bolt 21. Charge light circuit assembly 22. Cover 23. Regulator

Marks “+” and “,” indicate that the key points of operation are explained in the text. NOTE z


EE-3-5

ALTERNATOR

0202 152, 0201 152, 0201 222

Model 0201 222

1. Nut 2. Lock washer 3. Washer + 4. Pulley assembly + 5. Front cover 6. Bearing felt 7. Retainer

8. Ball bearing 9. Retainer 10. Cover 11. Rotor assembly 12. Stator assembly 13. Field coil assembly 14. Housing

15. Through bolt 16. Needle bearing 17. Regulator 18. Heat sink 19. Terminal 20. Cover

Marks “+” and “,” indicate that the key points of operation are explained in the text. NOTE z


EE-3-6

ALTERNATOR

Key point of disassembly 6 Models 0202 152 and 0201 152 5 Model 0201 222

} Front cover

To separate the front cove assembly, insert a screwdriver into the clearance between the front cover and stator core. NOTE z

Be careful not to damage the stator coil with the screwdriver tip.

4 Models 0202 152 and 0201 152 4 Model 0201 222

} Pulley assembly

When separating the pulley assembly, secure the rotor periphery with a vise. Then, remove the pulley nut, pulley assembly and spacer. If the pulley assembly is difficult to remove, use a generalpurpose puller.

INSPECTION z

z


STATOR COIL Continuity test of the stator coil Unit: Ω Maintenance standard

Service limit

0202 152 0201 152

0.18 - 0.22

—

0201 222

0.14 - 0.18

—

Item

Resistance

Remarks Between two phases at 20ºC (68ºF)

If there is no continuity, the stator coil may be broken. Replace the stator coil as an assembly.

Insulation test of the stator coil Make sure there is no continuity. If there is continuity, the stator coil may be shorted. Replace the stator coil as an assembly.

EE-3-7

0202 152, 0201 152, 0201 222

ALTERNATOR

FIELD COIL Continuity test of the field coil Unit: Ω Maintenance standard

Service limit

0202 152 0201 152

5.6 - 6.8

—

0201 222

5.0 - 7.0

—

Item

Resistance

Remarks

At 20ºC (68ºF)

If there is no continuity, the field coil may be broken. Replace the field coil as an assembly.

Insulation test of the field coil Make sure there is no continuity. If there is continuity, the field coil may be shorted. Replace the field coil as an assembly.

PERFORMANCE CHECK NOTE

Use leads with a cross-sectional area greater than 8 mm2 (0.0124 sq in) and a length less than 2.5 m (8.2 ft) to connect the line between the alternator’s B terminal and positive battery terminal, the E terminal and battery ground terminal, and the L terminal and battery ground terminal. z Use switches with as small a contact resistance as possible in the circuit. z Conduct performance test in areas where ambient temperature is maintained at 20ºC (68ºF). Start-up revolution 1. Install the alternator on a vehicle or connect to a variable velocity motor and connect the leads as shown in the figure. 2. Turn switches SW1 and SW2 “ON”, then gradually increase alternator speed. 3. When the voltmeter registers a voltage higher than the voltage when the alternator is stopped, turn switch SW1 “OFF”. 4. While observing the voltmeter, increase alternator speed. 5. Read alternator speed (rpm) when the voltmeter registers 27 volts. z

EE-3-8

0202 152, 0201 152, 0201 222

ALTERNATOR Unit: rpm Maintenance standard

Service limit

0202 152 0201 152

Less than 950

—

0201 222

Less than 900

—

Item No-load speed

Remarks

At 20ºC (68ºF)

Measuring of regulating voltage Turn switch SW1 off and turn switch SW2 on. Increase the alternator speed up to the rated rpm of 5,000. Then, measure the voltage. Unit: V Maintenance standard

Service limit

28.0 - 29.0

—

Measuring output current 1. 2.

Adjust the variable resistor to zero and turn switches SW1 and SW2 on. Keep the alternator speed at the rated rpm and adjust the variable resistor so that the terminal voltage is at the specified value. Then, read the current. Terminal voltage: 28V - 5,000 rpm Unit: A Maintenance standard

Service limit

0202 152 0201 152

Less than 50

—

0201 222

Less than 80

—

Item

Remarks

At 20ºC (68ºF)

EE-3-9

0202 152, 0201 152, 0201 222

AIR HEATER

AIR HEATER CONSTRUCTION

INSPECTION z

z

1. 2.

Clean all disassembled parts in cleaning solvent. Check for scratches, cracks or damage and replace faulty parts. If measurement indicates that the service limit has exceeded, repair or replace faulty parts. Check wiring for improper connections or discontinuity. If there is no continuity, replace the air heater assembly. If carbon builds up on the ribbon heater, clean. Check the heater for discontinuity. If there is discontinuity, replace the air heater assembly.

EE-4-1

- MEMO -

AUXILIARY EQUIPMENT

CONTENTS SERVICE DATA ...................................... EA-1-1 SPECIFICATIONS............................................ EA-1-1 SERVICE DATA ............................................... EA-1-2 TIGHTENING TORQUE ................................... EA-1-4 TOOLS .................................................... EA-2-1 AIR COMPRESSOR......................................... EA-2-1 AIR COMPRESSOR ............................... EA-3-1

= MODEL F8040 = CONSTRUCTION............................................. REMOVAL ........................................................ DISASSEMBLY ................................................ INSPECTION.................................................... REASSEMBLY .................................................

EA-3-1 EA-3-1 EA-3-2 EA-3-3 EA-3-5

= MODEL 408738 = CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY..................................................

VACUUM PUMP ...................................... CONSTRUCTION ............................................. DISASSEMBLY................................................. INSPECTION .................................................... REASSEMBLY..................................................

PUMP SUPPORT .................................... CONSTRUCTION ............................................. REMOVAL ........................................................ DISASSEMBLY AND REASSEMBLY............... INSTALLATION ................................................

EA-3-7 EA-3-9 EA-3-10 EA-3-13 EA-3-14 EA-4-1 EA-4-1 EA-4-2 EA-4-2 EA-4-3 EA-5-1 EA-5-1 EA-5-1 EA-5-2 EA-5-2

EA

SERVICE DATA

SERVICE DATA SPECIFICATIONS AIR COMPRESSOR Model

F8040

Bore x Stroke - No. of cylinders

mm (in)

80 x 40 - 1 (3.15 x 1.57 - 1)

cm3 (cu in)/rev

Theoretical discharge Operating speed (max. service revolutions) Working pressure (max. service pressure)

201 (12.27)

rpm

1,600

2

834 {8.5, 121}

kPa {kgf/cm , psi}

408738

Model

5600

Bore x Stroke - No. of cylinders mm (in) Theoretical discharge

cm3(cu in)/rev

5601

5610

5611

5741

5780

85 x 40 - 1 (3.35 x 1.57 - 1)

85 x 60 - 1 (3.35 x 2.36 - 1)

227 (13.85)

340 (20.75)

Operating speed (max. service revolutions) rpm

1,600

Working pressure (max. service pressure) kPa {kgf/cm2, psi}

834 {8.5, 121}

VACUUM PUMP Model

1290 009 00 (VD-30)

Type

Vane

Theoretical discharge

cm3 (cu in)/rev

Max. operating speed

rpm

Vacuum performance

1290 011 00 (VD-120)

Time required to reach 66.7 kPa {500 mmHg, 19.69 inHg}/Engine speed Max. degree of vacuum/Engine speed

Alternator model

30 (1.83)

120 (7.32) 7,800

Less than 40 seconds/1,000 rpm Less than 10 seconds/5,000 rpm

Less than 27 seconds/1,500 rpm

More than 90.6 kPa {680 mmHg, 26.77 inHg}/5,000 rpm

More than 80.0 kPa {600 mmHg, 23.62 inHg}/900 rpm

0202 152 0220/0202 152 0221

0202 152 0310/0202 152 0311

EA-1-1

SERVICE DATA

SERVICE DATA AIR COMPRESSOR Model F8040 Unit: mm (in) Maintenance standard

Service limit

800 rpm

290 sec.

—

3,200 rpm

85 sec.

—

Piston top

0.25 - 0.35 (0.0098 - 0.0138)

0.38 (0.0150)

Piston skirt

0.10 - 0.20 (0.0039 - 0.0079)

0.25 (0.0098)

Compression ring

0.30 - 0.50 (0.0118 - 0.0197)

1.0 (0.039)

Oil ring

0.30 - 0.50 (0.0118 - 0.0197)

1.0 (0.039)

Compression ring

0.01 - 0.05 (0.0004 - 0.0020)

0.08 (0.0031)

Oil ring

0.01 - 0.05 (0.0004 - 0.0020)

0.08 (0.0031)

0.01L - 0.02T (0.0004L - 0.0008T)

0.08 (0.0031)

L: Loose T: Tight

Clearance between connecting rod small-end piston pin hole and piston pin

0.015 - 0.045 (0.0006 - 0.0018)

0.07 (0.0028)

Replace piston pin or connecting rod.

Clearance between connecting rod bigend bushing and crank pin

0.015 - 0.085 (0.0006 - 0.0033)

0.1 (0.004)

Replace bushing if worn so that copper color shows. Replace crankshaft in the cases.

0 - 0.22 (0 - 0.0087)

—

Item Charging performance

Air compressor proper

Piston-to-cylinder clearance

Piston ring joint gap

Piston ring-to-ring groove clearance

Engine speed

Piston pin hole-to-piston pin clearance

Cylinder head

End play of crankshaft Suction valve Tension of valve spring N {kgf, lbf} Delivery valve

Valve lift

Remarks Tank capacity: 30 liter (6-5/8 Imp gal) Tank pressure: 0 - 785 kPa {0 - 8 kgf/cm2, 0 - 114 psi}

Replace piston or cylinder.

Replace ring.


Replace.

4.41 {0.45, 0.99}

3.53 Measured length 7.0 mm (0.276 in) {0.36, 0.79}

4.51 {0.46, 1.01}

3.63 Measured length 9.5 mm (0.374 in) {0.37, 0.82}

Delivery valve

3.0 (0.118)

—

Unloader valve

1.0 (0.039)

—

Suction valve

2.6 (0.102)

—

EA-1-2

SERVICE DATA

Model 408738 Unit: mm (in) Maintenance standard

Service limit

500 rpm

448 sec.

—

3,200 rpm

66 sec.

—

500 rpm

264 sec.

—

3,200 rpm

46 sec.

—

Piston skirt

0.07 - 0.12 (0.0028 - 0.0047)

0.25 (0.0098)

Compression ring

0.15 - 0.30 (0.0059 - 0.0118)

0.6 (0.024)

Oil ring

0.15 - 0.35 (0.0059 - 0.0138)

0.7 (0.028)

Compression ring

0.02 - 0.05 (0.0008 - 0.0020)

0.08 (0.0031)

Oil ring

0.03 - 0.07 (0.0012 - 0.0028)

0.10 (0.0039)

Piston pin hole-to-piston pin clearance

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Clearance between connecting rod smallend piston pin hole and piston pin

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Replace piston pin or connecting rod.

Clearance between connecting rod bigend crank pin hole and crank pin

0.034 - 0.075 (0.0013 - 0.0030)

0.1 (0.004)

Replace connecting rod if worn so that copper color shows. Replace crankshaft in other cases.

0 - 0.50 (0 - 0.0197)

1.0 (0.039)

Replace.

Suction valve spring

1.18 {0.12, 0.26}

1.0 {0.1, 0.2}

N {kgf, lbf} Delivery valve spring

7.65 {0.78, 1.72}

Item

Charging performance

5600 5601 5610 5611

Engine speed

5741 5780

Engine speed

Air compressor proper

Piston-to-cylinder clearance

Piston ring joint gap

Piston ring-to-ring groove clearance

Cylinder head

End play of crankshaft

Tension

Valve lift

Tank capacity: 30 liter (6-5/8 Imp gal) Tank pressure: 0 - 785 kPa {0 - 8 kgf/cm2, 0 - 114 psi} Replace piston or cylinder.

Replace ring.



6.08 When compressed to {0.62, 1.37} 12.5 mm (0.492 in)

Suction valve

2.0 (0.079)

—

Delivery valve

1.5 (0.059)

—

EA-1-3

Remarks

SERVICE DATA

VACUUM PUMP Unit: mm (in) Item Vane height


Service limit

1290 009 00 (VD-30)

13.5 (0.531)

13.0 (0.512)

1290 011 00 (VD-120)

21.5 (0.846)

21.0 (0.827)

Remarks

TIGHTENING TORQUE AIR COMPRESSOR Model F8040 Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Suction valve holder

98 - 118 {10.0 - 12.0, 72 - 87}

Unloader valve connector

29 - 34 {3.0 - 3.5, 22 - 25}


98 - 118 {10.0 - 12.0, 72 - 87}

Nut for connecting rod cap

23 - 25 {2.3 - 2.6, 17 - 19}

Cylinder head mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Cylinder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Lock plate mounting bolt

14 - 18 {1.4 - 1.8, 10 - 13}

Model 408738 Unit: N·m {kgf·m, ft·lbf} Item

Tightening torque

Unloader valve connector

44 - 54 {4.5 - 5.5, 33 - 40}

Cylinder head bolt

44 - 54 {4.5 - 5.5, 33 - 40}

Bearing holder mounting bolt

Except model 5780

Bearing holder mounting screw

Model 5780 only

13.2 - 16.2 {1.35 - 1.65, 9.8 - 11.9} 5.3 - 6.5 {0.54 - 0.66, 3.9 - 4.8}

Cylinder bolt

26 - 32 {2.7 - 3.3, 20 - 24}

EA-1-4

TOOLS

TOOLS AIR COMPRESSOR Model F8040 Tool name and number

Description

Piston inserting kit 99750 Z5500 (1) 99754 96002 (2) 99756 Z5500 (3) 81-11025-1A (4) 81-10825-1A

Used to install piston in air compressor (1) Piston inserting tool (2) Crankshaft holder (3) Bolt (M10 x 1.5) (4) Bolt (M8 x 1.25)

Valve holder tool 99744 97000

Used to remove and install air compressor suction valve holder

Shape

Model 408738 Tool name and number

Description

Piston inserting kit 99750 Z5501 (1) 99754 96001 (2) 99756 Z5500 (3) 81-11025-1A (4) 81-10825-1A

Used to install piston in air compressor (1) Piston inserting tool (2) Crankshaft holder (3) Bolt (M10 x 1.5) (4) Bolt (M8 x 1.25)

Oil seal replacer 99753 Z5501

Used to install sleeve and oil seal in air compressor [Air compressor crankshaft rear end outside diameter: 25 mm (0.98 in)]

EA-2-1

Shape

AIR COMPRESSOR

AIR COMPRESSOR = MODEL F8040 = CONSTRUCTION

REMOVAL 1. 2. 3.

Release air from the air reservoir tank. Drain the cooling water from the radiator through the drain cock. Remove the injection pump (see section “ENGINE DISASSEMBLY AND REASSEMBLY”).

EA-3-1

F8040

AIR COMPRESSOR

F8040

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Cylinder head 2. O-ring , 3. Cylinder 4. O-ring 5. Piston and connecting rod assembly 6. Snap ring 7. Piston pin , 8. Connecting rod cap , 9. Connecting rod , 10. Bushing , 11. Compression ring , 12. Oil ring 13. Piston 14. Injection pump drive gear 15. Lock plate

+ 16. Ball bearing 17. Bearing holder 18. O-ring 19. Crankshaft ,+ 20. Ball bearing 21. Oil seal collar , 22. Oil seal 23. Crankcase , 24. Delivery valve assembly 25. Delivery valve holder 26. O-ring 27. Spring holder 28. Valve spring 29. O-ring

30. Delivery valve 31. Valve seat , 32. Unloader valve assembly 33. Unloader valve connector 34. O-ring 35. Unloader valve 36. Valve guide 37. Valve spring , 38. Suction valve assembly , 39. Suction valve holder 40. Valve spring 41. Suction valve 42. Valve seat 43. Packing


EA-3-2

AIR COMPRESSOR

Key point of disassembly Before disassembling the air compressor, measure the end play of the crankshaft. Unit: mm (in) Maintenance standard

Service limit

0 - 0.22 (0 - 0.0087)

—

16, 20 Ball bearing Using a puller, remove the ball bearing from the crankshaft. NOTE z Remove the ball bearing on the oil seal side together with the oil seal collar.

INSPECTION z

z


Piston-to-cylinder clearance Unit: mm (in) Item


Service limit

Piston top

0.25 - 0.35 (0.0098 - 0.0138)

0.38 (0.0150)

Piston skirt

0.10 - 0.20 (0.0039 - 0.0079)

0.25 (0.0098)

Piston ring joint gap Unit: mm (in) Item


Service limit

Compression ring

0.30 - 0.50 (0.0118 - 0.0197)

1.0 (0.039)

Oil ring

0.30 - 0.50 (0.0118 - 0.0197)

1.0 (0.039)

EA-3-3

F8040

AIR COMPRESSOR

Piston ring-to-ring groove clearance Unit: mm (in) Item


Service limit

Compression ring

0.01 - 0.05 (0.0004 - 0.0020)

0.08 (0.0031)

Oil ring

0.01 - 0.05 (0.0004 - 0.0020)

0.08 (0.0031)

Piston pin hole-to-piston pin clearance Unit: mm (in) Maintenance standard

Service limit

0.01L - 0.02T (0.0004L - 0.0008T)

0.08 (0.0031)

Remarks L: Loose T: Tight

Clearance between connecting rod small-end piston pin hole and piston pin Unit: mm (in) Maintenance standard

Service limit

0.015 - 0.045 (0.0006 - 0.0018)

0.07 (0.0028)

Clearance between connecting rod big-end bushing and crank pin Unit: mm (in) Maintenance standard

Service limit

0.015 - 0.085 (0.0006 - 0.0033)

0.1 (0.004)

NOTE z

Replace the bearing if its lining is worn to the extent that copper color shows. In other cases, replace the crankshaft.

Tension of valve spring Unit: N {kgf, lbf} Item


Service limit

Remarks

Suction valve

4.41 {0.45, 0.99}

3.53 {0.36, 0.79}

Measured length 7.0 mm (0.276 in)

Delivery valve

4.51 {0.46, 1.01}

3.63 {0.37, 0.82}

Measured length 9.5 mm (0.374 in)

EA-3-4

F8040

AIR COMPRESSOR

REASSEMBLY 38 Suction valve assembly, 32 Unloader valve assembly, 24 Delivery valve assembly 1. Install the suction valve assembly (using special tool 99744 97000), unloader valve assembly, and delivery valve assembly to the cylinder head through the packing or Oring. Unit: N·m {kgf·m, ft·lbf} Item Suction valve holder Unloader valve connector Delivery valve holder

Tightening torque 98 - 118 {10.0 - 12.0, 72 - 87} 29 - 34 {3.0 - 3.5, 22 - 25} 98 - 118 {10.0 - 12.0, 72 - 87}

NOTE z

Apply 0.1 to 0.2 milliliter (0.003 to 0.007 Imp fl oz) of a screw lock (TB1323B) to the threads on the cylinder head side of the delivery valve holder.

2.

Using an inspection rod, measure the lift of each valve to see if it is within the maintenance standard. Unit: mm (in) Item


Service limit

Delivery valve (A)

3.0 (0.118)

—

Unloader valve (B)

1.0 (0.039)

—

Suction valve (C)

2.6 (0.102)

—

39 Suction valve holder Lock the suction valve holder with a punch. NOTE z Do not caulk in the same position as before. 22 Oil seal Install the oil seal to the crankcase. NOTE z Coat the oil seal lip with engine oil. 20 Ball bearing Install the ball bearings on the crankshaft by press-fitting. NOTE z

The ball bearing on the oil seal side should be installed with its shield plate facing outward (oil seal side).

EA-3-5

F8040

AIR COMPRESSOR 12 Oil ring, 11 Compression ring Install the piston rings in the ring grooves, and attach the connecting rod to the piston. NOTE z

Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturer’s mark faces up.

10 Bushing, 9 Connecting rod, 8 Connecting rod cap Fit the bushings in the connecting rod and connecting rod cap, and install the connecting rod to the crankshaft through the spring washer. : 23 - 25 N·m {2.3 - 2.6 kgf·m, 17 - 19 ft·lbf} NOTE z

Match the alignment marks on the connecting rod and connecting rod cap, and ensure the marks face the drive gear.

3 Cylinder Using the piston inserting kit (99750 Z5500), install the cylinder with the O-ring in place. : 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf} Piston insert kit (99750 Z5500) (1) Piston inserting tool (99754 96002) (2) Crankshaft holder (99756 Z5500) (3) Bolt (81-11025-1A) (4) Bolt (81-10825-1A)

EA-3-6

F8040

AIR COMPRESSOR

= MODEL 408738 = CONSTRUCTION Model 5600, 5601, 5610 and 5611

EA-3-7

408738

AIR COMPRESSOR Model 408738-5741

EA-3-8

408738

AIR COMPRESSOR Model 408738-5780

REMOVAL 1. 2. 3.

Release air from the air reservoir tank. Drain the cooling water from the radiator through the drain cock. Remove the injection pump (see section “ENGINE DISASSEMBLY AND REASSEMBLY”).

EA-3-9

408738

AIR COMPRESSOR

408738

DISASSEMBLY Model 5600, 5601, 5610 and 5611

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) , 1. Cylinder head assembly 2. O-ring , 3. Cylinder 4. O-ring 5. Piston and connecting rod assembly 6. Retaining ring 7.Piston pin

8. Piston 9. Connecting rod , 10. Piston rings , 11. Oil seal 12. Bearing holder 13. O-ring

, 14. Sleeve + 15. Ball bearing + 16. Ball bearing 17. Crankshaft 18. Crank case 19. Unloader valve


EA-3-10

AIR COMPRESSOR

408738

Model 5741

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) , 1. Cylinder head assembly 2. O-ring , 3. Cylinder 4. O-ring 5. Piston and connecting rod assembly 6. Retaining ring 7. Piston pin

8. Piston 9. Connecting rod , 10. Piston rings , 11. Oil seal 12. Bearing holder 13. O-ring



EA-3-11

AIR COMPRESSOR

408738

Model 5780

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) , 1. Cylinder head assembly 2. O-ring , 3. Cylinder 4. O-ring 5. Piston and connecting rod assembly 6. Retaining ring 7. Piston pin

8. Piston 9. Connecting rod assembly , 10. Piston rings , 11. Oil seal 12. Bearing holder 13. O-ring



EA-3-12

AIR COMPRESSOR

Key point of disassembly Before disassembling the air compressor, measure the end play of the crankshaft. Unit: mm (in) Maintenance standard

Service limit

0 - 0.50 (0 - 0.0197)

1.0 (0.039)

15, 16 Ball bearing Using a puller, remove the ball bearing from the crankshaft. NOTE z Remove the ball bearing on the oil seal side together with the oil seal collar.

INSPECTION z

z


Piston-to-cylinder clearance Unit: mm (in) Item Piston skirt


Service limit

0.07 - 0.12 (0.0028 - 0.0047)

0.25 (0.0098)

Piston ring joint gap Unit: mm (in) Item


Service limit

Compression ring

0.15 - 0.30 (0.0059 - 0.0118)

0.6 (0.024)

Oil ring

0.15 - 0.35 (0.0059 - 0.0138)

0.7 (0.028)

Piston ring-to-ring groove clearance Unit: mm (in) Item


Service limit

Compression ring

0.02 - 0.05 (0.0008 - 0.0020)

0.08 (0.0031)

Oil ring

0.03 - 0.07 (0.0012 - 0.0028)

0.10 (0.0039)

EA-3-13

408738

AIR COMPRESSOR

Piston pin hole-to-piston pin clearance Unit: mm (in) Maintenance standard

Service limit

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Clearance between connecting rod small-end piston pin hole and piston pin Unit: mm (in) Maintenance standard

Service limit

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Clearance between connecting rod big-end crank pin hole and crank pin Unit: mm (in) Maintenance standard

Service limit

0.034 - 0.075 (0.0013 - 0.0030)

0.1 (0.004)

Tension of valve spring Unit: N {kgf, lbf} Item


Service limit

Remarks

Suction valve spring

1.18 {0.12, 0.26}

1.0 {0.1, 0.2}


Delivery valve spring

7.65 {0.78, 1.72}

6.08 {0.62, 1.37}


REASSEMBLY Key point of reassembly 14 Sleeve Press-fit the ball bearing onto the crankshaft, and using the oil seal replacer (99753 Z5501), install the sleeve. 11 Oil seal Using the oil seal replacer (99753 Z5501), install the oil seal.

EA-3-14

408738

AIR COMPRESSOR 10 Piston rings Install the piston rings in the ring grooves, and attach the connecting rod to the piston. NOTE z Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturer’s mark faces up.

3 Cylinder Using the piston inserting kit (99750 Z5501), install the cylinder with the O-ring in place. : 26 - 32 N·m {2.7 - 3.3 kgf·m, 20 - 24 ft·lbf} Piston insert kit (99750 Z5501) (1) Piston inserting tool (99754 96001) (2) Crankshaft holder (99756 Z5500) (3) Bolt (81-11025-1A) (4) Bolt (81-10825-1A)

1 Cylinder head assembly Using a checking rod, etc., measure the valve lift of each valve. Make sure it is within the maintenance standard and install the cylinder head assembly. Unit: mm (in) Item


Service limit

Suction valve

2.0 (0.079)

—

Delivery valve

1.5 (0.059)

—

z

Make sure that the end play of the crankshaft is within the maintenance standard. Unit: mm (in) Maintenance standard

Service limit

0 - 0.50 (0 - 0.0197)

1.0 (0.039)

EA-3-15

408738

VACUUM PUMP

VACUUM PUMP CONSTRUCTION Model 1290 009 00 (VD-30)

Model 1290 011 00 (VD-120)

EA-4-1

VACUUM PUMP

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Housing 2. Valve 3. Packing 4. Connector 5. Packing

6. Connector 7. Packing 8. Retaining ring 9. Oil seal

, 10. Center plate 11. O-ring , 12. Rotor assembly , 13. Vane


INSPECTION z

z


VANE Unit: mm (in) Item Height


Service limit

1290 009 00

13.5 (0.531)

13.0 (0.512)

1290 011 00

21.5 (0.846)

21.0 (0.827)

CENTER PLATE Check for damage at the sliding surface with the rotor and replace when worn or damaged.

HOUSING Inspect the sliding surface with the rotor for damage and replace when worn or damaged, especially when the inside diameter is worn or damaged.

EA-4-2

VACUUM PUMP

OTHERS z z

Replace the O-ring at each disassembly. Replace and discolored copper packing. Moreover, check the threads of each part for damaged and replace when damaged beyond use.

REASSEMBLY Key point of reassembly 13 Vane Assemble the four vanes with the end having the round chamfer at the outside.

12 Rotor assembly, 10 Center plate 1. Insert the rotor into the housing. The side which has “no crossed oil groove” should face the center plate. 2. Position the center plate on the housing. Make sure a gasket is used between both parts.

3.

Position the vacuum pump assembly so that it is horizontal when the center plate is placed downward. Make sure that the hole in the center plate is aligned with the hole in the rotor shaft when looking through the rotor’s hole from the floor side.

EA-4-3

PUMP SUPPORT

PUMP SUPPORT CONSTRUCTION

REMOVAL Remove the injection pump support. NOTE z

Measure the backlash of the front gear train before removing the injection pump support.

EA-5-1

PUMP SUPPORT


Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.) 1. Key 2. O-ring 3. Retaining ring

4. Drive shaft assembly 5. Ball bearing 6. Ball bearing

INSTALLATION Install the injection pump support using an O-ring (if removed after measuring front gear train backlash).

1.

Rotate the flywheel in the standard direction to determine the 1.6 point at TDC of No. 1 cylinder on the compression stroke. (TDC is the point at which both intake and exhaust valves for No. 1 cylinder are closed and there is a valve clearance.)

EA-5-2

7. Drive shaft 8. Oil seal 9. Bearing holder

PUMP SUPPORT 2.

Align the scribe mark on the injection pump drive gear tooth with the pointer at the check window on the upper side of the timing gear case. Then, install the injection pump support.

EA-5-3

- MEMO -

Servic d r Motor Nissan Fe6 Fe6t Fe6ta

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