Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II
Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II
Mitsubishi 6D22 6D22T 6D22TC Engine Service Manual II
MITSUBISHI
MOIORS
diesel engine
Shop Manual
m
GROUP INDEX
GENERAL
m
ID
FOREWORD ENGINE
m
Ill
are subject to change owing to improvements, etc.
that may be introduced after publication of this shop ENGINE ELECTRICAL
manual.
CLUTCH
1. GROUP CLASSIFICATION
This manual is organized into several groups classified according to the engine basic elements.
00 General External view. major specifications. engine outputs classified by application, engine numbers.
caution plate. general precautions for servicing. general bolts and nuts tightening torque table
11 Engine Engine proper !cylinder head. valve mechanism. camshaft. piston. crankshaft, timing gear. flywheell.
specifications. service standards, special tool, troubleshooting
12 Lubrication Lubrication system (oil pump, oil filter, oil coolerl, specifications, service standards, special tool,
troubleshooting
13 Fuel and engine Fuel system (injection pump. injection nozzle, fuel filter, pump drive case, water separator!. specifications.
control service standards, special tool. troubleshooting
14 Cooling Cooling system (water pump. thermostat. radiator, cooling system cleaning procedures, fanl. specifications,
service standards. special tool, troubleshooting
15 Intake and exhaust Air cleaner, turbocharger, after cooler, specifications, service standards. special tool, troubleshooting
16 Engine electrical Starter, alternator, preheating system. relays, aut6matic stop device, specifications. service standards.
special tool, troubleshooting
21 Clutch Clutch proper, bearing case, specifications. service standards, special tool, troubleshooting
61 Special equipment Air compressor, air pressure governor, specification, service standards, special tool
NOTE:
Each group starts with page 1 .
2
ORGANIZATION - TERMS AND UNITS, TABLE OF
CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
The terms "front" is the fan side and "rear" the flywheel side of the engine.
The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine.
(3) Service Standard Terms
• Nominal value
Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an
assembly, or the standard performance of an assembly.
• Limit
Shows the value of a part at which the part is no longer serviceable from the performance as well as strength
viewpoints, requiring replacement or repair.
Over- or undertightening of bolts and nuts has critical effects on performance and functions.
Tightening torque is therefore specified for some tightening points.
All tightening torque specifications may be considered as "dry" unless "wet" is specified.
Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening
Torque Table.
(5) Units
For length, weight, area, and volume, the SI unit (International System of Units) is used with the metric notation
jointly shown in parentheses.
°
Temperature is shown in centigrade ( C).
3
ORGANIZATION - READING THE ILLUSTRATION
Damage. discoloration
:���-3
--<) '-.·�
�Piston pro1ect1on
J NV 0.87 to 1.33 mm
\
indicates inspection to
be made before disassembly.
'., 2
co·nnecting rod cap
Connecting rod bearing
® Oil ring
7 Snap ring
@ Piston 8 Piston pin
© 1st compression ring 9 Connecting rod
® 2nd compression ring
\
Indicates that the disassembly
procedure is explained in the text.
C2337C
4
ORGANIZATION - READING THE ILLUSTRATION
(Ex. 2: Reassembly)
Expander spring
1st compression ring
bull portion
end gap direction
Piston proJecl1on
1Flange projection
i _________,
._
NV O 87 lo 1 33
1 NV O lo 0.08 mm I
2nd compression
ring end gap ring end gap direction
direction
Replace 0-ring
/
Replace rubber ring Gives instruction for jobs to
be done at assembly
34 Nm
(3.5 kgfml
7 0-r ;"'
/�- ___J
I
Replace lock Install with
washer J r-------� arrow upward
Bend lock
2 -""=::IL--'--'-'.J.J.\ \\
1 --=i-w::\.'.-.L�+ -�..L.._/-+�
Lug
direction
175 Nm
(18 kgfm)
10 15
14
Face oil groove
370 Nm 115 Nm
toward sliding surface.
(38 kgfm) (12 kgfml Connecting rod
I
Wet Wet Apply engine oil end play
or lithium grease NV 0.2 to 0.5 mm Crankshaft end play
to lips L 1.0 mm I NV 0.09 to 0.23 mm
L 0.4 mm
J
Indicates that the assembly
procedure is explained in the text.
C5835C
5
m·
GENERAL
CONTENTS
00-1
GENERAL - EXTERNAL VIEW
1. EXTERNAL VIEW
.. -· . -- - - - ------
- ---- ----
-
<Natural-aspirated engine>
A0243A
<Turbocharged engine>
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS
2. MAJOR SPECIFICATIONS
2.1 MAJOR SPECIFICATIONS
Engine dimension
(without fan)
Overall length mm 1 390 1 390 1 401
Overall width mm 898 872 882
Overall height mm 1 023 1 162 1 209
,,
Empty weight k g' 980 1 010 1 015
del 6022-TC
6022-T
6022 (Turbocharged, with
(Turbocharged)
App after coolerl
Intermittent rated output kW(HPl/rpm 109 ( 1461/1 500 161 (216)/1 500 179 (2401/1 500
129 (173)/1 800 186 (2491/1 800 207 (277)/1 800
141 (1891/2 000 195 (261)/2 000 219 (2341/2 000
149 (200112 200 201 (2691/2 200 227 (3041/2 200
Continuous rated output kW (HP)/rpm 99 (1321/1 500 146 (196)/1 500 163 (218)/1 500
117 (157)/1 800 169 (2261/1 800 188 (2521/1 800
128 (1711/2 000 178 (2381/2 000 199 (2671/2 000
135 (181)/2 200 183 (2451/2· 200 206 (2761/2 200
NQTE:
1. The output (SAE, gross) is corrected to
standard ambient conditions based on
SAE J1349.
2. The continuous rated output allows
10% (one hour) overload operation.
00-3
•
3. ENGINE
GENERAL - ENGINE NUMBERS AND CAUTION PLATE
EXHAUST0.6rnrnW.024in)
Fl RING ORDER 1-5-3-6-2-4 2
FUELINJECTION 11MINGdBTDC II
1 Valve clearance
2 Firing order
3 Fuel injection timing
89012A
E0143
I �-----
illustrated.
E0175
00-4
GENERAL - GROUP PRECAUTIONS FOR SERVICING
Ao o oG A
_ _ _ _,
L_
_ _ _ _ _ _ _ _
_______
_ _ _ _ _
A0012A
00-5
• GENERAL - GENERAL BOLTS AND NUTS
NOTE:
ENING TORQUE TABLE 1 . Threads and seat surfaces must be in
Unless otherwise specified, the parts and equipment dry state.
of vehicle must be tightened by the following stan 2. When there is a difference between the
dard bolts and nuts. Tightening torques for these nut and bolt (stud) identification marks,
bolts and nuts are shown below. tighten to the torque corresponding to
the bolt (stud) identification mark.
Standard bolts and nuts
Unit: Nm (kgfm)
5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 (0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
10 1.25 18.6 to 27.5 (1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.5 to 6.0)
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
12 1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
14 1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
16 1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 (19 to 26)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 (1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
1.5 18.6 to 28.4 (1.9 to 2.9) 35.3 to 53.0 (3.6 to 5.4) 44.1 to 63.7 (4.5 to 6.5)
12 1.25 37.3 to 53.9 (3.8 to 5.5) 78.5 to 108 (B.O to 11) 88.3 to 118 (9.0 to 12)
1.75 33.3 to 51.0 (3.4 to 5.2) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
®
�I
8T
@
4T 7T
Numerical Notched
mark
0 8 @
<+
mark
®
ldented
mark
(2)
Embossed
mark
� �
A0067A
A0066A
00-6
m-
ENGINE
CONTENTS
11-1
•
1. GENERAL
ENGINE - GENERAL
Injection
nozzle
B0376A
Piston
For more effective cooling of the combustion cham
ber, water directors which direct coolant flow are
pressed into the bottom of the cylinder head.
(2) Valve Mechanism
Valve ca·p
Adjusting screw
Rocker shaft Valve cotter
bracket _,__--'!..-�//
B0375A Valve spr_ing
Valve spring
inner
The combustion chamber is made up of the cylinder Lower retainer
head and piston top. The injection nozzle as well as Valve stem
seal
the nozzle tube is mounted to the cylinder head. The
nozzle tube holds the nozzle in position and protects Valve guide
B0377A
11-2
ENGINE - GENERAL
<6022, 6022-TC>
Weight
<6022 _T;·· - Size mark
(A, B, C) 1 _ Part number
_
•
7":;;�, - · --..)
�da��� I ''�
�L\e,
,-::.
If]-'� __ --,,)// insert
, . -y\_./ l'-0--,-;:.,
1
84205A
B0319E
(a) Seven camshaft bushings are installed to the The piston, made of aluminum alloy casting, has a
camshaft bearing portion of the crankcase. To facili toroidal type combustion chamber at its top.
tate insertion and removal of the camshaft from the
rear end of the case, the bearing I.D. is narrower
toward the front.
11-3
Ill ENGINE - GENERAL
A Niresist piston ring insert is cast into the 1st piston (5) Connecting Rod and Connecting Rod
ring groove to increase durability. Bearing
Stamped on the top surface of the piston are a size
mark (or oversize dimension on oversize pistons) for <6022-T C> I
selection fit with the cylinder liner, a piston weight
mark, part number, identification mark, and the "F" ,
with an arrow for the front mark showing the piston
installing direction. -··-- -·�-----· I
Piston pin for connecting piston to connecting rod is
of full-floating type and is prevented from moving out
by means of a snap ring installed on each end of the
pin ends.
On the piston for the 6022-TC, a cooling cavity is
provided.
(b) Piston ring
11-4
(6) Crankshaft and Main Bearing
ENGINE - GENERAL
� Torsional damper
84206A
�------- -
- ------- - - - ----�
Flywheel housing 9-ring 1rr1i Crankshaft B4489A
80351A
11-5
m
(a) Main bearing
ENGINE - GENERAL
B0382A
Camshaft gear
2�63
Injection pump gear
2=63
Crankshaft gear
Z=63
Idler gear
2z47
11-6
ENGINE - GENERAL
Cylinder No.
''
1111111111
80386A
Idler gear "A"
11-7
•
2. SPECIFICATIONS
ENGINE - SPECIFICATIONS
Item Specifications
11-8
3. SERVICE STANDARDS
ENGINE - SERVICE STANDARDS
m
3.1 SERVICE STANDARD TABLE
Unit:mm
Compression pressure 2.75 MPa 1.96 MPa Difference between cylinder within
lat 200 rpm) (28 kgt/cm 2 l 20 kgf/cm2 0.39 MPa (4 kgf/cm 2)
Squareness - 2.5
Cylinder head bottom surface distortion 0.07 or less 0.08 Correct or replace.
Height from top to bottom surface of cylinder head 130 129.8 Replace.
Valve stem to valve Inlet 1121 0.05 to 0.09 0.2 Replace valve guide.
guide clearance
Exhaust 1121 0.09 to 0.12
Depth of valve from cylinder head Inlet 0.25 to 0.75 1.0 Replace valve seat insert.
bottom surface Service limit: value when a
new valve is installed.
Exhaust -0.05 to 0.45 0.7 (- indicates projection amount.)
Seat width of valve seat insert 2.69 to 2.96 3.5 Correct or replace.
11-9
• ENGINE - SERVICE STANDARDS
Unit:mm
End play of idler gear 0.1 to 0.28 0.4 Replace thrust plate.
·'
Idler shaft "A" to idler gear "A" bushing clearance [401 0.2 Replace bushing.
0.03 to 0.06
Idler shaft "C" to idler gear "C" bushing clearance [461 0.2 Replace bushing.
0.03 to 0.06
End play of camshaft gear 0.05 to 0.22 0.4 Replace thrust plate.
11-10
ENGINE - SERVICE STANDARDS
m Unit:mm
6022-TC 11301 -
0.188 to 0.214
Piston 1st ring 0.06 to 0.11 0.25 Replace piston ring or piston.
ring
groove 2nd ring 6022 0.05 to 0.08 0.15
to ring
clearance 6022-T, 6022· TC 0.07 to 0.10
Projection of piston from top surface of crankcase 0.87 to 1.33 - Check each part.
Piston pin hole to piston pin clearance 1501 0.1 Replace piston or piston pin.
0.01 to 0.02
Flatness of cylinder liner flange supporting surface - More than Replace crankcase.
on crankcase 0.1
Crankshaft End play 0.09 to 0.23 0.4 Adjust with oversize thrust plate.
Out-of-roundness of journal and pin 0.01 or less 0.08 Grind and correct to undersize.
11-11
•
3.2 TIGHTENING TORQUE TABLE
ENGINE - SERVICE STANDARDS
11-12
4. SPECIAL TOOL
ENGINE - SPECIAL TOOL
m
Tool name Part No Sh;,pe Use
Distance
between
centers 46
85001A
85011A
Valve lifter Valve liher MH061668 Removal and installation of valve cotter
Valve lifter
Hook MH061679
I.D. 42 Hook
85042A
Diameter 12.5
�
�-+
Diameter 8.7
85051A
Maximum pulling
0.0. 200 85071A
85091A
11-13
• Tool name
ENGINE - SPECIAL TOOL
B5311A
B5111A
Valve seat insert Caulking tool body Installation and caulking of valve seat
caulking tool MH061360 insert
Caulking tool
Diameter 12
B5202A
B5261A
fdler gear bushing puller MH061228 Removal and installation of idler gear
bushing (Idler gear "A")
B1480A
11-14
ENGINE - SPECIAL TOOL
m
Tool name P,irl No. Shape Use
B5131A
B5321A
Rear oil seal slinger installer MH061652 Press-fitting of rear oil seal slinger
Froni oil seal slinger installer MH061817 Press-fitting of front oil seal slinger
Diameter '-
95 \/
B0585A
Piston Piston guide clamp MH061666 Piston guide 1.0. 130 Insertion of piston
guide clamp
Piston guide lever MH061658
11-15
• Tool name
ENGINE - SPECIAL TOOL
between
centers 46
Diameter 8
85181A
Diameter 24
85191A
11-16
5. SERVICE PROCEDURES
ENGINE - SERVICE PROCEDURES
NOTE:
•
5.1 MEASUREMENT OF COMPRESSION Cover the mounting holes and injection
PRESSURE pipes to prevent entry of dust and dirt.
85561A
85554A
85560A
Oil hole
ing
�
,V
Wear. damaged
-!ear
threads
Water leaks.
9 19 gas leaks
Wear. damage
23
Carbon deposition,
cracks, scale
deposition, damage
18
Carbon deposition,
burn. cranks.
damage, ridge wear
Water leaks,
oil leaks,
gas leaks
<Disassembly sequence>
1 Rocker cover 13 Outer valve spring
2 Rocker bracket mounting bolt 14 Inner valve spring
3 Cylinder head bolt @ Valve stem seal
4 Thrust plate 16 Lower retainer
5 Rocker 17 Inlet valve
'6 Set screw 18 Exhaust valve
7 Rocker shaft {[9) Nozzle tube
® Rocker shaft bracket 20 Water director
9 Push rod 21 Sealing cap
10 Valve cap @ Cylinder head
@ Valve cotter 23 Crankcase side cover
12 Upper retainer 24 Tappet
For disassembly of parts with an encircled number, see following items.
C1542A
11-18
Disassembly Procedure
ENGINE - SERVICE PROCEDURES
Rocker cover
Cylinder head
Adjusting
screw B9014B
nut
C1543B
The cylinder head is held in position by the dowel
pins on the top surface of the crankcase. To remove
(a) Where the push rod is forcing the rocker up, the the cylinder head, lift it directly upward.
rocker adjusting screws should be loosened before all NOTE:
bolts are removed. 1. To remove the cylinder head, make
sure that the injection nozzle is re,
moved beforehand. (Refer to Group 13
Fuel and Engine Control.) If the cylinder
head is placed on a workbench with the
nozzle still installed, the end of the
nozzle extending from the bottom sur,
face of the cylinder head will be dam,
aged.
2. When the cylinder head gasket is re,
moved, use care to prevent damage to
the cylinder head and crankcase.
C1544B (3) Removal of Valve Cotter
Valve cotter
/
� I
852828
11-19
m ENGINE - SERVICE PROCEDURES
Nozzle tube
C1527A
NOTE:
The nozzle tube need not be removed
unless water leaks, gas leaks, etc. are
evident.
11-20
5.2.2 Inspection
ENGINE - SERVICE PROCEDURES
•
�---- - - - - - -
---- - --- - -
- ------ -- ·-··-- -------------------- - ----
Free length
NV 65.04
L 62.0
Valve guide to valve stem clearance Valve seat insert seat width
Inlet valve Exhaust valve NV 2.69 to 2.96
BO 12 BO 12 L 3.5
NV 0.05 to 0.09 NV 0.09 to 0.12
L 0.2 L �2 Distortion of cylinder head bottom surface
NV 0.07 or less
Depth of valve from bottom surface of L 0.08
cylinder head
Inlet valve Exhaust valve Height from top to bottom surface of cylinder head
NV 0.25 to 0.75 NV -0.05 to 0.45 NV 130
L 1.0 L 0.7 L 129.8
11-21
m
Inspection Procedure
ENGINE - SERVICE PROCEDURES
Squareness
!inner spring only)
�
Measuring
C2701A
position
C2734A
Mesure the free length and installed load of the spring
If the limit is exceeded, replace the bushing in the and replace if the measurement exceeds the limit. For
rocker. the inner spring, check also for squareness.
Measuring
<Measurement on tappet side>
position
To remove To install
C2745A
NOTE:
1. Align the bushing and rocker oil holes.
2. Face the bushing joint toward the ad·
justing screw.
C2763A
11-22
ENGINE - SERVICE PROCEDURES
DI
(5) Runout of Push Rod (7) Valve Stem O.D.
Measuring position
C2747A C3102A
Check for runout and replace if the reading on the dial Replace the valve if the measurement is below the
indicator exceeds the limit. limit.
(6) Cylinder Head Bottom Surface Distor (8) Valve Guide to Valve Stem Clearance
tion
Measuring position
C3126B
C3125A
11-23
•
· (9) Replacement of Valve Guide
ENGINE - SERVICE PROCEDURES
C2707A
To install C3113A
If any unusual contact pattern is noted, correct as
Using Va!.ve Guide Puller (special tool), replace the follows.
valve guide. Minor fault: Lapping
NOTE: Serious fault: Correct valve and valve seat.
When the valve guide is installed, make (11) Correction of Valve Face
sure that the valve guide flange is securely
seated on the cylinder head.
Valve seat
(10) Valve Contact with Valve Seat Insert angle
Valve .margin ,,,_
--+---�,,-r·- .. J-
Valve
C2708A C27108
11-24
ENGINE - SERVICE PROCEDURES
(12) Correction of Valve Seat Insert (13) Replacement of Valve Seat Insert
m
Since the valve seat insert is installed by expansion
fit, replace it by the following procedures.
C3127A
Valve
Valve Valve seat
sinkage
margin angle 0.5 to 1.0
Cut off.
C2711A
Valve
C2710A
811118
(b) Make sure that the cylinder head and valve seat
insert are provided with sufficient interference.
(c) Immerse the valve seat insert in liquid nitrogen
for cooling it, and fully heat the cylinder head.
[email protected] Parts phone: 269 673 1638
11-25
• ENGINE - SERVICE PROCEDURES
(d) Install the valve seat insert using the Caulking NOTE:
Tool Body, Caulking Ring and Caulking Tool (special 1. Make sure that no compound sticks to
tools) and caulk the periphery of the valve sert insert. the valve stem.
NOTE: 2. Use intermediate-mesh compound ( 120
When the valve seat insert is installed, to 1 50 meshes) first, then fine-mesh
direct the chamfered side of the caulking compound (200 meshes or more) for
ring toward the valve seat insert. finishing.
3. Addition of a small amount of engine oil
(e) Reface the valve seat insert so that the seat width
to the compound helps make it easier
and valve sinkage are up to specifications.
to apply it evenly.
(14) Lapping the Valve and Valve Seat
Insert
The valve and valve seat insert contact must be even
throughout their contacting surfaces.
They must be lapped whenever either the valve or
valve seat insert has been corrected or replaced.
C3130A
11-26
5.2.3 Reassembly
ENGINE - SERVICE PROCEDURES
m
� - - - -
� �---
- ·- - - - - - - -- - -· ---· -·----------- - - - - --- --
-- - -
1 14 10 11 12
3
4 5 6 8 7
59 Nm
(6 kgfm) Close-coiled end of on the
cylinder head side
Leak test:
No leaks are allowed
9 with a 196 kPa (2 kgf/cm')
hydraulic pressure.
24
<Assembly sequence>
L
('l2,+:2o·�{;i1L+,i9,.-,18-17--,,1 s�1�14-,13-12�r, ,-,___,1 O
T'
,z4,�23_J
�B->7__,�5-,4->(3)-..,2--,1
For assembly of parts with an encircled number, see following
items.
C6641C
11-27
•
Reassembly Procedure
ENGINE - SERVICE PROCEDURES
Water director
aling cap
Align notch with this line.
Cylinder head
6 mm 2 mm
�
® g 0 O
Valve stem seal
Cylinder head
� 0 ®�o C6G38A
C6642A
The valve stem seal should be installed by applying
Install the water director with its notch directed as engine oil to the lip and striking down Valve Stem
shown. Seal Installer (special tool) until it touches the cylinder
head.
(2) Installation of Nozzle Tube
NOTE:
1. Before the valve is installed, apply a
Nozzle Tube
Installer Bolt small amount of engine oil to the stem.
MH061231
2. After installation, check to ensure that
the valve stem seal spring has not been
deformed or damaged.
(4) Installation of Valve Cotter
Apply sealant
(THREEBOND 1211
or equivalent).
Valve hook
MH061679
[email protected]
Parts phone: 269 673 1638
11-28
ENGINE - SERVICE PROCEDURES
(5) Installation of Rocket Shaft Bracket (6) Tightening of the Cylinder Head Bolts
m
and Cylinder Head
C6649A
B9014C
11-29
•
5.3
ENGINE - SERVICE PROCEDURES
10A�
oSJ
�'
Damage,
unusual wear
in gear
\
5
. 7
4 Oil leaks
Wear,
1 3 deterioration
Streaks on worn surface,
cracks, taper wear
<Disassembly sequence>
1 Flywheel mounting bolt (ri) Collar
2 Pilot bearing 7 Flywheel housing
@Flywheel 8 Rear oil seal slinger
© Oil seal retainer ® Ring gear
5 Oil seal 10 Tachometer drive
1 OA Speed sensor
For disassembly of parts with an encircled number, see following
items.
C1926F
11-30
ENGINE - SERVICE PROCEDURES
��- •
NV .. Nominal Valu e
L Limit
-�·Timing gciir b·acklash
.
Crankshaft ge ar -,c11er gear .. B ..
NV O 12 to 0.26 ··
L 0
· 20 Oil le aks
lrller g�:r "A"�c am shaft gear
NV 0.13 to .26
L 0.4
lc11er gear "A"�-, er gear "C "
�� Oil hole
NV 0. 13 to
clogging
L 0.4
- 9 ear "C"
Inj e ction pum P gear -idler
NV o 12 t o 0.26
19
:
L 04
17
-�-Idler ge ar end play 16
NV O 1 to 0.28
:
L 04
We ar, damage
13
We ar
12
14 Wear
*/
<Disassembl y sequence>
/11· Camshaft
F) Camshaft gear
13 Thrust plate
1 4 Idler shaft b o I t
15 Thrust plate
16 Idler gear "C"
17 Idler gear "A"
18 Idler gear "B"
19 Idler shaft "A"
19Aldler shaft "C"
20 Rear plate
For disassem blY of parts with . an encircled n m see fo llowing item s.
�::·
The par t m arked .;;:. must b , pec ted befor� d ssem bly
� � �
Part mar kec1 w,t h ' shou ld o ,-n �o: ed unless de fects are evident.
e remov
__ _ _ _
- _ � � � : � � � � � : �: C1927C
_
_ _ _ ---
11-31
•
Disassembly Procedure
ENGINE - SERVICE PROCEDURES
Threaded hole
for removal
C1930A
C1928B
If the backlash exceeds the limit, check idler gear
Thread the mounting bolt into the removing threaded bushing and gears and replace parts as necessary.
hole to remove the flywheel. NOTE:
(2) Removal of Oil Seal Retainer and Coller For a pair of gears, the backlash should be
measured at more than three points to
determine whether it is acceptable.
(4) Measurement of End Play in Idler Gear
and Camshaft Gear
Threaded holes
for removal il:"
11-32
(5) Removal of Camshaft Gear
ENGINE - SERVICE PROCEDURES
NOTE:
m
Do not strike the gears with a hammer.
Thrust plate Make sure that the gears are removed by
use of a gear puller.
Camshaft gear
(7) Removal of Ring Gear
Camshaft ._r
r .
Remove thrust plate
mounting bolt through ---1
this hole. /
Thrust plate mounting ___ .J,-1(]
bolt E::=1
C1932B
11-33
•
5.3.2 Inspection
ENGINE - SERVICE PROCEDURES
C2758C
11-34
�- - - --- -----
-
ENGINE - SERVICE PROCEDURES
----
- --------�----
· - ----
-- - · ---
- - -------�
-
m-
BO .. Basic Diameter
NV.. Nominal Value
L Limit
Clearance
BO 40
NV 0.03 lo O 06
L 0.2
Clearance
BO 46
NV 0.03 to 0.06
L 0.2
Bend
NV 0.05 or less
L 0.08
[email protected]
Parts phone: 269 673 1638
C2759C
11-35
•
Inspection Procedure
ENGINE - SERVICE PROCEDURES
Friction surface
C35098
+
Measuring position
C38078
[email protected]
Parts phone: 269 673 1638
11-36
(4) Replacement of Idler Gear Bushing
ENGINE - SERVICE PROCEDURES
Idler Gear
Bushing Puller
MH061228
(for idler gear "A")
MH062046
(for idler gear "C")
� Bushing
Idler gear
bushing.
If the limits are exceeded, the bushing in the crank
(5) Cam Profile
case should be· replaced.
(7) Bend of Camshaft
Measuring
position
Forward
C4101A
C4118A
Measure the lobe height and base circle diameter and
replace the camshaft if the difference between the
two is below the limit. Measure the bend of the camshaft. If the limit is
exceeded, replace.
NOTE:
The cam must be measured at locations NOTE:
shown as it is tapered. Turn the camshaft a turn and read the
deflection of the pointer, using a dial in·
dicator.
One half of the reading is the bend.
[email protected] Parts phone: 269 673 1638 11-37
m
5.3.3 Disassembly
ENGINE - SERVICE PROCEDURES
Mounting condition
Eccentricity
20 7 L 0.2
265 Nm
(27 kgfm) (wet)
10
Camshaft gear end play
NV 0.05 to 0.22
L 0.4 16
12
/19A
15 155 Nm
315 Nm --(16 kgfml
14
(32 kgfmHwet) 98 Nm
(10 kgfm)
Backlash
NV 0.12 to
0.26
L 0.4
Backlash
NV 0.12 to 0.26
L 0.4
69 Nm (7 kgfm) �--------'
<Assembly sequence>
11-38
Reassembly Procedure
ENGINE - SERVICE PROCEDURES
I fo_fel_
L�
264 Nm
' (27 kgfm) (Wet)
Lock washer
(to be bent)
84227A
C6230C I
Install the camshaft gear so that the side having
The bottom of gasket installed between the rear plate stamped numbers "4" faces front.
and crankcase will protrude. After the flywheel hous (4) Installation of Camshaft
ing has been installed, cut away the protruding
portion.
(2) Installation of Idler Gears
Crankshaft gear
\
Idler gear B
C6231C
11-39
• ENGINE - SERVICE PROCEDURES
(7) Installation of Rear Oil Seal Slinger (9) Installation of Flywheel Housing
Threaded groove
C5529B C6230D
(8) lnst�llation of Ring Gear Install the flywheel housing and gasket so that they
are aligned with the locating pins in the crankcase.
Cut the bottom portions of the gasket aher installatioh
Ring gear
as they are excess.
Cut at the same time the excess portions of the gasket
between the rear plate and crankcase.
(10) Flywheel Housing Eccentricity Check
Flywheel
B2357C
(a) Heat the ring gear for 3 minutes with piston heater
(approx. 100 °c).
· (b) Fit the ring gear onto the flywheel with the
nonchamfered side of the teeth end toward the
Flywheel housing
flywheel. C6233B
[email protected]
Parts phone: 269 673 1638
11-40
ENGINE - SERVICE PROCEDURES ID
(11) Installation of Oil Seal (1 2) Flywheel Runout Check
Oil seal
Seat oil seal end on
the retiliner positively
all around.
315 Nm
(32 kgfm)
(Wet)
When press-fitting an oil seal to the retainer, apply Install the flywheel to the crankshaft by tightening to
force uniformly to the entire periphery. the specified torque.
Measure the flywheel mounting condition (runout). If
the pointer of the dial indicator deflects beyond the
limit, check the bolt tightness or mounting surface.
11-41
•
5.4
ENGINE - SERVICE PROCEDURES
��,
0---- 6
Damage. discoloration 7
·>:<· Piston projection
8 NV 0.87 to 1.33
racks
9
- C � k
- - - -- _ _ _ _�
�-
·>:<· Connecting rod end play ·::::'__..... 10
NV 0.2 to 0.5
L 1.0 3 Inner or outer periphery damaged,
corroded or peeled
�
NV Nominal Value
L Limit
Inner or outer periphery damaged,
corroded or peeled
Disassembly sequence
Connecting rod cap ® -Oil ring
2 Lower connecting rod bearing 7 Piston pin
3 Upper connecting rod bearing ® Piston
© 1st compression ring ® Connecting rod
® 2nd compression ring *10 Connecting rod bolt
11-42
--- -
- ---·�---------
-
ENGINE - SERVICE PROCEDURES
26
5.4.)
Main bearing
18, 20
15
NV Nominal Value
L Limit
19
Scratches, cracks, indentation,
seizure, plugged oil hole, I
corrosion
-�· End play
12 NV 0.09 to 0.23
L 0.4
<Disassembly sequence>
11
11 Torsional damper 17 Thrust plate '1 22 Cylinder liner
.,
(i 2) Crankshaft pulley 18 Lower main bearing '2 23 Check valve
13 Front oil seal 19 Crankshaft 24 Oil jet
14 Front cover 20 Upper main bearing 25 Oil spray plug
'1 15 Front oil seal slinger 'l ii) Crankshaft gear 26 Crankcase
16 Main bearing cap
11-43
ID ENGINE - SERVICE PROCEDURES
�o
Measuring point
C2341A
C2339B
NOTE:
When removing the pistons, use care to
(a) Hold the dial indicator to the top surface of the prevent damage to the cylinder liner
crankcase and make zero adjustment. (4) Separating Piston from Connecting Rod
(b) Find the top dead center of piston with a dial
indicator.
Snap ring
(c) Measure three points on the top surface of piston
to find the average value.
(d) If the projection is out of specification, check the
connecting rod, bushing, piston pin, connecting rod
bearing, etc. and replace defective parts.
(2) Connecting Rod End Play
Remove the snap ring and, using a rod, tap piston pin
off.
If, however, the piston pin is hard to remove, heat the
piston with a piston heater or in hot water.
C2340A
11-44
(5) Removal of Piston Ring
ENGINE - SERVICE PROCEDURES
(6) Crankshaft End Play The rearmost main bearing cap is held in position by
dowel pins. Remove it by use of a slide hammer.
(8) Removal of Crankshaft Gear
/ Crankshaft gear
B0181C
11-45
m
5.4.2 Inspection
ENGINE - SERVICE PROCEDURES
0
NV 0.4 to 0.6
L 1.5
0
0
Clearance
BO 50 Piston ring groove to piston ring
NV 0.01 to 0.02 clearance
L 0.1 1st ring
NV 0.06 to 0.11
L 0.25
2nd ring
NV 0.05 to 0.08 <6022>
0.07 to 0.10 <6022-T, 6022-TC>
L 0.15
Oil ring
NV 0.03 to 0.06
L 0.15
Clearance
BO 50
NV 0.02 to 0.05
L 0.1
Clearance
BO 130
NV 0.178 to 0.204 <6022>
0.173 to 0.199 <6022-T>
Bend or torsion 0.188 to 0.214 <6022-TC>
L 0.05 or less
BO Basic Diameter
Projection of cylinder liner NV Nominal Value
from top surface of crankcase L Limit
NV O to 0.08
Inside diameter
NV 130.014 to 130.054
L 130.25
Oil clearance
BO 84
NV 0.07 to 0.13
L 0.25
11-46
ENGINE - SERVICE PROCEDURES m
Bend
NV 0.04 or less
L 0.1
Out of roundness
NV 0.01 or less
L 0.08
Cylindricity
NV 0.006 or less
Measurement points
C4417A
Replace the crankcase with new one if the limit is surface grinder.
exceeded.
11-47
m
:==-
NOTE:
E'.NNGINE - SERVICE PR O CCIEDURES
------� --- ---�=-� �� ---------- --�
::
�m �
A-. Cra n kshaft d'
di recti o:
."ection
B: Cran ksh ft right-an gl e
.
If the proJection
/
i ou t of specification ' replace the
cylinder liner or ran kcase. (For rep! acement of the
cylrnder liner ' refer to Item ISi.i
c"'" (5) Replacement of Cylinder Liner
(a) Removal
Measurn the c_Y 1·inder liner I.D at .".x positions as
.
shown in the nght flgurn If th. l.D . is more ti,an the
.
limits ' replace the cyl'm der liner or b ore It to oversl,e.
Cylinder Liner E xtractor
( For replacement of the cylinder liner, refer to Item MH061490
ISi.i
C4414B
11-48
ENGINE - SERVICE PROCEDURES
m
--------- - ---- ----1
�
(b) Installation
Strike in.
Cylinder Liner Installer
MH061759
Cylinder liner
C4427B
C4813C
3) Securely seat the cylinder liner on the crankcase
1) When replacing the cylinder liner, use a cylinder by lightly striking the flange portion, using Cylinder
liner with the same size mark as that of the piston to Liner Installer {special tool).
be selected. NOTE:
1. Apply soap suds to the crankcase and
Size rnark of piston A 8 C cylinder liner fitting portions and make
Size mark of cylinder liner A 8 C sure that the rubber packing and O,ring
are not twisted when inserted.
2. After installation, conduct the leak test
to verify air-tightness. Apply thrust
force to cylinder liner flange.
0-ring
C44268
11-49
m ENGINE - SERVICE PROCEDURES
J
Weight
"T" mark
Weight
'><:?z-
(
� Size mark /
----------....
/� Part number
70
f'
Pa,< aornbe< or more // A: Axial direction of
/ crankshat
8: Direction at right angles
to crankshaft
Size mark
C4424A
Oversize piston O.D.
C4428A
Cylinder liner Piston
842210
1) Determine the amount of metal to be bored from
1) Select the piston with the same size mark as that the cylinder liner by taking into account the portion
stamped on the cylinder liner. which wears most with reference to the measure
2) Make sure that the weight of pistons for one ments of 1.0.s of all cylinders.
engine (six pistons) is in the range of± 10 g of the 2) Bore and hone-finish the cylinder liner to obtain
weight stamped. the specified clearance between the oversize piston
and cylinder liner.
NOTE:
Whenever the piston is replaced, replace NOTE:
the piston rings. 1. Even when only one cylinder requires
boring, bore au· cylinders to the same
oversize.
2. Replace the piston rings to those cor-
responding to the oversize.
(7) Piston to Cylinder Liner Clearance
If the clearance is out of specification, replace the
piston or cylinder liner.
[Refer to Item (6)]
11-50
ENGINE - SERVICE PROCEDURES
DI
(8) Piston to Piston Ring Clearance (9) Piston Ring Gap
0
Piston '-
-- -
- .-..
Measure the piston to piston ring clearance. If the Measure the piston ring gap with the piston ring
,,
limit is exceeded, replace the piston rings or piston. horizontally pushed into a standard cylinder liner or
NOTE: actual one in the crankcase with a piston.
1. After carbon has been removed, mea· Replace the piston ring if the gap exceeds the limit.
sure the clearance all around the pis Standard cylinder liner I.D.: 130 ± 0
ton. NOTE:
2. Replace the piston rings as a set. Use the piston to push the piston rings
horizontally into a standard gauge.
Thickness gauge ( 10) Piston to Piston Pin Clearance
Piston
Straight
EB
1st Piston pin
compression ring edge
C4815A
11-51
m ENGINE - SERVICE PROCEDURES
(11) Piston Pin to Connecting Rod Small (a) Align the oil hole of the bushing with the oil hole
End Clearance of the connecting rod.
(b) Press the bushing in from the chamfered side of
connecting rod end.
Connecting rod (c) Aher the bushing has been pressed in, insert the
piston pin and check to ensure that it turns lightly
without play.
(13) Connecting Rod Bend and Twist
�
®
Piston pin
C4812C
Twist
100
Ii
·. --9J
1/
0
Piston rin
Connecting rod
aligner
Connecting Rod
Bushing Puller C5207A
.- MH061238
/Bushing
Measure the bend and torsion of the connecting rod
'r='==st./
__ ;- Oi I hole
. ·· , Connecting rod with Connecting Rod Aligner (measuring instrument) .
If the reading 1s in excess of the limit, replace or
To remove To install correct with a press.
NOTE:
1. Install the bushing and connecting rod
bearing to the connecting rod before
measurement.
2. Tighten the connecting rod and con
C5221B necting rod cap to the specified torque
before measurement.
11-52
(14) Tension of Connecting Rod Bearing
ENGINE - SERVICE PROCEDURES
C5209A C5523A
C5223A
Connecting rod bearing I.D.
C5524A
C5214A
11-53
• ENGINE - SERVICE PROCEDURES
+g- 2
H
42.0 54.0
0
+I
"
0
C5223A
[email protected]
Parts phone: 269 673 1638
C5526A
11-54
ENGINE - SERVICE PROCEDURES •
Grinciing Finishing
Whestone or
sand paper
Crankshaft
C5509A
Unit: mm
11-55
•
5.4.3 Reassembly
ENGINE - SERVICE PROCEDURES
· -
--
----------------- - ---
Cylinder liner
flange protrusion
<Assembly sequence> NV O to 0.08
21
[
26---,22-25--- 24- 23-· 20-• 19--· 17 � 18 -· 16
}-· 2- 1
a-9-7-s-s-4 3-----�
,o_J
-,s-1£1-. 13-12-11
For assembly of parts with an encircled number,
see following items.
10
Locating
1st compression pin
Expander spring ends ring ends
Bend lock
washer
23 34 Nm
(3.5 kgfm)
2 ---+--*--!------!-'-:�\\ 24
��?,.,g!YU Lug direction
1 �-+--¥1-'I----L�--\-.
Piston projection
NV 0.87 to 1.33
370 Nm 115 Nm
22 (38 kgfm) (12 kgfm)
(Wet) (Wet)
Locating
NV Nominal Value
L Limit
C5835F
11-56
Reassembly Procedure
ENGINE - SERVICE PROCEDURES
�--- - ---------
- -
- - -
-
Lug Upper main bearing
\� :
;_·.•1,
. I
f�is�
Install the oil spray plug with the arrow stamped on NOTE:
the plug toward the top of the engine. 1. Install the thrust plate with the oil
grooveless side toward the crankcase.
(2) Installation of Oil Jet and Check Valve
2. Line up the lug of the main bearing and
the groove of the crankcase. ·
The upper main bearing is one with oil
Check valve
holes. Take care not to confuse it with
]\
m the lower one.
3. Oversize (0.15, 0.30, 0.45 mm) thrust
After assembf3l41n5gN,�f Lock
) washer bending portion
bend lock washer plates are available for adjusting the
tab.
end play in crankshaft [refer to Item (6),
0 ' 0 Section 5.4.1]. If any one of these is
used, ensure the correct of the thrust
6> plate to be installed to the main bearing
cap [refer to Item (7)].
C5836B
(4) Installation of Crankshaft Gear
(a) Install the oil jet, while making sure that its
Dowel pin
locating pin fits in the crankcase.
(b) Mount the lock washer in such a way that its
bending portion will fit the end of the oil jet.
(cl After the check valve has been tightened to the
specified torque, bend the lock washer to fit the
hexagonal portion of the check valve.
°
(a) Heat the gear to about 100 C, using a piston
heater, etc.
11-57
• ENGINE - SERVICE PROCEDURES
(b) Locate the gear so that the dowel pin of the (7) Installation of Lower Main Bearings and
crankshaft will fit in the notch of the gear and fit the Main Bearing Caps
gear by lightly striking the gear end with a soft Follow the procedure given below.
hammer.
(c) Install the rear oil seal slinger.
[Refer to Item (7), Section 5.3.3.]
�o l lo� t
(5) Installation of Front Oil Seal Slinger
Dowel pin
81897A
Install the front oil seal slinger, using Oil Seal Slinger
Installer (special tool).
(6) Installation of Crankshaft
C5838A
r �
0
Main bearing cap
C5833A embossed number
·1
I�
keeping it in horizontal position, slowly lower it into
-=---
engine
the crankcase.
JL,,
0 0
---i
84222A
·,_�· ,t��-·,/
thrust plate
� Max 5.9 kN (600 kgf)
, ·�fl
'. , Use the same
. �i
r \�
size.
If an oversize thrust plate is used, use the After checking the connecting rod for damage and
bearing cap rear thrust plate of the same burr in the bolt hole, apply engine oil to the connect
size as that of the thrust plate in the ing rod bolt and press-fit it into the connecting rod.
crankcase rear end [Refer to Item (3)].
Note, however, that the bearing cap front
and rear thrust plates may be of different
sizes.
(d) Install the main bearing caps, making sure that
the side with the lug groove placed on the right-hand
side of the engine and they are installed in the order
of embossed numbers from the front of engine.
(e) Tighten main bearing cap bolts to specified
torque. Then, tighten main bearing cap side bolts to
specified torque.
After the bolts are tightened, make sure that the
crankshaft is free to rotate by hand.
11-59
• ENGINE - SERVICE PROCEDURES
I
Rod
:�;�
,,.- Piston
Arrow showing front
Ends
Manufacturer
mark
stamped
Connecting rod
C5841B
Etched cylinder
No.
Stamped or
etched weight
mark
Direct lug groove _-,,--,..,
Stamped alignment
mark toward
mark
front
C58408
Using Piston Ring Tool (special tool), install the piston
Connect the piston to the connecting rod with the rings in the following sequence.
piston pin so that the Front mark on piston and lug 1. Oil ring
groove mark in connecting rod are placed on the 2. 2nd compression ring
same side. 3. 1st compression
. ring
If the piston and piston pin are hard to insert, heat the
, piston with a piston heater or in hot water.
NOTE:
The parts for an engine must be of the
same weight mark.
Weight marks
Heavy-E------------------- Light
A B C D E F G H J K
11-60
ENGINE - SERVICE PROCEDURES ·111
(11) Installation of Upper and Lower Con NOTE:
necting Rod Bearings 1. Make sure that the size symbol of the
piston is the same as that of the cylin
Lower connecting der liner.
rod bearing gn these.
�li Align these.
- _
· Upper conn ct1ng · - 2. Make sure that the piston ring open end
v._ ;
· rod bearing
�
,
_
. J directions do not change.
'I
.
' _, .
. 3. Put a vinyl hose or something else on
the bolt of connecting rod for protec•
tion of the crankshaft pin against dam•
Rl
I '· . . age by the bolt.
. Using the Piston Guide Clamp and Piston
. Guide Lever (special tools) .
Connecting rod
cap B4223A Piston Guide Clamp
NOTE:
Piston Guide Lever
Note that the only the upper connecting Adjusting
bolt
rod bearing has an oil hole. B5291C
C5834B
11-61
• ENGINE - SERVICE PROCEDURES
..
Connecting rod cap The valve clearance should be checked and adjusted
as described below while the engine is cold.
Front of
engine
)8 \\-
Alignment mark -
-co ' I'
-- _- I I
-----
- I
C5844B
_.--:;
Make sur� that the alignment marks and lug groove
marks on the connecting rod cap and connecting rod 85713A
are aligned.
(14) Check the connecting rod end play. (1) Crank the engine to align the pointer of the
inspection window of the flywheel housing with the
[Refer to Item (2), Section 5.4.1.]
inscribed mark 1.6 of the flywheel. Check the push
(15) Check the projection of the piston. rods, and the piston whose push rod is not pushing
[Refer to Item (1), Section 5.4.1.] up the rocker is at the top dead center of the
(16) Installation of Front Oil Seal compression stroke.
(2) When the No. 1 cylinder piston is at the top dead
center on the compression stroke, check and adjust
the clearance of valves marked "o" in the following
Front oil seal Press-fit
table.
Oil seal flange When the No. 6 cylinder piston is at the top dead
center on the compression stroke, check and adjust
the clearances of valve marked "x". Turn the crank
shaft through a rotation, and make sure that valve
clearance inspection and adjustment are performed
for all of the six cylinders.
Cylinder No. 1 2 3 4 5 6
84187A
Valve In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
arrangement
Evenly press the oil seal throughout its entire No. 1 at TDC
periphery to prevent it from tilting. Press-fit the oil on the compres- 0 0 0 0 0 0
sion stroke
seal into the front cover until the oil seal flange is held
No. 6 at TDC
tight up against the front cover. on the compres- X X X X X X
sion stroke
11-62
-- - - - . ------- - - - - ------ - - --
ENGINE - SERVICE PROCEDURES
m
1 Valve clcar<1ncr. lwhr.n colcll
Inlet O 4 mm
Exhaust 0.6 mm
(3) Measure the rocker arm to valve cap clearance
with a thickness gauge to determine whether the
clearance is up to specification.
If the thickness gauge of the specified thickness is
somewhat hard to move, the clearance is good.
If the clearance is out of specification, loosen the lock
nut and adjust with the adjusting screw. After adjust
Thickness gauge ment, turn down the lock nut to lock the adjusting
MH061359
screws.
NOTE:
After the lock nut has been turned down,
857148
recheck the clearance.
11-63
•
6. TROUBLESHOOTING
ENGINE - TROUBLESHOOTING
Defective preheater
• Defective starter switch Correct or replace Group 16
• Clogged muffler
11-64
ENGINE - TROUBLESHOOTING
m
Symptom Probable c,l\1se Remedy Ref. group
Large oil Oil leaks from lubrication system Check and correct Group 12
consumption
Oil leaks from engine and related parts
• Defective gasket and oil seal Replace
11-65
DI ENGINE - TROUBLESHOOTING
• Worn connecting rod small end bushing and piston pin Replace
11-66
m
LUBRICATION
CONTENTS
12-1
lfJ LUBRICATION - GENERAL
1. GENERAL
Engine lubrication is accomplished by forced lubrica
tion system using gear pump. The engine oil in the oil
pan is drawn up through the oil strainer by the oil
pump and force-fed to the oil filter and oil cooler to
lubricate all parts.
Oil pressure
gauge
Warning lamp
"OIL" 0-----�
Oil pressure
gauge unit
Oil pressure
switch
Main oil gallery
Water
pump
Oil spray
plug
12-2
LUBRICATION - GENERAL
Oil pump
idler gear
Drive gear
Driven gear
From oil strainer
81541A
12-3
•
(2) Oil Filter
LUBRICATION - GENERAL
- Oil filter
· head
Element
Oil filter
case
!Full-flow filter!
815448
81543A
When the oil filter element is clogged and the
The oil filter is a double oil filter consisting of a difference in pressure between the filtered and unfil
full-flow filter made integral with bypass filter. Ele tered oil exceeds the limit specified, the valve in the
ment is a filter paper element. oil bypass alarm moves against the spring force,
Engine oil fed under pressure from the oil pump allowing the unfiltered oil to flow to the filtered oil
passes through the oil hole in the crankcase and flows path.
from the oil filter head into the full-flow filter and The oil bypass al·arm has electric contacts that are
, bypass filter. The engine oil filtered through the closed to turn on the pilot lamp, warning the driver of
full-flow filter is routed from the oil filter head through clogged element when the valve is opened.
the crankcase oil hole to the oil cooler. The engine oil
filtered through the bypass filter returns to the oil pan.
12-4
(3) Oil Cooler
LUBRICATION - GENERAL
m
Oil cooler element
Coolant�
To main oil
gallery
81545A
The shell-and-plate type (multi-plate type) oil cooler is (4) Bypass Valve
mounted in the coolant path on the left side of the
crankcase.
Engine oil forced through the oil filter flows inside the
oil cooler element; whereas the coolant forced from
the water pump flows around the element. The
engine oil in the element is then cooled or heated
be�ore it flows to the main oil gallery.
81530A
12-5
DI LUBRICATION - GENERAL
81529A 81547A
The reguliJtor valve is mounted in the main oil gallery Lubrication of the camshaft bushings is accomplished
in the crankcase to make sure that no excessive by the oil flowing through the oil holes from the
pressure acts on the lubrication system. outside periphery of the crankshaft main bearing to
the individual camshaft bushing.
(6) Lubrication of All Parts
The engine oil routed to the main oil gallery lubricates (c) Valve mechanism
all parts as described in the following.
/ Piston Rocker
- Connecting
rod bearing
Crankshaft --
815468
The oil hole extends from the main oil gallery to the
crankshaft main bearing to lubricate the main bear
ing. Part of the engine oil that has lubricated the main
bearing passes through the oil hole in the crankshaft
81548A
to lubricate the connecting rod bearing, and then
through the oil hole in the connecting rod to lubricate
The engine oil that has lubricated the No. 7 camshaft
connecting rod bushing.
bushing flows through the oil hole provided at the top
On 6022-TC, there is a hole provided in top of
of the crankcase to each cylinder head.
connecting rod, from which oil spurts out to the
piston.
12-6
LUBRICATION - GENERAL
Engine oil fed to the cylinder head flows through the (e) Cooling the piston (oil jet)
oil holes in the rocker shaft bracket and rocker shaft to
lubricate each rocker bushing. The engine oil is also
sprayed out of the rocker arm oil holes for lubrication
of the sliding surfaces of valve cap and valve stem as
well as the sliding surfaces of push rod and adjusting
screw. The oil then flows through the push rod holes
in the cylinder head and crankcase to lubricate the
tappet and cam of the camshaft and returns to the oil
pan.
Check valve
Oil spray
plug
815358
-Camshaft
bushing
section The oil jet provided under the main oil gallery for each
cylinder sprays engine oil against the reverse surface
Main oil of the piston to cool the piston.
gallery The oil jet is equipped with a check valve which opens
and closes at specified oil pressure, preventing the
decreased amount of ·oil at low oil pressure and loss
in oil pressure.
On the piston for the 6022-TC, a cooling cavity is
provided. The oil injected from the oil jet enters the
81549A cooling cavity to cool the piston.
12-7
•
(7) Lubrication of Turbocharger
LUBRICATION - GENERAL
Gear rt ain
12-8
(9) Lubrication of Water Pump
LUBRICATION - GENERAL
m
To oil pan
The engine oil drawn by the oil pump is routed The engine oil is then forced back from the drain port
through the crankcase oil passage to the water pump. to the crankcase and returns to the oil pan.
The engine oil delivered to the water pump flows
through the oil hole of the water pump and lubricates
the bearings.
12-9
m
2. SPECIFICATIONS
LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS
Item Specifications
3. SERVICE STANDARDS
3.1 SERVICE STANDARD TABLE
Unit:mm
12-10
LUBRICATION - SERVICE STANDARDS
m
Description Nommal val11c Limit Correction and remarks
!Basic <i,amctcrl
Oil bypass alarm valve opening pressure 345 to 390 kPa Replace.
ION start pressure) (3.5 to 4 kgflcm'I
Oil cooler bypass valve opening pressure 175 to 215 kPa Replace.
11.8 to 2.2 kgflcm'I
Spring load 76 to 80 N
(Installed length: 48.3) 17.8 to 8.2 kgfl
Oil pump idler gear shaft nut M12 x 1.25 59 to 78 Apply LOCTITE
(6 to 81 No. 262.
12-11
•
4. SERVICE PROCEDURES
LUBRICATION - SERVICE PROCEDURES
NOTE:
1. To remove the oil cooler, remove the
At idle injection pump beforehand.
NV 145 kPa (1.5 kgf/cm')
or more 2. After the element has been installed,
L 49 kPa (0.5 kgf/cm') start the engine and check connections
At maximum speed for oil leaks.
NV 295 to 490 kPa
(3 to 5 kgf/cm')
L 195 kPa (2 kgf/cm2 )
(2) Oil Pump, Oil Strainer
NV ... Nominal Value
L Limit
89016A
NOTE:
1. Measure the backlash in advance of
removal of oil pump.
2. The oil strainer and oil pipe should be
removed together with the oil pump
unless anything wrong is evident.
3. After the oil pump has been installed,
Regulator valve
verify that the backlash is within the
specified range.
C1158D
12-12
LUBRICATION - SERVICE PROCEDURES
�\\�, 9
4 tooth surface
or worn busing
2 'Clearance between gear
Worn busing Clearance tooth tip to oil pump case
Clogged or cracked BD 20 NV 0.11 to 0.18
NV 0.04 to 0.07 i L 0.2
L 0.15
BD . Basic Diameter 'Ditterence between oil pump
NV . Nominal Value . case depth and gear height
L Limit NV 0.05 to 0. 11
L 0.15
<Disassembly sequence>
Oil strainer 6 Idler gear
(j) Oil pump cover 7 Seat
3 Driven gear 8 Spring
4 Driven gear shaft 9 Ball
5 _Idler gear shaft 10 Case and gear assembly
NOTE:
1. Do not remove the driven gear shaft unless it is faulty.
Removal of the shaft may result in loss of allowance
for tightening the oil pump case.
2. The case and gear assembly is a non-disassembled
type. Replace the assembly if it is defective.
C9518D
12-13
m LUBRICATION - SERVICE PROCEDURES
C9521A
(b) Remove the oil strainer and drive out the oil pump
cover with a plastic hammer etc.
NOTE:
The oil pump cover is located by the dowel
pins installed to the oil pump case.
(c) Before the driven gears are removed, measure
and record the following items.
C9506A
12-14
(2) Reassembly
LUBRICATION - SERVICE PROCEDURES
•
Rernove oils or greases
Backlash between driven gear
from threaded area and
and idler gear Shaft oil hole should 6
then apply Loctite 262. Apply sealant to the
NV 0.11 to 0.24 be in this range
L 0.4 portion to be filled
59 to 78 Nm in bushing (Moly
(6 to 8 kgfml bdenum base grease)
5�- --- - �
-
I
7 1
(Wetl /
2 3 4
9
< Assembly sequence>
I10 -� 9 - a - 7 - 6 - s - 4 - 3 - 2 - 1
NOTE:
1. Before reassembly, apply engine oil to all parts unless
otherwise specified.
2. Temporarily tighten the oil strainer, taking into consid·
eration its installation to the crankcase.
C9525C
12-15
m
4.2.2 Oil Filter
LUBRICATION - SERVICE PROCEDURES
Cracks
Clogging, deformation
<Disassembly sequence>
Drain plug
2 Center bolt
------ 4 Cracks, deformation 3 Washer
4 Oil filter case
5 Oil filter element
6 Element retainer
7 Oil filter head
8 Oil bypass alarm
C9705C
Pressure ga g e
u __
/ � _ _____
/ Valve opening pressure
U0700C
12-16
4.2.3 Oil Cooler
LUBRICATION - SERVICE PROCEDURES
m
Damage, cracks,
scale, oil leaks
Cracks, scale
3
. "
""' @@
@ @
@ @@ 2 .
�
Bypass valve opening
� NV ... Nominal Value
pressure
NV 175 to 215 kPa
(1.8 to 2.2 kgf/cm')
C9804C
12-17
•
4.2.4 Regulator Valve
LUBRICATION - SERVICE PROCEDURES
98 to 115 Nm
(10 to 12 kgfm)
Lost tension 3
1 Snap ring
2 Valve
Opening pressure 3 Spring
NV 360 to 420 kPa
(3.7 to 4.3 kgf/cm') 4 Body
C9902A
I �2
�� .
After assembling, ,,.
bend lock washer 0
tab against check =e,j._----1 34 Nm (3.5 kgfm)
valve. (mounted on crankcase)
Check valve
2 Lock washer
3 Oil jet body
C9951B
For the check valve mounting position, refer to (e) in (6) in 1 General and (2) in 5.4.3 in Group 11 Engine.
12-18
5. TROUBLESHOOTING
LUBRICATIONS - TROUBLESHOOTING m
Symptom Probable cause Remedy Ref. group
Loaded oil strainer, loose oil pump joint, cracked pipe Correct or replace
12-19
FUEL AND ENGINE
CONTROL
CONTENTS
13-1
DJ FUEL AND ENGINE CONTROL - GENERAL
1. GENERAL
- Injection
pipe
Injection
nozzle
Fuel feed
Fuel
pump
Governor filter
Fuel leak-off
pipe
Fuel
feed pipe
pipe
Fuel tank
NOTE:
The figure shows the AD improved
version injection pump.
B2115A
13-2
FUEL AND ENGINE CONTROL - GENERAL
Control rack
Oil sump
Control sleeve
Control rod
Tappet
Cam chamber
Camshaft
89082A 89083C
The camshaft driven at half the engine speed is 3) To prevent the fuel in the oil sump from leaking
supported by taper roller bearings at both ends. The into the cam chamber, an 0-ring is provided on the
camshaft has a cam for operating the plunger and a outer circumference of the plunger barrel, thereby
cam for operating the feed pump. maintaining its tightness.
A tappet operating with the pump housing as the 4) A deflector is provided on the outer circumference
guide is in contact with the camshaft. The tappet of the plunger barrel to prevent erosion of the pump
changes the rotary motion of the cam to up-and-down housing that may be caused by counter flow of fuel at
motion which is transmitted to the plunger. the end of an injection.
The P type injection pump offers the following
features.
1) The pump housing is a totally enclosed type.
2) The plunger barrel has an oblique hole made to
return the fuel that has leaked to the oil sump to
minimize the leakage of the fuel into the cam
chamber.
13-3
m
(b) Plunger
FUEL AND ENGINE CONTROL - GENERAL
82204A
Control rod
Control sleeve
Driving face
82224A 82206A
A deflector is installed on the periphery of the plunger which engages with the control rod (or the control
barrel so that high pressure fuel oil discharged from rack and pinion). Since the driving face of plunger
· inlet and outlet ports will not erode the pump meshes with the control sleeve at the lower part
housing. Fuel injection volume is controlled by the thereof, the plunger turns with the rotation of control
governor which moves the control rod (or the control sleeve and injection volume is controlled through the
rack) left and right and rotates the control sleeve changing of the effective stroke.
13-4
FUEL AND ENGINE CONTROL - GENERAL
DJ
A delivery valve stopper, provided on the top of the
delivery valve spring, limits the lift of the delivery
Eff P.ctive strokP. valve to prevent the surging of the valve during high
speed operation. It also reduces the dead volume
between the delivery valve and nozzle and stabilizes
the injection rate.
B2205A Spring
B2208A
(c) Delivery valve
When the fuel pressure in the injection pump exceeds
a predetermined pressure, the steel ball in the
Suction stroke
overflow valve is pushed up to let the fuel flow out
from the injection pump and return to the fuel tank,
thereby stabilizing the fuel temperature and tempera
ture distribution in the injection pump and maintain
ing the injection rate into each cylinder constant.
13-5
DJ FUEL AND ENGINE CONTROL - GENERAL
(2) Governor
(a) RSV type governor
Supporting lever
Guide lever shaft
Governor housing
Tension lever
Shackle
-Adjusting lever
Control lever
Governor spring
Camshaft
Flyweight
Ungleich spring
Stop lever
The RSV type governor is a centrifugal type all-speed The governor, as shown, consists of flyweights
governor coupled to the camshaft of the injection mounted to the injection pump camshaft. When the
pump. The governor not only controls the maximum flyweights turning on the flyweight suppqrting shaft
and minimum speeds but also automatically controls open outward, the roller mounted to the end of
the engine speed at any intermediate speed position. flyweight arm pus.hes the end of the sleeve in the
axial direction. The governor sleeve, being made
integral with the control block through a bearing,
Slider
moves only in the axial direction.
The control block, mounted to the guide lever hung
on the supporting lever shaft of the governor cover,
prevents rotation.
Guide
lever
Supporting
shaft
Shifter Governor
sleeve Flyweight
82658C
13-6
FUEL AND ENGINE CONTROL - GENERAL
DJ
When the governor spring receives tension, the
bottom end of the tension lever touches the adjust
Start spring
able full-load stopper bolt.
When the angle of the adjusting lever is changed, the
angle of the swivel lever is also changed and the
rack
tension of the governor spring changed. This is
because the turning center of the swivel lever and the
mounting position of the governor spring installed to
Control
lever the tension lever are eccentric to each other as
Guide lever
mentioned above.
An adjusting screw is also mounted to the swivel
lever. Adjustment of the screw changes the tension of
the governor spring, thereby making it possible to
adjust the speed regulation.
An Ungleich spring is provided in the bottom portion
of the tension lever. Adjust the tension of the spring
by adding or removing shims.
An idling sub spring adjustable from outside is
provided in the middle of the governor cover. During
idling, the spring always keeps in contact with the
Supporting Return Stop tension lever to maintain a constant idling speed.
lever spring lever
B2659A The stop lever, mounted through the supporting lever
to the bottom end of the control lever, returns the
The control lever is mounted to the middle of the control rack to the stop position with a slight pressure
guide lever by the shaft with the bottom end as the irrespective of the adjusting lever position.
fulcrum, whereas the top of the lever is coupled
through the shackle to the control rack. 1) Start of engine
The start spring, attached to the top end of the control
lever, always pulls the control rack in the direction Adjusting lever
that fuel is increased. Start spring
Control
Swivel lever
Governor spring
Full-load
stopper bolt B2660A
13-7
DJ FUEL AND ENGINE CONTROL - GENERAL
At that time, the flyweights are stationary, and the 3) Maximum speed control
start spring with weak tension pulls the control lever
---------------- - -
-------�
in the direction that fuel is increased.
At the same time, the control block and governor
Adjusting lever
sleeve push the flyweight roller to the left.
As the result, the tension lever and control block are
spaced that much apart, and the corresponding
amount of fuel is supercharged to facilitate starting.
2) Idling control
Start spring
Shifter Full-load stopper bolt 82662A
13-8
FUEL AND ENGINE CONTROL - GENERAL
DJ
4) Ungleich operation The air intake rate of the engine falls as the engine
speed increases. The injection pump, on the other
hand, increases the per-stroke injection as the speed
When max. injection is set increases, even with the control rack at the same
at low-speed operation
njection matched position.
with air intake rate
\ Therefore, if full load is set at point A to derive
Injection/stroke
A -�----1 B B'
enough output at low speeds, the injection will reach
- T Bas the speed increases, and the engine will produce
A'._-,---- I
When max. injection is set
at high-speed operation
black smoke.
I If full load is set at point B' to prevent black smoke, the
Engine speed low speed injection will come down to A', allowing
combustion of more fuel.
82663A
So the Ungleich device accomplishes the function of
setting full load at point A to derive the largest
The Ungleich device controls fuel injection in such a possible torque in the low speed range, and changing
way as to ·match the engine performance (the re it to adjust the injection to point B' in the high speed
quired injection varies with engine speed). range.
t R2
R1 t Without
Ungleich effect
E
z
a,
:,
0
f-
N2 N1
N2 N1
Engine speed (rpm) _.
Pump speed (rpm) _....
82664A
13-9
FUEL AND ENGINE CONTROL - GENERAL
5) Stopping of engine
Full load
Adjusting lever
Tension lever
Control rack
Shifter
82665A Stop
t
E
C D
I D
.,,
P1 P1
82667A
Construction machinery engines are often subjected often lead to stalls. To prevent this, a torque spring is
to a large load during operation, and reduced speeds provided.
13-10
FUEL AND ENGINE CONTROL - GENERAL
DJ
When the adjusting lever is fixed in the lever set At the time, the tension lever pin pushes the bottom
position, a sudden increase of load, if no torque of the torque control lever, and the lever moves with
spring is provided, will move the control rack along the pin "A" as the fulcrum, whereas the portion "8" is
the 8-D curve as the speed falls. The rotational pushed to right. As the result, the torque spring
displacement at the time may be expressed as P 1 . performs the function of reducing movement of the
If a torque spring is provided, the control rack moves tension lever.
along 8-C, and the rotational displacement at the time
may be expressed as P 2. Therefore, large changes (b) RFD type governor [Option]
occur in P 2 and engine speed, and because of
increased fuel injection, the engine torque increases, Governor Stop lever Governor
Guide cover housing
and large combustion noise warns the operator of the lever \,
\
/
/
Go�ernor
�
increased load, enabling him to take proper action to Tension '\'
. \
/ spring
lever ', ·,, '
prevent stopping the engine. ,_ \
///
Floating ,, '·, ',,.,
lever link
Swivel lever
Camshaft
Speed control
lever
Idling
spring
Stroke Flyweight
/
adjusting
bolt Floating Sliding
lever lever
82682A
13-11
DJ FUEL AND ENGINE CONTROL - GENERAL
Floating lever
Tension lever
Idling spring
Idling spring
B2605A
B2603A
If the load control lever is placed to the idling position
When the engine is stationary, the flyweight is in after the engine has started, the floating lever will
closed position, pushed by the governor spring, idling move the control rod back to a position where a fuel
spring and start spring. injection rate suitable for the idling speed is available,
If, in this condition, the load control lever is moved all with the point B as the fulcrum.
the way to the FULL position (in the direction of As the engine speed increases, the flyweights will
greater fuel delivery), the start spring and idling move outward by the centrifugal force and will shift
,spring will cause the control rod to move to the fuel the shifter by the point A until the shifter compresses
13-12
FUEL AND ENGINE CONTROL - GENERAL
At the same time, the fulcrum B will also slightly As the engine speed increases, the centrifugal force of
m
move toward the pump housing to push the control the flyweight will increase, and the flyweight will
rod back in· the direction for decreasing the fuel push the shifter. In the normal speed range, however,
injection rate. the shifter will have only a thrust enough for com
In this manner, the idling speed is maintained stable pressing the idling spring and will not be able to push
by slight adjustment of the injection rate. the tension lever out by overcoming the tension of the
governor spring.
2) Normal speed operation In this manner, the fuel injection rate is increased or
reduced simply by operation of the load control lever
which moves the control rod.
Tension lever
Eccentric shaft
Idling spring
82606A
Flyweight Shifter
If the control lever is moved toward FULL (in the
direction of greater fuel delivery), the eccentric shaft
coupled to the load control lever will cause the sliding 82607A
13-13
DJ FUEL AND ENGINE CONTROL - GENERAL
826748
11111111
As indicated by the governor characteristics shown
above, when without the smoke set assembly, the
shifter and floating lever are pushed back by the
idling spring force, moving the control rack toward
fuel increasing direction when pump speed reaches
N,. Namely, N, is the smoke limit in this case.
When with the smoke set assembly, the spring force
of the smoke set assembly overcomes that of the
idling spring so that the floating lever motion is
inhibited until the speed reaches N,. Thus, the smoke
limit decreases from N, to N,.
It is also possible to secure rack position Rs needed at
time of start.
82763A
13-14
FUEL AND ENGINE CONTROL - GENERAL DJ
5) Engine stop The floating lever A pushed by the floating lever link
turns in such a way as to make the cancel spring bend
Stop lever over the shaft B. So no load is placed on the floating
lever C blocked by the idle stopper bolt outside the
Normctl position governor.
Operation of the ungleich device is the same as the
RSV type governor.
/ Priming pump
Control rod
I
Floating lever link 82608A
�I
The priming pump mounted to the feed pump makes
it possible to lift fuel manually when the engine is
Internal lever
I stop lever I
J� stationary.
' Floating lever link
Control rod
spring
81631A
13-15
FUEL AND ENGINE CONTROL - GENERAL
Flyweight
Flange
Timer case
Flyweight holder
83210A
13-16
FUEL AND ENGINE CONTROL - GENERAL
At high speeds
Flyweight
When the engine runs at a high speed, a centrifugal
Flyweight
holder pin
force acts on the flyweights and causes them to open
outward with the pins of the flyweight holder as the
fulcrums. The flange legs are pushed by the curved
surfaces of the flyweights in the direction of the timer
At low speeds spring compression, but they cannot be moved
8321 lA
because they are coupled to the drive side.
As a result, the pins of the flyweight holder are drawn
During low speed operation of the engine, no centri in the turning direction, while compressing the timer
fugal force acts on the flyweights, so the timer springs springs, and move the camshaft of the pump in the
have the longest installed length. turning direction to advance the injection timing.
If the engine speed changes from a high to low speed,
the centrifugal force of the flyweights will decrease
and the flyweights will return to their original posi
tions. At the same time, the pins of the flyweight
holder will be pushed back by the timer springs.
13-17
• FUEL AND ENGINE CONTROL - GENERAL
Oil seal
0-ring
Cover
Spring seat
Timer housing
B3201A
Two flyweights are fitted on the pins of the timer Timer springs are held between the spring seats fitted
housing and are held in the timer housing. On the on the timer housing pins which extend through the
other hand, the injection pump connection side flange flange and flyweight. These parts are housed in the
has a curved surface, and the roller fitted on the pin timer housing and are totally enclosed with a cover,
installed in the flyweight touches the curved surface. 0-ring and oil seal.
13-18
�-------- ----�-----------
FUEL AND ENGINE CONTROL - GENERAL
-
- (5) Coupling
m
[For AD type]
Timer snring Flange
Cross coupling
Driving coupling
Air compressor
crankshah
Advance angle
Coupling
plate Cotter bolt
83405A
[For P type]
Cross coupling
"·
Driving coupling
83202A
Crankshaft,
air compressor
When the engine is running at a low speed, the timer
spring pressure is stronger than the centrifugal force
of flyweight, so the roller of flyweight is held down by
the flange, creating no advance state. Cotter bolt
13-19
DJ FUEL AND ENGINE CONTROL - GENERAL
(6) Pump Drive Case The high pressure fuel which has forced the needle
valve up is injected from the orifice at the end of the
nozzle into the engine combustion chamber.
Some of the high pressure fuel lubricates the needle
valve, etc. and is returned through the fuel leak-off
pipe to the fuel tank.
The injection pressure of the injection nozzle is
adjusted by changing the tension of the nozzle spring
with the adjusting screw.
B4191A
Adjusting screw
B3406A
Nozzle holder
To injection pump
cover
From fuel
feed pump
1 11
�
�Element
B3501A B3551A
The fuel filter is a spin-on type. So the element is The sedimenter type water separator separates gas
easily replaceable. oil and water centrifugally by taking advantage of
The fuel filter separates the water contained in the their difference in specific gravity.
fuel fed under pressure from the feed pump of the The fuel that has flowed in from the inlet connector is
injection pump and removes dust and dirt by the squeezed by the fuel path of the head to increase the
element. flow velocity and spins. The separated water is
sedimented in the case, whereas the water-separated
fuel is drawn through the fuel path in the center of the
head into the feed pump.
The water separator sediments not only water but
also mud components.
A red float goes up and down with the water level in
the semi-transparent case, making it possible to
visually check the water quantity.
13-21
DJ FUEL AND ENGINE CONTROL - SPECIFICATIONS
2. SPECIFICATIONS
Item Specification
Type Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line
type type type type type
Model AD AD p p p
Turning direction Clockwise Clockwise Clockwise Clockwise Clockwise
(as viewed from drive side)
Plunger Diameter mm 10.5 10.5 12 12 12
Governor Type All speed Minimum All speed Minimum All speed
governor maximum governor maximum governor
mechanical mechanical
governor governor
Model RSV RFD RSV RFD RSV
Model SA SA SP SP SP
Type Hole type Hole type Hole type Hole type Hole type Hole type
(1-spring nozzle) (1-spring nozzle) (2-spring nozzle) (1-spring nozzle) (1-spring nozzle) (2-spring nozzle)
Injection pressure 21.6 (220) 21.6 (220) 17.7 (180) 21.6 (220) 21.6 1220) 17.7 (180)
MPa (kgf/cm')
Fuel filter Type Spin-on type
13-22
FUEL AND ENGINE CONTROL
SERVICE STANDARDS
3. SERVICE STANDARDS
3.1 SERVICE STANDARD TABLE
(1) Injection Pump
Unit: mm
Governor Dimension from governor housing RSV type 19 to 19.2 - Adjust shims.
to shiher
RFD type 33 to 33.4 -
13-23
FUEL AND ENGINE CONTROL
SERVICE STANDARDS
Unit:mm
Feed Tightness !when 195 kPa (2 kgf/cm') of air pressure O cc/min. - Replace.
pump is applied!
K type 260
K type 530
K type 520
Injection nozzle injection One-spring nozzle 21.6 MPa (220 kgf/cm'I Adjust or replace
pressure nozzle.
Two-spring nozzle 17.7 MPa (180 kgf/cm 2)
13-24
FUEL AND ENGINE CONTROL
SERVICE STANDARDS
Cap screw 29 to 39 (3 to 4)
·'
Cover mounting bolt 22 to 24 12.2 to 2.41 ·
B B bolt 29 to 34 (3 to 3.51
��c
-
9f
-
��
B
B3408A
B bolt 59 to 64 (6 to 6.51
C bolt 59 to 64 16 to 6.5)
� B
·
1� ,'
(,,. (· -
I
,
�·(� I/
C I
B
B3401A
Set screw 49 to 59 (5 to 61
13-25
DJ
FUEL AND ENGINE CONTROL
SERVICE STANDARDS
Fuel overflow - 20 to 29 (2 to 3)
P type - 20 to 29 (2 to 31
Injection pump gear mounting nut of pump drive case M24 x 1.5 22 12.21
13-26
FUEL AND ENGINE CONTROL - SPECIAL TOOL
4. SPECIAL TOOL
Unit: mm
B5032A
B5031A
85222A
13-27
FUEL AND ENGINE CONTROL - SPECIAL TOOL
105782-4020
Holder 157931-4400
Plate 157944-3820
105782-4270
13-28
FUEL AND ENGINE CONTROL - SPECIAL TOOL
SA type automatic timer special tool set 105790-5010 Disassembly and reassembly
Base 157924-0110
Block 157924-0800
Guide 157924-0900
Guide 157924-0400
13-29
DJ
FUEL AND ENGINE CONTROL - SPECIAL TOOL,
SERVICE PROCEDURES
SP type automatic timer special tool set 105790-5050 Disassembly and reassembly
Extractor 157926-7220
Connector '157892-1320
Base '157892-1800
Gasket '157892-1500
Gasket '026508-1140
13-30
5.1 INJECTION PUMP
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
5.1 .1 Removal
<P type>
5
(1) At removal, first loosen bolts indicated by arrows (2) Use a wood block to store injection pump lest
in figure from coupling. excess force might be applied to timer.
13-31
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Damage, seizure
1 ��';'0'!��0 :'"�I
�
Bend,
broken tooth C ��
,,b.,.,.-c�
*Sliding resistance
' ;1
(when stationary) 5 4
1.5 N (0.15 kgf) or less
6 Damage, wear, seizure
of cam surface
Backlash
NV 0.15 mm *End play
L 0.3 mm <E> NV 0.02 to 0.06 mm
26 L 0.1 mm
Overflow valve opening pressure Cracks, damaged thread n
NV 155 kPa (1.6 kgf/cm') � � �--------'
3
Remarks For general power application
f::
Broken tooth 8
NV 255 kPa (2.6 kgf/cm') Seizure, wear, peeling
Remarks For construction machinery
15
�
<Disassembly sequence>
1 Housing cover Cracks, deterioration
<2) Screw
Damage, seizure,
3 Screw gloss of lapped surface
(D Bearing cover �12
5 Oil seal
e::=,o
�:
6 Camshaft
7 Taper roller bearing
8 Center bearing
Damage, break
® Tappet
10 Shim 20 Delivery valve spring
@ Plunger 21 Delivery valve
@ Lower spring seat 22 Delivery valve seat
13 Plunger spring 23 Plunger barrel
14 Upper spring seat 24 Screw
15 Control sleeve 25 Control rack
16 Pinion 26 Pump housing
17 Lock plate
@ Delivery valve holder For disassembly of parts with an encircled number, see following
items.
19 Stopper The part marked • must be inspected before disassembly.
D15668
13-32
- -�---
- -- - --- ---
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
--·------ --------
m
Tappet Pin
157931-7320
B9089A
'----- - - - - -
--- - -
--- - -
- --�-
(a) Install the injection pump in Universal Vice (spe (f) Remove the housing cover.
cial tool). Insert Tappet Pins (special tools) into the tappet holes
(b) Remove .the feed pump. of all the cylinders to space the tappets away from the
(c) Remove the coupling and automatic timer. [Refer camshaft.
to 5.4.1.]
(d) Remove the governor. (Refer to 5.2.1 or 5.2.2.)
Measuring Device
105782-4130
B9092A
13-33
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
,--------- -------
- --- - -- -
- -,
i
Wrench
157910-1120
89093A 89095A
(h) Remove the screws at the bottom of the injection (j) Push the tappets up from the bottom of the
pump with Wrench (special tooll. injection pump with Roller Pincers (special tool) and
remove the Tappet Pins (special tools).
Tappet Pincers
157931-6120
89094A
89096A
B9098A
-
-
(ffi'""
-
- -
i -c
Slid gn o�,
o ,,
m o
/
"-.. r�;�?
,,_
�)
'"-.""----- (��--=i
t�,·,
� !
(,')
u BO .. Basic Diameter
Overall lappet clearance ----.. NV.. Nominal Value
(',:,
L 0.2 mm ----- ,.c·.• L Limit
8
---- --'._i--:-:'\
D1555B
(a) Plunger and plunger barrel After cleaning in gas oil, check to see that the plunger
falls smoothly in the plunger barrel under its own
weight.
Check by the following procedure.
1) Tilt the plunger barrel approx. 60° .
2) Pull the plunger about 20 mm out.
3) Turn the plunger and check several points.
01584A
13-35
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Extractor
157925-6520
01525A
B9105A
Clean theyalve and valve seat portions of the delivery
valve in gas oil and check worn condition. To remove, use Extractor (special tool).
Seal off the bottom of the valve seat portion with a To install, put the ring and shims and then install the
finger tip and press down the valve portion with a taper roller bearing.
finger. If the valve portion bounces back when
released, the valve portion is good. If it does not Outer race
bounce back, the valve portion is badly worn.
Replace the delivery valve.
Bearing cover
Extractor
157925-0520 (timer side)
157925-0120 (governor side)
Pin 01531A
Bushing
Roller The bearing cover side outer race should be removed
Tappet body
by use of Outer Race Extractor (special tool).
01526A
To install, put a new oil seal in position, and then
install the outer race.
Hold a dial gauge to the roller portion of tappet and
[email protected] Parts phone: 269 673 1638
check the overall clearance by moving the roller up
and down.
If the overall clearance is in excess of the limit, replace
the tappet assembly.
13-36
(3) Reassembly
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
--------------- --- - ·-- ·-- ·----·-·-··-·--- ------------ ----;
., 17 4.5 to 5.8 Nm
(0.45 to 0.6 k\j(ml
�jq.-:i·
l]
---
18 64 to 68 Nm
\J ..__ 19 (6 5 to 7 kgfml
21, l--20
�!--:B:���\ /
',l!:)
..----td "'X'l
1
24_.&/r:::.=;.,;;;i. • L.-;;-"�-'r\
':) 'r\..,;1� 7 . {];��· 7
' ,r(if; ; ,,,,.;" ',.,
0
25
I ·f> :·1\g /<·11'
,
� ------=
- ='--,,
JJ �
'3
Sliding resistance of control
rack (when stat,onaryl
71·
i\,,.,. l£_\,--_,,.;...\
'i�\ J !7/y)
'{,; ._:! •
6___
End play
_____
_
� <··) \ -?-""
NV 1.5 N (0.15 kgfi or less
---�.
26 8. o -il .
NV o 02 1o 0.06 mm
/ L 0.1 mm
�� 3
�........_ 16
��15
26 -· 25 -· 24 ·- 23 -• 22 - · 21 -· 20
- 19 - 18 •• 17 -- •16 - ·15 - 14 ·-
��� 13 -· 12 - 11 .• 10 -· 9 -- 8 -· 7 ·-
� ·-12 6 - 3 - 5 - 4 -- 2 - 1
D15678
Positioning
groove
89107A D1590A
(a) Mount the pump housing in Universal Vice (spe (b) Insert the plunger barrel into the housing.
cial tool). After the control rack has been inserted, NOTE:
thread the screw into the back of the pump housing. 1. Align the notch of the plunger barrel
Check to see if the control rack lightly operates. with the dowel pin of the housing.
2. Do not lightly strike the plunger barrel
but securely push in by finger.
13-37
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
!-------�
Manufacturer mark
inscribed
Plunger number
inscribed
89109A 89111A
(c) Place the pump housing on its side and set the NOTE:
control rack so that the punched marks of the control Install the plunger with the stamped model
rack will be positioned the same dimension away number toward you (the housing cover).
from the ends of the housing. After the pinion and
control sleeve have been combined, put the pinion in
mesh with the teeth of the control rod. Tappet Pincers
157931-6120
NOTE:
1. Install the pinion and control sleeve so
that the joint of the pinion and notch of
the control sleeve will be faced toward
you.
2. After each pinion has been installed,
move the control rack to confirm that it
can be moved the same amount to right
and left. 89096A
Tappet Pin
157931-7320
89097A
13-38
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
�----------�--��--- ----�
Wrench
Inscribed 157910-1120
line
89114A 89093A
13-39
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
----------------------------�
16
Rotating condition 1
I
Cracks, 33
damage
7�
<Disassembly sequence>
13-40
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
D1507A
D1504A
13-41
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
.----- - - - -- -
-··------ (I) Remove the plunger, using Plunger Insert (special
too!).
NOTE:
Put the removed plungers orderly in a tray
containing clean gas oil.
Extractor
105792-0030
(k) Remove Tappet Mounting Device (special tool),
install a wire in the hole of the lower spring seat, pull
it together with the plunger until the lower spring seat
can be removed, and remove only the lower spring
seat.
01517A
01513A
13-42
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Fitting Plate
157944-3520
(o) Disassemble the plunger block assembly by the (q) Remove the governor side screw bushing with
following procedure. special Wrench (special tool) and remove the pin and
a) Mount Pitting Plate (special tool) in the vice. bushing.
Then remove the control rod and bushing from the
timer side.
NOTE:
1. Arrange all removed parts orderly by
cylinders.
Socket Wrench 2. Be sure not to change the combination
157914-0500
of the paired plunger barrel and plunger
and that of delivery valve and delivery
valve seat.
D1519A
13-43
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
01531A
13-44
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
(3) Reassembly
Control rod
sliding resistance
(when stationary) 16
NV 1.3 N
(0.13 kgO or less
Align guide
groove with
4
9
1
I
33 .,.J�
7�
A
y
<Assembly sequence>
(27-25-----,24----.23-,22-,21-+Q(l)-,26-, 19) 18
17-,15-----,14----.13
33-,32-+ 30-+31--, 29-,28-·______,
--,(12,>-> 11->(lcf'--' 7_,9_,(�6-,5-----,4----,3-,2-, 1-> 16
For disassembly of parts with an encircled number see following
items.
D15698
13-45
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
110 to 115 Nm
(11 to 12 kgfm)
(Tighten in three stages.)
D1540A
(a) Mount the pump housing in Universal Vice (spe (c) Using Socket Wrench (special tool), tighten the
cial tooll. delivery valve holder to the specified torque (tighten
Then install bushings and control rod, pin and screw in three stages).
bushing with Special Wrench (special tooll. Check to NOTE:
see that the control rod lightly operates. If the tightening torque is smaller than the
specified torque, oil leakage or damage to
the related parts could result.
If the tightening torque is excessive, un
smooth plunger movement or damage to
the related parts could result.
0-ring Insert
105792-0000
D1537A
13-46
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
-------------------- ----
(e) Mount Tappet Mounting Device (special tool) to (g) Install the governor housing. At this time, perform
the pump housing. the following operation. Mount Measuring Plate (spe
Then install . the tappet by operating the Tappet cial tool) to the timer side taper portion of the
Mounting Device. camshaft, and install and position the governor side
At this time, compress the plunger spring and insert taper roller bearing outer race in the ring so that the
the mitt portion of the plunger into the guide groove dimension from the end of the pump housing to the
in the control sleeve, and insert Tappet Holder end of the Measuring Plate will be 13.85 ± 0.5 mm.
(special tool) into the screw plug hole. The operation
of inserting the mitt portion of the plunger into the
guide groove of the control sleeve can be easily
performed by inserting the mitt portion, while moving
the control rod to right and left.
13-47
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
01550A
(h) Measure the camshaft end play. (i) Install a spring balance to the control rod and
Install Camshaft Measuring Device (special tool) to check to see that the control rod slides smoothly over
the timer' side of the camshaft to measure the end the entire stroke without exceeding the standard
play. sliding resistance value.
Remove the Tappet Pin (special tool) before checking.
(j) Install the following parts.
Governor (Refer to 5.2.1 or 5.2.2.)
Feed pump
Automatic timer (Refer to 5.4.2.)
Coupling
(k) After reassembly has been completed, adjust the
injection pump.
Bearing cover
Shim
D1551A
13-48
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Tappet clearance
NV 0.3 or more
B9143A
NOTE:
1. Supply oil to the injection pump cam
chamber.
2. · Adjust the injection amount after ad
justing the governor.
Injection sequence
1-5-3-6-2-4
13-49
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
03423A
NOTE:
Nozzle holder wrench
If the injection pump is not running at the 157916-8220
speed mentioned above, position O won't
be obtained even if the control rack is
pressed with a strong pressure, and there
will be danger of damage to the link
mechanism of the pump. 03426B
13-50
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
NOTE:
The pressure of the fuel forced into the
injection pump must be higher than the
delivery valve opening pressure.
Inscribed line
of timer
81912A
Angle scale
Preslroke 819138
13-51
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Holder
157931-4400 D34718
034728
Control sleeve
13-52
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Adjustment of injection
start interval
NV 60' !:30"
Adjustment of prestroke
NV 4.8 ± 0.05 mm Checking stroke of control rod
NV 21 or more
NOTE:
1. Supply oil to the injection pump cam chamber.
2, Adjust the injection amount after adjustment of the
governor.
B9146A
13-53
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
D3410A
13-54
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
I
5) Slowly turn the flywheel of the pump tester
clockwise until the fuel ceases to flow out from the
overflow pipe (until static injection begins).
Prestroke
035188
035198
03412A
13-55
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
8) After adjustment of the prestroke, check to see 3) Slowly turn the flywheel of the pump tester
that the inscribed line of the timer and that of the clockwise until the fuel ceases to flow out from the
pointer are in alignment. tester nozzle.
If they are out of alignment, inscribe another line on Read the rotation angles (injection start intervals)
the timer. When the automatic timer was replaced where the fuel ceases to flow, according to the
with a new one, proceed in the same way. injection sequence.
4) If the injection start interval is out of the standard
angle, adjust by the same procedures as for prestroke
adjustment.
NOTE:
Injection sequence: 1 - 5 - 3 - 6 - 2 - 4
to let the fuel flow out from the overflow pipe of the
tester nozzle. (f) Adjustment of fuel injection amount
NOTE: At the specified rack position and speed, measure the
The pressure of the fuel forced into the injection amount and uneven ratio with a measuring
injection pump must be higher than the cylinder to check whether they are up to specification.
delivery valve opening pressure. If the injection amount is out of specification, adjust
by the following procedures.
13-56
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
DI
1) Loosen the two nt1ts tightening the flange sleeve. Minimum injec- Average injec
2) Turn the flange sleeve by lightly striking. tion amount in - tion amount of
each cylinder each cylinder
3) Tighten the nuts to the specified torque to secure
Uneven ratio (-1 - x 100 (%)
the flange sleeve. [39 to 44 Nm (4 to 4.5 kgfm)] Average injection amount of
Perform the operations repeatedly. each cylinder
NOTE:
(g) Adaptation to engine
1. A maladjusted injection amount will
produce considerable effects on engine After the governor has been adjusted, measure the
performance. Make sure that the injec fuel injection rate adaptable to the engine.
tion amount is carefully adjusted. (h) Inspection of fuel and oil leaks
2. Since the injection amount varies on • Fuel leaks from delivery valve attaching position
different nozzles and pipes, make sure and other parts.
that the measuring conditions are • Oil leaks from oil seals and other parts
observed.
(i) Inspection of parts
3. Injection amount uneven ratio
Check parts for unusual noise and bearings for
Maximum injec- Average injec
tion amount in - tion amount of excessive heat.
each cylinder each cylinder
Uneven ratio ( ! I
Average injection amount of
each cylinder
5.1 .5 Installation
2 <P type>
13-57
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Injection Pump
Injection Pump Centering Tool
Centering Tool
MH061270 \
MH061340
'·,
Air compressor
Air compressor
C0603A 89148A
L-____ _
_ _______ ______ _ _____
(a) Place Injection Pump Centering Tool (special tool) (b) Slide the dial indicator of the centering tool
on the injection pump bracket, hold a dial indicator to toward the air compressor (or injection pump drive)
the mandrel of the centering tool, and perform and measure the positions of the compressor crank
0-point adjustment. shaft (or injection pump drive shaft) shown in the
illustration with the dial indicator.
C0597A
13-58
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Keyway
COGOOA
(c) If the eccentricity between the mandrel and air (b) At this point, check to ensure that the keyway of
compressor crankshaft is in excess of the nominal the crankshaft of the air compressor (or injection
dimension, adjust by adding or removing injection pump drive) is in the uppermost position.
pump bracket shims. If the keyway is not in the uppermost position, turn
C0599A
13-59
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
9.8 to 13 Nm
(AD type]
Cross coupling - (AD type] 29 Nm (3 kgfml
(: to 1.3 kgfm)
Driving coupling 20to 29 Nm
"- /,:·- --
� (2to 3 kgfm) \ 20to 29 Nm
. \ /I
/Nfi· /y,A
.,,.
//J;// \ _ � 'n -
!( l I /(/ /�
29to 34 Nm
(3to 3.5 kgfm)
� \t ,- ,s-�-.1,a
'[!i!/, 'lf)l
')f 1 Air
l
compressor .. 'iJ'irl ·... : i�
{. �\
< ,,<, cran; shaft _J :"=' ' ,.�
"'
� f" • c;-=,
?\ L .__
.
r�z_\�
\' V I
I Jcl � l--------i..____
I '1
' >( �- .1
( 4'9\
\
c'.__ } 5'ci
Coupling plate 7=tter bolt ·------...1 \-i ,./ '.\ L___)
\/ 15to 18 Nm
,/
49to 54Nm
(5to 5_.5kgfm) 20to 25 Nm (1.5to 1.8 kgfm)
(P type] 83405C (2to 2.5 kgfml 84390B
Cross coupling
'· (P type] 20to 29 Nm
(2.0to 3.0 kgfml
Driving coupling
20 to 29 Nm i / 29 Nm (3 kgfm)
59to 64Nm
(6to 6.5 kgfm) j�"-J �
(2.0 to 3.0 kgfm) JJ
""
/
u u,n_,ri_ff
"-- 1 -co�rry,n.,ri. u u
/
20to 29 Nm
<
d1c (2.0to 3.0 kgfm)
l �
Air compressor
cranksha ft
(
� 1:) 1tr'.�I
� ' �� �
-
c,iL.L..__
20 to 2;-Nm
(2.0to 2.5 kgfm)
7·-\\ L_·�
\
"-�
r ,
Coupling� Cotte bolt 12to 15Nm 20to 25Nm
p l ate 74to 83 Nm
(7.5to 8.5 kgfm) B3402D (1.2to 1.5 kgfm) (2.0 to 2.5 kgfm)B4308C
(d) Install the driving coupling on the crankshaft of (el Tighten each pipe to the specified torque.
the air compressor, and put it a little toward the air
compressor. 5.1 .6 Bleeding the Fuel System
Install the injection pump on the injection pump Bleed the fuel system as described below.
bracket. Move the driving coupling toward the cou
pling plate and tighten it with the timing adjusting
bolt.
Then tighten the cotter bolt to the specified torque to
'reduce the clearance between the driving coupling
and coupling plate to less than 0.5 mm.
NOTE:
After the injection pump has been instal·
led, be sure to check and adjust the fuel
injection start timing. (Refer to 5.1. 7 .)
B5909A
13-60
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
.'··'fl '
/ .
f/! -......._,
, -r--
I·
-/ ,'·i '\ \/,
J I
-r .
,,
__
I
--... ,,,,,:.,
J
--- ) ---
85908A
861198
13-61
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
/J�'I
Idling positi on Full speed positi o n
Stopper / o / .
bolt ".A" Stopper
1 I / bolt "8"
j
'"- r, =
� ,O
c�i=: ·
.�
86120A
Adjusting bolt
59 to 64 Nm
(al Inspection and adjustment of idling
(6 to 6.5 kgfm)
Run the engine at idle and check to ensure that the
control lever touches the stopper bolt "A", and
measure the engine speed at the time.
If the idling speed is not within the specified limits,
adjust with the stopper bolt "A",
(b) Inspection and adjustment of no-load maximum
speed
86117A
Push the control lever until it touches the stopper bolt
"B". If the engine speed is out of the maximum speed
(3) If the fuel injection start timing is not correct,
limits, adjust with the stopper bolt "B".
loosen the two timing adjusting bolts and adjust the
,timing by turning the automatic timer. NOTE:
Tighten the adjusting bolts to the specified torque. After idling adjustment, quickly move the
Recheck the fuel injection start timing by the proce control lever from the full load position to
dure described in Items (1) and (2). the idling position to verify that the engine
does not stall and no hunting occurs. If
NOTE:
abnormal condition occurs, make adjust
Do not loosen any other parts than U1e
ment as far as the specified idling limits
adjusting bolts.
allow. If adjustment is impossible, dis
assemble and inspect the injection pump.
13-62
(2) RFD Type Governor
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
(e) In the above condition (d), measure the maximum
speed to determine whether it is within the specified
limits.
(f) If it is not within the specified limits, adjust the
fixed position of the speed control lever with the
Idle stopper stopper bolt.
bolt
NOTE:
1. If the fixed position of the full load
Stopper bolt stopper bolt is changed, the amount of
Full load
stopper bolt
Speed control fuel injection will change. Be careful
lever
not to change the fixed position.
Load control lever
2. Check to ensure that even if the load
863128 control lever is quickly returned from
the full load position to the idling posi·
(a) Check to ensure that the load control lever is tion, the engine does not stop and is
touching the' idle stopper bolt. free from hunting.
(b) In the above condition (a), measure the idling
speed to determine whether it is within the specified
limits.
(c) If it is not within the specified limits, adjust with
the idle stopper bolt.
(d) Operate the load control lever to the full load
position (until it touches the full load stopper bolt).
13-63
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
5.2 GOVERNOR
5.2.1 RSV Type Governor
(1) Disassembly, Inspection and Reassembly
Cracks, deterioration
23 Cracks,
deterioration
6
. -��
�
29
12
24
<Disassembly sequence>
1 Closing cover 11 Tension lever shaft 21 Bushing
@ Ungleich spring capsule 12 Control lever 22 Oil seal
3 Idling subspring capsule 13 Collar 23 Swivel lever
4 Torque spring capsule 14 Shim 24 Stop lever
5 Governor cover 15 Governor spring 25 Shim
6 Start spring 16 Tension lever 26 Spring cap
7 Round nut 17 Guide lever assembly 27 Return spring
® Flyweight @ Sleeve 28 Bushing
9 Governor housing 19 Floating lever link 29 Sliding lever
10 Plug 20 Snap ring 30 Bolt
31 Snap ring
32 Spring
For disassembly and reassembly of parts with an encircled number, 33 Torque control lever
see following items.
For reassembly, reverse the order of disassembly. 34 Adapter
B9150A
13-64
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
D2051A
Special Wrench
157915-0100
B9152A
13-65
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Shim
Sleeve
Bearing
Shifter
(c) Replacement of sleeve or guide lever assembly 6) When the shim has to be replaced, assemble all
1) Remove the bearing from inside the shifter, using related parts correctly and select the right shim
a press. thickness to make sure that the dimension from the
2) Using a press, remove the shifter of the guide end of the housing to the shifter complies with the
lever assembly from the bearing. specified value.
Shim thickness (6 types):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
NOTE:
Measure the assembly dimension without
lifting the flyweights.
81358A
13-66
5.2.2 RFD Type Governor
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
(1) Disassembly, Inspection and Reassembly
Cracks, deterioration
Cracks. deterioration
13
23 14 11
Oil leaks
22 21 9
26
Cracks, damage
4 5
Damaged contacting surface
ar
L�
�18
19
16
<Disassembly sequence>
Governor cover 15 Governor spring
0 Lock nut 16 Load control lever
@ Idling spring assembly 17 Bushing
4 Cap nut 18 Lever shaft
5 Lock nut 19 Sliding lever
6 Damper spring 20 Speed control lever
7 Governor cover 21 Snap ring
8 Start spring 22 Bushing
9 Tension lever plug 23 Swivel lever
10 Tension lever shaft @ Round nut
@ Guide lever assembly @ Flyweight
© Sleeve ® Governor housing
13 Floating lever link
For disassembly and reassembly of parts with an encircled number,
14 Tension lever see following items.
For reassembly, reverse the order of disassembly.
89155A
13-67
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Handle
157910-1120
89156A
� - - - --- -
----- - -
- - �
-
13-68
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
--- - - -
- -
- ----------
- - -
Shim
Sleeve
Washer Washer
Bearing
Snap ring
(d) Replacement of sleeve or guide lever assembly (e) Assembly dimension of shifter
To disassemble the shifter and sleeve, remove the When the shifter and sleeve are assembled, be sure
snap ring in 'the sleeve, and the shifter and sleeve can not to change the adjusting shim, as the assembly
be separated. dimension of the shifter has been adjusted by the
shim.
If readjustment is necessary, assemble all related
parts correctly and select the right shim thickness to
make sure that the dimension from the housing end
to the shifter complies with the specified value.
Bushing
Shim thickness (6 types):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
NOTE:
Shifter
Measure the assembly dimension with all
flyweight lifted.
� Chrome plated surface
02024A
13-69
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Adjustment of torque
spring
Adjustment of idling
spring or ungleich
spring
Adjustment of stopper
bolt
NOTE:
1. Supply engine oil to the injection pump cam chamber.
�®� :.)
2. Loosen the adjusting lever stopper bolt.
3. Remove the idling s.ub spring.
� (?speed
Adjustment of intermediate
control
4. Do not allow the Ungleich spring or idling sub spring
and torque spring to work.
B9163A
'----- - ------ - -- - - - -
----·-------
· - -- -- --- --- �
-
Re
E -·-·· e
Ri
E
C
0
·;:;
·.;;
0
Ng Ni Na Nb Ne Nd Ne
a.
13-70
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Full position
Special Wrench
157916-2620
Maximum speed
stopper bolt
89169A 89166A
(c) Temporary adjustment of high speed control (e) Adjustment of Ungleich spring (governor with
With the adjusting lever in full position, adjust the Ungleich spring only)
maximum s'peed stopper bolt so that high speed 1) Keep the pump running at a speed which is a
control starts to work when the pump speed is "Nd". littler lower than "Na" (speed at which Ungleich
spring starts to work).
2) Fix the adjusting lever at the full position.
3) Using the special tool, Special Wrench, tighten
the Ungleich spring so that the rack will move from
"Re" to "Ra". Fix the spring with lock nut.
4) Check that the pump speed is "Na" and "Nb"
when the rack position is "Ra" and "Rb", respectively.
E Re K
89164A E
0
13-71
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
--·-------------------'
89170A
Swivel lever
Adjusting bolt
D3482A
------·--------- -------------�
If the pump fails to.do so, adjust tightening amount of
the swivel lever adjusting screw.
89168A
Tightening gives better speed regulation.
Loosening gives poorer speed regulation.
2) Adjustment of idling sub spring
Ne - Nd
Adjust the idling sub spring so that the rack is Speed regulation X 100 (%)
Nd
positioned at "Ri" when the pump speed is "Ni". NOTE:
Check that the rack is positioned at "Rh" when the 1. If the speed regulation is poor, the
pump speed is further increased. engine will e.xceed the specified max
(h) Adjustment of high speed control imum speed at no load and will enter a
hazardous condition.
Adjust as in (c) and fix the maximum speed stopper
2. The maximum extent to which the ad
bolt in position.
justing screw can be loosened is 20
notches (5 turns) from the fully tight
ened position. Loosening it any further
can be dangerous.
3. If the adjusting screw is adjusted, the
tension of the governor spring will
change and the high speed control start
point will change. Be sure to readjust
the high speed control in accordance
with (h).
13-72
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
84055A
81370D
1) Install the lever to the governor cover.
2) With the adjusting lever at the full position, adjust After adjustments, lock the governor with wires.
the full load stopper bolt so that the rack is positioned
NOTE:
at "Re".
Locking of the sections marked with *
(I) Adjustment of torque spring must be done after adjustment of no-load
minimum and maximum speeds.
t��f--------�
f---------+---t-1 k
E
E
C
0
U)
0
a.
-"'
()
a:
Ni N/ Nk
Pump speed lrpm)---s-
891728
13-73
DJ
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
I Adjustment of idling k
'-- ------
- ·,-._
I
Adjustment of stopper bolt
NOTE: Adjust the relation between pump speed and the rack
1. Remove the damper spring. position to specified governor performance curve by
2. Remove the idling spring. the following procedure.
3. Keep the stopper bolt of the speed (a) "O" position setting of control rack
control lever loosened. [Refer to Item ( 1) (b) or (2) (bl, Section 5.1.4.]
' 4. Keep the stopper bolt of the load con· (b) Install the angle scale plate for fixing the control
trol lever loosened. lever.
5. Supply engine oil to the injection pump
cam chamber.
E Ru
_§ Ra
C
Rf
High
:�
_speed
Re ' control
Rb
Re
Rt
Nv NeNuNdNc Na Nb Nt
Pump speed lrpml
03486C
13-74
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES m
1 Ra
.g
·;;;
'ii Rt
0 Nu 700 to 800 Nt
Pump speed lrpml -
84061A 819158
(c) Adjustment of flyweight lift and full load position 3) Lower the pump speed to "Nu" and adjust the
Divide the flyweight full lift into the lift necessary for high speed lift "L" with the stroke adjusting screw.
high speed ·control and the lift necessary for idling (d) Adjustment of high speed control
control.
1) With the load control lever fixed at the full load
position, temporarily set the speed control lever so
that high speed control works when the pump speed
is 700 to 800 rpm.
81917A
13-75
m
c---------
- --- - ---- --
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
Ra
E
E
0
Rb
·.;
0
Na Nb
Pump speed (rpm) 04434B
2) Check of speed regulation 2) Lower the pump speed to "Ne" and adjust the
Increase t_he pump speed slowly until the control rack idling spring using the special tool, Wrench so that
is pulled back to "Rb" position. the rack is positioned at "Re".
Upon reaching "Rb" position, check that the pump 3) When the pump is stopped the rack should be at
speed is "Nb". "Rf" or higher position. Also check that the rack is
Further increase the pump speed and check that the positioned at "Re" when the pump speed is increased
rack pull back amount "L" is as specified. to "Nd".
NOTE:
1. If the speed regulation check point
(point b) is where the damper spring
acts, check the speed regulation aUer
idling and damper spring adjustment.
2. If the value is out of specification,
replace the governor spring.
(e) Adjustment of idling spring (governor with idling
spring only)
D4506A
13-76
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
E Ra + (
E Ra
a: 0 Nf NgNh N�
Pump speed (rpm)
84581A
Pump speed (rpm)
84580A
B4582A
Special Wrench
157916-2620
84317A
3) Slowly increase the pump speed from "Nf" to
"Ng" and adjust the screw position so that the
1) Set the pump speed at "Nf" and place the load Ungleich spring will start working.
control lever in the full load position. 4) Increase the pump speed to check that the
2) Using the special tool, Special Wrench, adjust the Ungleich spring stops working at "Nh".
Ungleich spring capsule position so that the Ungleich 5) Change the pump speed between "Nf" and "Na"
stroke tin the state of Step 1 will have the specified to check that the Ungleich stroke has the specified
va�ue. After the adjustment, firmly tighten it with the values.
lock nut. NOTE:
1. If the Ungleich stroke is out of speci•
fication, readjust the Ungleich spring
capsule position.
2. If the speed at which the Ungleich
spring stops working is out of specifica
tion, replace the Ungleich spring cap
sule.
13-77
DJ
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
- .,
·;;;
·;;; Ri
I
'
-"
u
"' \
a:
\
0 Ne Nh
Pump speed (rpm) - B4062A
--·
1) Holding the load control lever at the idle position
(point el and slowly increase the pump speed from
"Ne" until the rack is positioned at "Rg - 0.2 mm".
Hold the pump speed "Nh" when the rack is so
positioned. 3) After adjustment, stop the pump and loosen and
adjust the stopper bolt so that the rack is positioned at
"Ri".
13-78
DJ
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
(i) Adjustment of rack limit After adjustment, install the cap nut securely.
1) Cap type 2) Screw type
/t ())
�
Guide Screw
157976-3100 \
�
B3767A B4583A
a) Remove· the guide screw from the back of the a) Place the load control lever in the full load
pump housing and install the special tool, Guide position and keep the pump speed at "Nv".
Screw. b) Adjust the screw of the rack limiter so that the rod
position and fuel injection (point E) will be up to
specification, and secure it with the lock nut.
B3768A
B3769A
1) With the load control lever set at the full load (I) Locking with wire
position, set the smoke set assembly adjusting nut at
O to 4 mm from the stopper tip.
2) Adjust to make sure that when the pump speed is
changed to "Nd", the rack position will change from
·,""'·
To be locked with wire
"Ra" to "Ra"'.
NOTE:
Lock parts marked with * after adjustment
03497A of no load maximum speed.
3) Set and fix the nut so that the rack is positioned at 5.2.4 Inspection and Adjustment of No
"Ru" when the pump speed is "Nu". load Minimum and Maximum
(k) Adjustment of adaptation to engine Speeds
After the governor has been adjusted, measure [Refer to 5.1.8.)
overall injection amount at the same lever angle as in
the high speed control and in accordance with the
adjustment standard and readjust as necessary.
13-80
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
<Disassembly sequence>
NOTE:
Before disassembly, know the trouble spots throughly by
making tests.
89175A
13-81
DJ
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
-tg::?f
minute
Delivery NV 25 strokes
Condition or less Feed pump
Fuel passed through 1.54-dia.
nozzle for 15 seconds when ·
pump is operated at 1 000 rpm
NV Refer to 3.1 Service Standard Table.
Test conditions
Fuel pipe
1.0. 8
Length 2 000
Cam lift
6 (eccentric cam) [KE type]
4 (double cam) [K type]
Height from oil level 1 000
Test bench FPT-1
Test oil
SAE Standard Test Oil (SAE J967c)
NV ... Nominal Value
06401A
13-82
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
Wear of
pin section
Damage on 10
curved surface
<Disassembly sequence>
CD Round nut
2 Timer plug
0 Timer case
4 Oil seal
5 Flange
6 Oil seal
7 Spring
8 Shim
9 Flyweight
pin section 10 Holder
1 4 3
Wear,
damage
For disassembly of parts with an encircled number, see following
items.
03152A
13-83
D]
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
Special Spanner
/157916-5320
y/
89176A 89179A
(b) Mount Special Spanner (special tool) in the cou (e) Remove the timer plug and place the automatic
pling mounting threaded hole to prevent turning, and timer on Base (special tool).
remove th'e round nut. NOTE:
Line up the hole in the timer plug with the
pin of the base.
@
Hand Spanner
157916-6120
Extractor
157926-6210
_____ , �'n==
89177A
'---- 6:il�
--- - - - - - -- - - - -
-
Guide Bolt
157924-0200
Base
157924-0110
89178A
13-84
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
(2) Reassembly
9 3
After reassembly,
pack AUTOMATIC
TIMER GREASE
(Diesel Kiki product)
or equivalent
150 g.
10
8
0-ring 5
<Assembly sequence>
10 -· 9·
03153A
Thrust Bushing
157924-1500
Guide Bolt Guide Bushing
157924-0200 157924-1200
Base
157924-0110
Oil seal
Flange
Block
157924-0800
B9178A B9182A
(a) Mount Base and Guide Bolt (special tools) in a (b) Install the oil seal in the flange.
vice. 1) Mount Block (special tool) to the base.
2) Put the flange so that its pins will fit in the holes in
the block.
3) Apply NEJI LOCK to the oil seal installing hole in
the flange.
4) Put the oil seal in the hole in the flange. Install the
oil seal by turning down Thrust Bushing (special tool)
with Guide Bushing (special tool) in between.
13-85
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
Thrust Bushing
flyweight, install the shim and spring.
157924-1500 Thread Guide (special tool) onto the guide bolt.
Guide Bushing
157924-1300
NOTE:
Select the proper shim thickness suitable
Timer case.___ � -- for the advance angle of the automatic
.........___ -::,__..,S< timer.
Guide
157924-0900
Oil seal
Block
157924-0800
Special Spanner
157916-5320 Thrust Bushing
B9183A 157924-0500
B9184A
B9187A
B9185A
13-86
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
m
(i) Inject approx. 150 g of automatic timer grease
from the timer plug hole.
After grease has been injected, tighten the timer plug.
Special Spanner
157916-5320
89180A
(h) After the oil seal guide has been removed, turn
down the timer case onto the holder with Hand B9190A
Spanner (sp.ecial tool), and punch it.
NOTE: (j) After the automatic timer has been installed on
Turn down the timer case until the injec the camshaft, fit Special Spanner (special tool) into
tion start timing lines inscribed on the the coupling mounting hole. While holding it to
timer case and flange are in alignment. prevent turning, tighten the round nut to the specified
torque.
B9189A
13-87
DJ
FUEL AND ENGINE CONTROL
SERVICE PRCEDURES
Wear
<Disassembly sequence>
1 Cap screw
3 Deformation
0 Round nut
Damage on Deterioration, 3 Cover
curved surface wear
4 Oil seal
11 9
® Washer
® Roller
(j) Bushing
8 Flange
9 Retainer
1 14 10 Timer spring
11 Spring seat
12 Shim
13 Flyweight
14 Timer housing
For disassembly of parts with an encircled number. see following items.
D3103A
Extractor
157926-7220
�
"-, Box Spanner
' 157915-2320
"" D3105A
Box Wrench
157916-2800 D3104A
(c) Mount Special Spanner (special tool) by taking
(b) Remove the cap screw of the timer. While using advantage of the coupling mounting thread. While
Box Spanner (special tool), remove the round nut holding it to prevent turning, remove the timer from
with Box Wrench (special tool). the injection pump, using Extractor (special tool).
13-88
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Base
L
157924-2520
8�
8
-
--
D3106A
(d) Mount Base (special tool) in a vice. (f) Mount Special Spanner (special tool) to the
flange. With the timer spring compressed, remove the
washer, roller and bushing.
13-89
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
(2) Reassembly
,--------- - --------- ---- - - -- --�
-------------- -
Apply engine 4
oil to rip.
1 29 to 39 Nm
(3 to 4 kgfm)
Gasket
0-rin� 8 14
<Assembly sequence>
14--> 13--> 12--> 11__, 10-->9-->8--> 7--, 6--> 5--,4__, 3-� 2--> 1
D31128
Base
157924-2520
_;_
B�G
(a) Mount Base (special tool) in a vice and secure the (b) Mount Special Spanner (special tool) to the
timer housing to the base. flange. With the timer spring compressed, install the
bushing, roller and washer.
13-90
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
m
Cover side
Roller side
03113A
NOTE: (d) Remove the plug at the rear end of the timer and
When the washer is installed, direct it as supply 250 to 270 cc of engine oil.
shown.
03114A
13-91
13-92
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
5.5 PUMP DRIVE CASE For removal and installation of the pump drive case,
J ""'"
5.5.2 Disassembly and Inspection
Cracked
5 Worn 4 10
L
<Disassembly sequence>
13-93
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
5.5.3 Reassembly
215 Nm
(22 kgfm)
<Assembly sequence>
10 -• 8 � 6 � 3 �
10
4�7-5J 2
For assembly of parts marked o, refer to the following section. B4197A
D92748
[}- -1
�� � Settling
Wear 4 f' �5
�9
S� 7 Wear
8 Carbon
deposited
w-- -
©
@)
6
Disassembly sequence
1 Cap nut 5 Connector
2 Adjusting screw 6 Retaining nut
3 Spring 7 Needle valve
4 Push rod 8 Nozzle
NOTE: 9 Nozzle holder
When installing, tighten two nozzle attaching I
bolts alternately and little by little.
07027A
C05778
(2-spring nozzle)
,-fj
Gasket--------0 Disassembly sequence
Cap nut
3�
I
2 Adjusting screw
2
Cracks,
d""''""'" :
---I -----G 3 Lock nut
4 No. 2 spring
5 Set screw
6 No. 2 push rod
Wear 6--t 7 Spacer
8 No. 1 spring
Shim _ �
(for prelift) � 9 No. 1 push rod
10 Retaining nut
�
Shim J 11 Nozzle
(for valve opening--®
pressure)
-t /j
_____fl
12 Needle valve
Cracks, 8 --� 13 Nozzle holder
deterioration
14 Connector
9
07015A
13-95
•
5.6.3 Cleaning and Inspection
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
(1) Cleaning
07004A
07029A
D70058
13-96
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
Next, pull up the needle valve vertically about 1/3 of ( 1) Injection Pressure
its entire stroke and check that it falls under its own
39 to 49 Nm
1 (4 to 5 kgfm)
/
69 to 78 Nm
- 2
(7 to 8 kgfm) 5 ---
9
3 07007A
----- 4
(a) Remove the cap nut and install to the nozzle
_ .- Locating pin
tester.
-8
59 to 78 Nm 6 ---- :; (b) Loosen the adjusting screw and operate the
(6 to 8 kgfm) nozzle tester two or three times for bleeding.
(c) Operate the nozzle tester at specified speed,
Assembly sequence
adjusting the adjusting screw for specified injection
9-+5-+4-+3-+2-1
pressure.
6-+8-+7-J
NOTE:
NOTE: Never let yourself exposed directly to the
1. Never touch the sliding surface of the needle atomized fuel injected from the nozzle.
valve by hand.
2. Install the cap nut after injection pressure
adjustment.
07028A
07008A
13-97
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
l
before adjustment.
i: I )
i
For adjustment, the following special tools are re
quired.
'°'
When adjusting the pressure with a nozzle tester,
check also for clogged injection orifices, spray condi
tion, and fuel leaks from the orifices. Replace the
nozzle if defective.
(3) Fuel Tightness Test 6
Test pressure
19.6 MPa (200 kgf/cm')
� 8
7
B3942A
the nozzle. The nozzle is functioning normally if there 8 Retaining nut for adjustment 157892-1420
13-98
DJ
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
4 .
1
��' i.�J�1 �
<. R-1 1 111 ) I 7 Nozzle holder
·,1 , \ filI 1,·111T
,
i!·t I . · s
- 13 r _
I, •\\ I� �-_ _I -
L -��
· Shim (for valve opening pressure)
14
I
69 to 78Nmj,i[�
(7 to 8 kgfml t1J.
:11 8
I'\t1l,P*'"
;\ \�J�
, i 9 Needle valve
J
12 RetainingNut for
Locating pin Adjustment
J--157892-1420
c
Assembly sequen e ��--
��78Nm
II\ 1 · 1I (6 to 8 kgfm)
, \ 11
i
I 13_,9-,B-,7-,5-,6
13-99
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
NOTE:
1. When using a shim, be sure to check its
Set screw
49 to 59 Nm thickness by a micrometer.
(5 to 6 kgfm)
2. Use same shim for prelift adjustment.
3. Use of a 0.02 mm thick shim changes
the valve opening pressure by about
235 kPa (2.4 kgf/cm2)
Spacer
(2) Selection of Prelift Adjusting Shim
Shim (for valve (a) 0 point adjustment of adjusting device
.opening pressure)
1st spring
Adjusting Device
157892-0220
/ Pin f = 60.5
157892-1100
D7018A Base
157892-1800
(c) Install the nozzle holder to the Nozzle Tester (b) Install the 2nd push rod to the nozzle holder.
(special tool) and adjust the shim thickness for NOTE:
nominal injection pressure. Do not install the 2nd spring and prelift
Shim types: adjusting shim.
0.50 to 1.54 mm (by 0.02 mm)
13-100
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
- --1
(2 to 2.5 kgfm) \bi
Intermediate screw Adjusting screw
Set screw of Adjusting Device
2nd spring ----@
Set screw
Nozzle holder
2nd push rod D7032A
D7031A
NOTE:
Do not install the prelift adjusting shim.
(c) Install the adjusting device to the set screw using
its intermediate screw. Operate lever at
60 to 100 strokes/minute
After installation, holding the dial gauge at its holder,
move it up and down to check that the gauge operates Injection pressure
NV 24.8 to 25.4 MPa
smoothly. (253 to 259 kgf/cm')
Push down the gauge, holding its holder and read its
Nozzle Tester
lift h. 105785-1010
NOTE:
Read to 1/100 mm.
(d) Selection of prelift adjusting shim
Keep bolt removed
t = t + h 070190
13-101
m
(4) Checking Full Lift of Needle Valve
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
NOTE:
Never loosen the lock nut as loosening it
changes the 2-spring adjusting pressure.
,r--l1
( \ "0-
, \'' Dial Gauge (b) Install the prelift shim selected in (2) between the
'. ;J 157954-3800
spacer and 2nd push rod.
39 to 49 Nm · ·� ';:! Connector
157892-1320 (c) Install the 2nd push rod and 2nd spring and
(4 to 5 kgfm)--v
0
Pin / = 50 mm tighten the setscrew, lock nut and adjusting screw as
157892-1200
an assembly to specified torque.
(d) Check again that the needle valve full lift dimen
sion "S" with the dial gauge by the procedures_
Retaining Nut for
Geske< [ Adfustment described in (4).
026508-1140 �
157892-1420
12, - - Bolt (6) Checking Prelift
D7033A
Check the prelift based on dimension "L" measured
in (4) and dimension "S" measured in (5).
(a) Install the special tools indicated in above illustra
tion anl set O point of the Dial Gauge. L - S = 6f
(b) Install the nozzle to the nozzle tester and operate where /' - 0.02 < 6 {' < f + 0.02 mm
the tester lever to bleed the inside of the retaining nut.
6 t: Prelift (measured)
Also check for fuel leaks.
t: Prelift (0.1 mm)
(c) · Operate the tester lever to increase the pressure
L: Needle valve full lift dimension (mea
to about 34.5 to 44 MPa (350 to 450 kgf/cm') so that
sured)
the needle valve of the nozzle is fully lifted. Read this
S: Needle valve lift dimension (measured)
lift dimension "L" off the dial gauge.
with prelift subtracted
(d) Remove the Dial Gauge, Connector and Pin
(special tool). If 6 t is outside of specified dimension e ± 0.02
mm, replace the prelift adjusting shim as de
(5) Installation of Prelift Shim scribed in (5) and repeat steps (4) and (5) so that
6 f will fall within t ± 0.02 mm.
Select thickness t' of shim to be used as follows.
Adjusting screw
t' t + ({' - !:,{')
Lock nut T t' ± 0.015 mm
D7034A
13-102
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
2-spring adjusting
pressure (lift 0.05 mm) I 3 5 ,;
NV 23 to 23.5 MPa
Good Good Poor Poor Poor Poor
(235 to 240 kgf/cm') I
I
l
Nozzle Tester ! '
)
I
105785-1010
..-�,
D7035A
� ;J
'!
�
(a) After checking the prelift in Item (6), increase the Good Poor
pressure again to about 34.5 to 44 MPa (350 to 450
kgf/cm') so that the needle valve of the nozzle is fully Evenly sprayed from 3 Asymmetrical
lifted. four (five with 6022-TC) 4 Branched
injection orifices 5 Thin
NOTE:
2 Even and symmetrical 6 Irregular
The Retaining Nut for Adjustment (special
tool) must have a bolt fitted at its tip.
07009A
(b) When the nozzle tester lever operation is stopped
with the nozzle needle valve fully lifted, the pressure
When adjusting the pressure with a nozzle tester,
will start to drop and the needle valve will go down.
check also for clogged injection orifices, spray condi
(c) At the moment the nozzle lift has dropped to 0.05
tion, and fuel leaks from the orifices. Replace the
mm, read the pressure gauge indication.
nozzle if defective.
(d) If the 2-spring adjusting pressure !cover pressure)
(c) Fuel tightness test
is out of specification, adjust the 2-spring adjusting
pressure as described in (3).
NOTE:
Adjust without installing prelift shim. Test pressure
15.7 MPa (160 kgf/cm')
(e) Remove special tools.
(8) Inspection
(a) Tighten the retaining nut and cap nut to specified
torque.
NOTE:
1. Make sure that the knock pin has sea
ted completely before tightening the
07010A
retaining nut.
2. Tighten the retaining nut finger tight
Install a nozzle that has been adjusted to specified
and then tighten to specified torque
injection start pressure to the nozzle tester. Slowly
using a torque wrench.
increase the pressure to the test pressure and keeping
this condition, check for fuel leaks from the bottom of
the nozzle. The nozzle is functioning normally if there
is no leak.
13-103
m
5.7 FUEL FILTER
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
<Standard> <Option>
Cracks, damaged
threaded portion
Cracks, damaged 25 Nm
thread
'·"----------/./
I I I I __ I
D7301E D73090
NOTE:
1. When removing the element, check for
the gasket left behind on the head side.
2. To mount, apply a thin coat of engine oil
to the gasket, and then secure the
element by tightening 3/4 to 1 turn aHer
the gasket comes in contact with the
fuel filter head.
3. After installation, bleed the fuel sys
tem.
4. After bleeding the air, start the engine Filter Wrench
MH061572
and check for fuel leaks. B9181C
13-104
FUEL AND ENGINE CONTROL
SERVICE PROCEDURES
1 Drain plug
2 Ring nut
4-
3 Case
7----Q
:�
4 Baffle plate
5 Isolation plate
6 Screen assembly
7 Water level ring
8 Cover
1--®
07405C
07404A
13-105
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
6. TROUBLESHOOTING
13-106
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
DJ
Symptom Probable cause Remedy Ref. group
Unstable
engine output .
Defective injection pump
Insufficient plunger sliding stroke Replace
.
• Worn or sticky tappet Replace
Control lever not in contact with full speed set bolt Adjust
13-107
• Symptom
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
Engine maximum Injection pump control rack or control rod not sliding smoothly Correct
speed to high
Defective governor
• Governor spring too weak Adjust
Defective governor
• Idling spring too weak Adjust
13-108
ID
COOLING
CONTENTS
14-1
ID COOLING - GENERAL
Radiator cap
When coolant
temperature
is high
(bottom bypass
,--- -,- -, valve is closed I
,---, r---, ,---, ,---, ,---, l
Oil cooler
L
o � � �
·, Water pump /{::i
I ..
/
I •,
Drain cock ) :
\ i'-.... /�
Dram cock "--__) B9017A
To water pump
( 1) Water Pump
When coolant temperature is low
(bottom bypass valve is open)
B1747A
[email protected]
Parts phone: 269 673 1638
B9018A
14-2
COOLING - GENERAL, SPECIFICATIONS
Considerations are, therefore, paid to the fan dia The pressure cap regulates the pressure in the
m
meter, radiator capacity and other factors. Some units cooling system. When the pressure builds up in the
for construction plants are equipped with an oil cooler system that exceeds a predetermined level, the
to cool hydraulic oil. pressure valve compresses the pressure spring, re
(4) Pressure Cap leasing the excessive pressure through the overflow
pipe into the atmosphere.
<With pressure release lever> If equipped with a reserve tank, the coolant that has
overflowed is channeled into it.
, . , -1
Pressure
release
lever When the coolant temperature drops and negative
Pressure :-.
spring · ,i pressure builds up in the system, the vent valve
--------'--
opens to take in air to prevent the radiator from
f"E�6:=- fl-
f-1· ;��j
�T. Jj,..."""- --,.;:-
becoming deformed.
If equipped with a reserve tank, coolant is taken from
�:"
---
�-
:· To overflow pipe the reserve tank to prevent the radiator from becom
��
ing deformed and to keep the quantity of coolant in
Pressure' ·· : ""-,,. · Vent valve
valve Vent valve ',;.. operation the system constant .
. spring condition
�
If equipped with a pressure release lever on the cap,
,....�ll�
� 817168
raising the lever upright opens the pressure valve and
releases the pressure in the cooling system.
<Without pressure release lever>
From
reserve
tank
80295A
2. SPECIFICATIONS
Item Specification
Radiator Type Tube and corrugated fin type or tube and plate fin type
14-3
•
3. SERVICE STANDARDS
COOLING - SERVICE STANDARDS, SPECIAL TOOL
· 4. SPECIAL TOOL
Unit:mm
48
B5251A
14-4
5. SERVICE PROCEDURES
COOLING - SERVICE PROCEDURES
B9019B
Tightening margin
BO 11.8
1 NV 0.03 to 0.06
Reassembly up to
Tightening margin
BO 25
NV 0.05 to 0.08
Reassembly up to
two times allowed
<Disassembly sequence>
1 Water pump pulley ® Water pump shaft
@ Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 Water pump cover 13 Unit seal
0 Impeller 14 Water pump case
For parts with an encircled number, refer to Disassembly and
Inspection Procedures that follow. 00044C
14-5
ID COOLING - SERVICE PROCEDURES
Impeller
Water pump
Impeller Puller
MH061417
000138
(3) Impeller to Water Pump Shaft Tighten•
(1) RemQval of Impeller ing Margin
Using two threaded holes (MB x 1.25) in the impeller If the tightening margin exceeds specification, replace
and the Water Pump Impeller Puller (special tool). pull the impeller or water pump shaft.
off the impeller. NOTE:
Do not reassemble more than three times
Water
even when the specification is met.
pump
flange
000318
14-6
COOLING - SERVICE PROCEDURES
ID
5.2.3 Reassembly
Apply engine
oil to lips.
12
Apply engine oil
to external cylinder.
13
Installation load
39.2 kN (4000 kgO
5
Apply engine <Assembly sequence>
oil to lips. 121
@J
NOTE:
1. After reassembly, turn the water pump pulley by hand
to make sure that the impeller is not in contact with
the case and cover.
2. When press-fitting the impeller and flange, make sure
that they cannot be installed with a load of 4.9 kN (500
kgf). 000470
Installation of Unit Seal To install the unit seal, use the press-fit jig as shown
and press-fit the unit seal until the installed dimen
Unit seal sions shown are obtained.
Installation load
31 to 44 N (3.2 to 4.5 kgt)
Installation speed
14 to 28 mm/sec
84153A
14-7
ID COOLING - SERVICE PROCEDURES
Thermostat
��
Heat source ----fl 003016
14-8
5.4 FAN DRIVE
COOLING - SERVICE PROCEDURES
m
5.4.1 Disassembly and Inspection
�---- -
---- ----- - - -
----- -
-- ------------------,
8
6 <Disassembly sequence>
Fan pulley
2 Flange
1 3 Snap ring
4 Fan drive shaft
5 Ball bearing
6 Spacer
7 Ball bearing
8 Bearing case
890230
To be packed with
approx. 86 g of grease 6 Rotating condition
(multipurpose grease)
<Disassembly sequence>
14-9
ID COOLING - SERVICE PROCEDURES
5.5.2 Reassembly
Inspection pressure
98 kPa (1.0 kgf/cm')
Sealing side to
be faced outward.
To be packed with grease
(multipurpose grease)
98 Nm
3 (10 kgfml
004098
4
(2) Connect a hose to one of the radiator ports, cap
the other port, and immerse the radiator into water.
To be packed with Using a radiator cap tester, force the compressed air
approx. 6 g of grease
(multipurpose grease)
under the specified inspection pressure from the hose
end to check for leaks.
If there is a leak, resolder the point of leakage or
<Assembly sequence> replace the radiator.
5 _, 6i
4 -, 3 ...... 2 -, 1
89024E
Radiator
cap 00420A
14-10
5. 7
COOLING - SERVICE PROCEDURES
Adjusting bolt
E0166
Adjusting bolt
80429A
80428A
14-12
COOLING - SERVICE PROCEDURES
m
Replace the coolant once every two years to retain its
anti-freeze and anti-rust effects.
For usage of Long Life Coolant, refer to its instruction
manual.
NOTE:
1. Be sure to use FUSO Diesel Long Life
Coolant.
2. Never mix it with DIAQUEEN Long Life
Coolant or other commercial long life
coolants, anti-freezes or anti-rusts.
B0426A
� - -
- - -
------ - -----
- - --
- -
81322A
14-13
ID COOLING - SERVICE PROCEDURES
(1 ) Inspection
Remove the pressure cap from the radiator, and run
the engine to raise the coolant temperature up to
around 90°C.
If bubbles continue forming in the coolant under the
condition, it indicates that air or exhaust gas has
leaked into the coolant.
(2)Causes
(a) If air is trapped in coolant, check cylinder head
bolts, water pump mounting bolts, and hose and its
connections for looseness. Check also hoses for
damage.
· (b) If the exhaust gas has leaked into coolant, check
the cylinder head gasket or nozzle tube end stake for
damage. Check also cylinder head for cracks.
14-14
6. TROUBLESHOOTING
COOLING - TROUBLESHOOTING m
Symptom Probable cause Remedy Ref. group
Overheating
.
Defective V -bell
Adjust
.
Incorrect tension
.
Defective water pump
Loose shaft to flange engagement Replace
.
.
Incorrect impeller to case clearance
Damaged impeller
I•
Defective radiator
• Radiator proper not air tight Replace
14-15
INTAKE AND EXHAUST
CONTENTS
15-1
m
1. GENERAL
INTAKE AND EXHAUST - GENERAL
Air
( 1 ) Air Cleaner
To engine
Vacuator
valve
Guide vane 80620A
B0608C
Outside air
To air cleaner 80610A
15-2
(3) Vacuator Valve
INTAKE AND EXHAUST - GENERAL
Warning lamp
Starter switch
Electrical
dust indicator
�
l Battery
80624A
Reset button
Indicator body
Compressor
wheel
Signal
Exhaust
outlet
Transparent
section
Inlet
manifold
806058
Bearing housing
Turbine
cover
wheel
,'l\.j��� Back
plate
Turbine
wheel
B1213A B1202A
15-4
(6) After Cooler
INTAKE AND EXHAUST - GENERAL, SPECIFICATIONS
Jf
,.,
Water pump
80627A
2. SPECIFICATIONS
Item Specification
15-5
m
3. SERVICE STANDARDS
INTAKE AND EXHAUST - SERVICE STANDARDS
I.D. 12.042
Length 11.94
15-6
INTAKE AND EXHAUST - SERVICE STANDARDS,
SPECIAL TOOL
• Unit:mm
4. SPECIAL TOOL
'5)
manifold mounting nut
Width across
flats 14 85341A
5. SERVICE PROCEDURES
5.1 REMOVAL AND INSTALLATION OF INTAKE SYSTEM
<6022>
35 Nm
(3.6 kgfm) 3
Earth plate
2 Inlet pipe
3 Air heater
4 Inlet manifold
NOTE:
1. Remove all harnesses before disassembly.
2. Pay attention to the air heater mounting direction.
3. For inspection of air heater, see "Group 16".
84556A
15-8
INTAKE AND EXHAUST - SERVICE PROCEDURES
<6D22-T>
5
�� .
35 Nm ��nstall
� the air heater with the
(3.6 kgfml embossed arrow directed to
downward.
1 Earth plate
2 Inlet pipe
3 Rubber hose
4 Air heater
5 Inlet manifold
NOTE:
1. Remove all harnesses before disassembly.
2. Pay attention to air heater mounting direction.
3. For inspection of air heater, see "Groupe 16".
84557A
15-9
INTAKE AND EXHAUST - SERVICE PROCEDURES
<6022-TC>
1 Inlet pipe
2 Air escape pipe
3 Water inlet pipe
4 Water return pipe
5 After cooler assembly
6 Earth plate
7 Air heater
8 Rubber hose
NOTE:
1. Remove all harnesses before disassembly.
2. Pay attention to air heater mounting direction.
3. For inspection of air heater, see "Groupe 16".
84558A
15-10
INTAKE AND EXHAUST - SERVICE PROCEDURES
Bl
5.2 REMOVAL AND INSTALLATION OF EXHAUST SYSTEM
<6D22>
To be installed with
stamped mark toward
manifold.
Seal ring
t
Ends
• Install the seal ring so that the ends of each ring are positioned
180° apart from those of the other.
• Install the expansion ring so that any one of its crests is not
positioned at the seal ring ends.
1 Heat insulator
2 Exhaust manifold
3 Seal ring
4 Expansion ring
5 Center exhaust manifold
B4560A
<6D22-T, TC>
4
35 Nm
(3.6 kgfml
�
26 Nm
----®L.
(2.1 kgfml
41 Nm
�
(4.2 kgfml ---......._
dt'
ic o_. (�1
--
[t]0�-- --- �',
J�� - �"-\1- � --r-\V tf}}
------ ------ �� Expansion ring
J\
Stamped mark "TOP" 0
Seal ring
To be installed with
stamped mark toward manifold. i E!ds
:;i • Install the seal ring so that the ends of each ring are positioned
\(
180° apart from those of the other.
• Install the expansion r.ing so that any one of its crests is not
positioned at the seal ring ends.
Heat insulator
2 Oil pipe
3 Oil return pipe
4 Turbocharger
5 Exhaust manifold
6 Seal ring
7 Expansion ring
8 Center exhaust manifold
84561A
15-12
5.3
INTAKE AND EXHAUST - SERVICE PROCEDURES
AIR CLEANER
m
5.3.1 Disassembly and Reassembly
Clarnp
Dust indicator
Baffle
nut
Element
Wing nut
Cover
Outer
Air cleaner body
Dust
Assembling
nut Baffle direction mark
Wing
nut Clip
nut
15-13
•
5.3.2
INTAKE AND EXHAUST - SERVICE PROCEDURES
C7209A
C7207A
After the element has been cleaned, put an electric
If there is dry dust on the element, clean the dust by lamp inside the element to check for damage and pin
blowing 685 kPa (7 kgf/cm 2 ) or lower compressed air holes. If there are thin portions in the filter paper,
against the element. replace the element. If the packing on the top surface
Blow the compressed air from inside the element up of the element is broken, replace the packing.
and down along the frills of the filter paper and clean (4) Cleaning of Air Cleaner Body
the whole element evenly. Clean the inside of the air cleaner body and discharge
NOTE: the deposited dust.
1. Do not strike the element or sirike it (5) Inspection of Dust Indicator
against a hard object to loosen the
dust.
2, Do not clean the inner element. Reset button
NV
7.47 ± 0.57 kPa
(762 ± 58 mmH,O)
NV... Nominal value
6.23 :!. 0.57 kPa
1635 ± 58 mmH,O)
C72108
Start the engine and close the inlet port of air cleaner
gradually to increase negative pressure. If the red
signal is displayed at the dust indicator, or warning
lamp lights for the electric type, the dust indicator is
normal.
NOTE:
Perform this inspection after cleaning or
replacement of the air cleaner element if
the element is heavily clogged.
15-14
INTAKE AND EXHAUST - SERVICE PROCEDURES
5.4 TURBOCHARGER
5.4.1 TD08 Type Turbocharger
(1) Disassembly
'&.
Interference with
turbine wheel, cracks
due to overheat, pitching,
deformation
13
Blade bend and damage,
17 corrosion, marks of interference
15 on back surface
Interference with turbine
wheel, damage
18
Bearing hole surface roughness,
damage, gas corrosion, turbine
side flange deformation
Disassembly sequence
1 Coupling assembly 10 Thrust sleeve
0 Turbine housing 11 Thrust bearing
3 Snap ring assembly 12 Thrust ring
© Compressor cover 13 Shaft and turbine wheel
5 Compressor wheel 14 Piston ring
6 Snap ring 15 Turbine back plate
(j) Insert 16 Bearing
8 Piston ring 17 Snap ring
9 Oil deflector 18 Bearing housing
C8965B
15-15
•
Disassembly Procedure
INTAKE AND EXHAUST - SERVICE PROCEDURES
Alignment mark
(a) Befo�e disassembling the turbocharger, make Remove the compressor cover by tapping it with a
alignment marks on the compressor cover, bearing plastic hammer with the snap ring loosened.
housing, and turbine housing so that they can be NOTE:
properly reassembled. Use care not to damage the compressor
(b) Removal of turbine housing wheel during the removal procedure.
(d) Removal of compressor wheel
Coupling assembly
�
Bearing housing
Turbine housing
Turbine housing
839468
82820C
To remove the turbine housing, remove the coupling
assembly and tap the housing with a plastic hammer 1) Fit the bearing housing into the turbine housing
or similar tool to prevent damage to it. which is clamped in a vise.
NOTE:
The turbine wheel blades are easy to bend.
Use care not to damage them.
15-16
INTAKE AND EXHAUST - SERVICE PROCEDURES
C8983C
88978A
2) While holding the shaft and turbine wheel boss,
remove the lock nut that secures the compressor 1) Remove the snap ring.
wheel.
NOTE:
Retain the snap ring by hand to prevent it
from springing out when slipping off the
snap ring pliers.
C8984A
C8985B
15-17
• INTAKE AND EXHAUST - SERVICE PROCEDURES
Clean Clean
0.0.
L 20.382
1.0.
L
Clean
Shaft concentricity
L 0.015
(total gauge reading)
Clean
C8988B
15-18
INTAKE AND EXHAUST - SERVICE PROCEDURES
(a) Cleaning
Turbocharger manufacturers use a blasting equip
ment for cleaning parts at their workshops. As an
alternative effective method for overhaul at the
dealer's workshop, use the following procedures.
When a commercially available neutral detergent is
used for cleaning, make sure that it does not contain
corrosive component.
1) Before cleaning, visually check the condition of
the parts. Check for burns, wear, etc. which could not
be identified after washing.
C8991A
C8989A
C8990A
15-19
INTAKE AND EXHAUST - SERVICE PROCEDURES
B9036A
C9034A
C8915A
C8971A
15-20
INTAKE AND EXHAUST - SERVICE PROCEDURES
5) Insert
m
Insert a new piston ring securely in the bore in the
Insert
Ends
insert and measure the end gap of the piston ring.
ring If the end gap is out of specification, replace the
insert.
B0467A
(3) Reassembly
15
20 Nm
(2 kgfm)
Shaft and turbine wheel to
Apply MOLYKOTE grease turbine back plate clearance
or equivalent to threads. NV 0.48 to 0.92
Assembly sequence
18->17->16->15 13
} 12 ->11
Shaft and turbine wheel
14->13
� axial play
_ (6)-->@->�)--->3->(2)->1 NV 0.075 to 0.155
9-> 10->(a_r-' 7
15-21
•
Reassembly Procedure
INTAKE AND EXHAUST - SERVICE PROCEDURES
Thrust sleeve
Piston ring
B0472C
Set the thrust sleeve into the oil deflector, and install
the piston ring.
NOTE:
1. When mounting piston ring to the thrust
sleeve, ensure that the ring is not ex•
panded and ring ends are not twisted.
2. If the piston ring is to be replaced with a
new one, be sure to replace also the
thrust sleeve and shaft and turbine Install the snap ring to the bearing housing with its
wheel with new ones. taper up.
After installation, using a screwdriver drive the snap
ring into the groove in the bearing housing by
hummering.
NOTE:
1. Retain the snap ring by hand to prevent
it from springing out when slipping off
the snap ring pliers.
2. Special care must be exercised, when
tapping the snap ring into position, to
prevent damage to the bearing housing
by the screwdriver.
15-22
INTAKE AND EXHAUST - SERVICE PROCEDURES
t
Set the bearing housing carefully to pre•
Turbine wheel vent damage on the turbine wheel blades.
�shaft
Shaft and
turbine wheel
Set the dial gauge on the shaft and turbine wheel end.
Move the shaft and turbine wheel in the axial
C9001B
t
direction and measure the clearance between the
turbine wheel and turbine housing.
If the clearance is out of specification, disassemble C9003B
and isolate the cause.
(d) Installation of compressor wheel (e) Set a dial gauge on the shaft and turbine wheel
end.
With compressor wheel moved in the axial direction,
measure the end play. If the play is out of specifica
tion, disassemble and check to locate the cause.
Bearing housing
Turbine housing
B2820C
Lock nut
-----
'-@
C9004B
C9002C
Using two thickness gauges, measure the clearance (h) Installation of turbine housing and com
between the turbine back plate and turbine wheel pressor cover
back surface. If the clearance is out of specification,
disassemble and check to locate the cause.
NOTE:
Be sure to use two thickness gauges and
take measurement at the tip of the blades. Alignment mark
Compressor cover
Snap ring
Coupling assembly
B2819E
B4468A
1) Tighten the coupling assembly to specified tor
que.
Check by the following procedures. 2) Hammer the coupling assembly all around.
3) Tighten again the coupling assembly to specified
1) Move up and down the compressor wheel to
torque.
measure runout (R)
4) After reassembly, turn the turbine wheel and
NOTE: compressor wheel by hand and check for smooth
Do not measure runout by turning the rotation.
compressor wheel. If the wheels turn heavily, or bind, disassemble, and
2) Measure compressor cover inside diameter (D) locate the cause of trouble.
'and compressor wheel outside diameter (d) at places
indicated in the illustration.
3) Calculate the clearance by the equation given
below.
If it is out of specification, disassemble and check
again.
Clearance 1/2(0 - d - R)
15-24
5.4.2
INTAKE AND EXHAUST - SERVICE PROCEDURES
covering layer,
Interference with
turbine wheel, damage
24
\ 20 7
NOTE:
1. Make alignment marks to clarify the positional rela 2. The compressor wheel and turbine wheel blades are
tionships among the compressor cover, bearing hous• easily bent. Use care not to allow them to fall and not
ing and turbine housing before disassembly. to strike them.
3. Do not remove the two pins of the bearing housing.
84265A
[email protected] Parts phone: 269 673 1638 15-25
Bl INTAKE AND EXHAUST - SERVICE PROCEDURES
Disassembly Procedure When the snap ring holding the bearing in position is
to be removed, use pliers (tip diameter 1 mm) to
prevent damage to the insid.e of the bearing housing.
Pliers
B4266A
,al���
(New piston ring to
j
be used for measurement!
!:>'
NV O o O
Clean
.... ·. �,£:t\
�
L 3.3
Clean
�
Bearing journal potion 0.0.
L 14.254
Shaft runout
(total indicator reading)
0.015
15-26
(a) Measurement
INTAKE AND EXHAUST - SERVICE PROCEDURES
New
piston ring
C8914A C8916A
Install a new'piston ring in the piston ring groove and Measure the piston ring groove width of the flinger
measure the clearance. sleeve.
If the reading is more than the limit, replace the shaft If the reading is more than the limit, replace the
and turbine wheel. flinger sleeve.
15-27
•
(3) Reassembly
INTAKE AND EXHAUST - SERVICE PROCEDURES
7
Engine oil
to be applied
10
Engine oil
to be applied
faced
13
Clearance between shaft and
4 turbine wheel and turbine
Grease to be applied housing in diametrical direction
to flange area NV 0.15
<Assembly sequence>
25--,24->�3)--22->21->®)-+@
-,18----, 17'
� 1 &-.15--,(11)
NOTE:
&-.7
1. The piston ring should always be replaced with a new
->13->12
one. J 9--> 8->5-> 4-, 3->2-> 1
Since it is easily broken, do not open it more than 11->10
necessary.
2. Apply engine oil to all sliding surfaces before installa· On parts marked o, refer to the assembly procedure described
below.
tion.
3. When the compressor cover and turbine housing are
[email protected]
installed, make sure that their alignment marks are in
Parts phone: 269 673 1638
alignment with the marks on the bearing housing.
84268A
15-28
Assembly Procedure
INTAKE AND EXHAUST - SERVICE PROCEDURES
Turbine housing
Compressor
�Turbine wheel
wheel
84266A
C8925A
Use pliers (tip diameter 1 mm) in installing snap rings.
NOTE:
Measure each clearance with a thickness gauge to
Install each snap ring with its round side
check that it is within the nominal value.
toward the bearing.
NOTE:
(b) Installing thrust bearing
When a clearance is to be measured, press
the shaft in the axial direction to minimize
Locating pin
the clearance.
Locating hole
15-29
•
5.4.3
INTAKE AND EXHAUST - SERVICE PROCEDURES
<Disassembly sequence>
G) Turbine housing 6 Flinger sleeve 11 Bearing housing
0 Compressor cover 7 Piston ring 12 Shaft and turbine wheel
3 Compressor wheel 8 Oil deflector 13 Piston ring
4 Snap ring 9 Thrust ring 14 Turbine backing plate
5 Insert 10 Thrust bearing 15 Bearing
NOTE:
1. Before disassembly, make alignment marks to indi·
cate the positional relationships among the compress
or cover, bearing housing and turbine housing.
2. The compressor wheel and turbine wheel blades are
easily bent. Use care not to allow them to fall and not
to strike them.
3. Do not remove the two pins of the bearing housing.
B9029A
15-30
INTAKE AND EXHAUST - SERVICE PROCEDURES
Disassembly Procedure
m
\"•·
89048A
89031A
(b) Remove the compressor cover.
(a) Remove the turbine housing.
NOTE:
Do not drop and strike the compressor
wheel and turbine wheel, as their blades
are readily bent.
15-31
m INTAKE AND EXHAUST - SERVICE PROCEDURES
Clean
·clean
Clean
Clean
Clean
Bearing journal 0.0.
L 11.18
Shaft concentricity
L 0.015
(total gauge reading)
Clean
Bearing hole diameter
L 19.06
NOTE:
The parts may be cleaned by use of a blast
equipment or any other effective methods, but a non·
corrosive neutral detergent should be used.
890348
15-32
(3) Reassembly
INTAKE AND EXHAUST - SERVICE PROCEDURES
m
Bend lock washer. Shaft and turbine wheel to
NV ... Nominal Value 17 Nm 11.7 kqfml turbine housing clearance
NV 0.53 to 1.04
12
Shaft and turbine wheel
Non-chamfered side axial play
toward insert NV 0.05 to 0.13
17 to 20 Nm 1
11.73 to 2.07 kgfml
Turbine backing plate to
shaft and turbine wheel clearance
/ I NV 0.74 to 1.55
/ I
/,t,, '"''"' "''
<Assembly sequence>
Gasket
11 - 14 - 13 - 12 - 15 - (H! - 9 - 8
15 5 - 7 - 6 ]-
NOTE:
1. The piston ring should always be replaced with a new
one. Since it is easily broken, do not open it more than
necessary.
2. Apply engine oil to all sliding surfaces before installa•
lion.
3. When the compressor cover and turbine housing are
installed, make sure that their alignment marks are in
alignment with the marks on the bearing housing.
B9037A
15-33
m
Reassembly Procedure
INTAKE AND EXHAUST - SERVICE PROCEDURES
Locating hole
17 Nm
(1.7 kgfm)
B9031A
B9041A
(c) Install the turbine housing tightening the bolts to
(al Apply engine oil to both sides of the thrust the specified torque.
bearing and thrust ring before assembling them on NOTE:
the turbine wheel shaft. Then install the oil deflector. Apply an anti-seizure agent to the cap
NOTE: screw.
Install the thrust bearing with the bronze
side up.
6.9 Nm
(0.7 kgfm)
B9048A
15-34
INTAKE AND EXHAUST - SERVICE PROCEDURES
2
Connector
2 Cover
3 Plate
Damage, water leaks,
4 Core assembly fin contamination,
4 scale and rust
5 Inlet manifold
inside core
5
C9305B
15-35
•
6. TROUBLESHOOTING
INTAKE AND EXHAUST - TROUBLESHOOTING
• Defective turbocharger
• Defective turbocharger
Defective turbocharger
• Oil leaks due to worn piston ring, and/or insert Replace
15-36
•
ENGINE ELECTRICAL
CONTENTS
16-1
ENGINE ELECTRICAL - GENERAL
1. GENERAL
Air heater
Heater relay indicator
<Except 6022-TC>
15
---,_,__
p
lO
Safety relay
(6022-TC)
15
60
0.85
Fuse
''
5
,--1
Ammeter
·c&·
I • '
i Battery
switch
- +
0.85 -=... Battery
0.85 --�
Oil pressure
unit
� _v Thermometer Code size
l 0.85
_5 _
0.85 mm2 or more
5 mm' or more
L_�_j
.1.§_ 15 mm2 or more
60 60 mm2 or more
B1646F
16-2
ENGINE ELECTRICAL - GENERAL
M;1�pH:{!i;
switch
Outer
race Roller Pinion
Field coil
Armature
Pole
Yoke
Pinion �ear B3711A B3703A
B3702A
16-3
ENGINE ELECTRICAL - GENERAL
(3) Operation
Starter switch
Starter relay
Starter relay
Plunger
Plunger
Pinion
Pinion
Ring gear
Ring gear
837098
837088
When the pinion comes into complete mesh with the
While the starter switch is ON, current flows from the ring gear, the contact "P1" closes and the large
terminal "SW" of the starter relay to the terminal "L" current of the battery directly flows to the motor
and closes the contact "P2". section to turn the pinion powerfully.
When the contact "P2" closes, current from the In this condition, no current flows to the pull-in coil.
battery flows from the terminal "S" of the magnetic The plunger is retained by the holding coil alone.
switch to the pull-in coil "P" and holding coil " H".
Furthermore, the current that has decreased flows
from the terminal "M" to the motor section.
The plunger, attracted by the magnetic flux of the
pull-in coil and holding coil, closes the contact "P,"
and simultaneously pushes out the pinion turning
slowly on weak current.
16-4
ENGINE ELECTRICAL - GENERAL
� - ----·------�--
-- - - - - - - - -
� 1.2 ALTERNATOR
( 1 ) 30A, 40A, 80A Alternator
Starter switch
kaj
SW
.--<CS,r>--1� ;�
� -
I
�
- L
Starter relay
,,
82976A
Rotor core
B2702D
16-5
•
(b) Stator
ENGINE ELECTRICAL - GENERAL
(d) Regulator
Stator core
Brush B2708A
B2703A
The regulator alters the strength of the field coil field
to stabilize output power which varies with engine
Togethe� with the rotor core, the stator core forms the
speed fluctuations.
magnetic flux path. The magnetic flux lines in the
The regulator is integral with the brush holder. The
stator core are affected by the passage of the rotor
assembly combines the IC regulator, the brushes and
core field and generate electricity.
the brush springs.
(c) Rectifier
(e) Charging circuit
1) Setting the starter switch to ON
Alternator
B2704A
I
Alternator IR terminal) Alternator (L terminal)
I Ground
16-6
ENGINE ELECTRICAL - GENERAL
Alternator
I
I
I
I
I
I
I
I
r
I
�-��--<E
l
Battery I
E I
I
When the engine is started and the alternator starts The 60A alternator is an open type three-phase
generation so that the voltage at the alternator "B" alternator. The three-phase AC generated in the stator
terminal becomes higher than the battery voltage, the coil is converted into DC by the silicon diodes.
current flows as shown below. A total of 12 diodes (6 on the positive side and 6 on
the negative side) are housed in 6 heat sinks, two in
Alternator each heat sink.
IB terminal!
The alternator generated voltage is controlled by the
regulator.
I Ground I
In this way, battery charge is started and at the same
time, the charge lamp (if provided) goes out.
16-7
ENGINE ELECTRICAL - GENERAL
1.3 SAFETY RELAY The alternator rpm is detected and when it exceeds
the reference level, the safety relay prevents the
starter from operating even if its switch is accidentally
turned on during engine revolution.
B1453A
Operat�on
Battery
switch
Safety l
relay
P, i Battery
-1..
�arter
+ �:lay
To starter 1
B1454A
(1) When the starter switch is set to ON, current flow (3) When the pulse frequency at terminal "P" ex
from the starter relay to terminal "S" and to terminal ceeds the specified value, continuity between termin
"E" of the safety relay, closing contact P1. The charge als "S" and "E" is lost. Then, the starter does not
lamp also illuminates if provided. operate even if the starter switch is set to ON while
(2) As the starter runs and the engine starts running, the engine is running.
pulses of frequency 1110th of the alternator speed
appear at terminal "P" of the alternator. The charge
lamp goes out.
16-8
1.4 REGULATOR (Model R7T01071)
ENGINE ELECTRICAL - GENERAL
r/}:t:I �
i '
even when the battery switch is left closed.
Connections of the alternator to the regulator are
I
A N E B4401B shown below. Following description of operations is
keyed to this figure.
This regulator is combined with the 60A alternator.
Operation of Regulator
Safety relay T
ransistor
Alternator Regulator
I
I
l__
I
__ j
Pilot lamp
'-----+- ---'>----+-----"----'
-
B1891A
(1) The battery switch in ON position causes field power, causing a current to flow in the coil VC1 in the
current to flow in the circuit as follows: following sequence:
Battery - Battery switch - Regulator IG terminal - Resistor R, - Voltage Alternator N terminal -• Regulator N terminal - Coil VC, - Ground
regulator K terminal - Voltage regulator F terminal - Alternator F terminal
- Field coil - Ground
As the coil VC1 is energized, the contact P1 is opened.
(2) When the starter switch is set to ON, the starter In this state, setting the starter switch to ON with the
relay coil is energized with its contact closed. When engine in operation leaves the starter inoperative.
the starter cranks the engine, the alternator generates
16-9
• ENGINE ..ELECTRICAL - GENERAL
(3) While the engine is in operation, field current 1.5 INTAKE AIR HEATER
flows in the following circuits, with alternator output
voltage controlled by the voltage regulator.
Alternator A terminal - Regulator A terminal - Contact P2 -- Voltage Starter
regulator K terminal - Transistor - Regulator F terminal - Alternator F switch Air heater
terminal - Field coil -Ground
B R1 ACC R2 C
OFF
If the transistor remains off too long, the alternator N
terminal output is decreased and the coil VC1 loses its HEAT
r
case.
Air heat er
t
indicator
y
�!\ t��
_ �
� Io �11
�---o_, �I ____,!
Battery
D8803C
16-10
(1) Energize-to-stop Type
ENGINE ELECTRICAL - GENERAL
•
,-·--·-·
-··------------- - - --------�
Solenoid relay
.
- ·-- -
- -
-
i
02
Do
RB
Battery switch
B4926C
(a) Start circuit 4) In the condition of the above item 3), the oil
1) When the battery switch is placed at "ON", pressure rises as the engine speed increases, and the
current flows from the solenoid relay (B) to the RY coil contact of the oil pressure switch is opened and no
and applies the voltage to the collectors of TR4 and voltage applied from R4 to TR1. In this condition, the
TRs but RY does not operate, as there is no input to alternator voltage is applied up to the base of TR1
the base. while the engine is running.
2) Current also flows from the oil pressure switch to (b) Automatic sto·p circuit
the solenoid relay (W) to R4 to Rs and applies the When the thermo switch and oil pressure switch
voltage to the base of TR3. When the voltage is detect an abnormal condition, the circuit operates as
applied to the base of TR3, current flow from R6 to C follows:
and E of TR3 to the ground, and RY does not operate,
1) Solenoid relay @ -• D1 C2 - Ground
as there is no input to TR4 and TRs of the stop circuit. T
L------ VR1 - Base of TR• -
[R6
3) The engine starts, and a voltage of 24V or more is Base of TRs - Ra- Ground
applied from the terminal "L" of the alternator • R• C andEof TR, - Base of TR2 - Ground
r
through VR1 to ZD1 (Zener voltage 24V), and charge L---�• CandEofTR2 _j
begins with the time constant (Oil pressure timer)
determined by VR1 and C1. (At this point the engine 2) Solenoid relay® - RY coil - C and E of TR• and TRs - Ra - Ground
16-11
•
3)
ENGINE ELECTRICAL - GENERAL
Solenoid relay
\....----�
RY
Stop DJ
switch
01
Ro
VR1
16-12
ENGINE ELECTRICAL - GENERAL, SPECIFICATIONS
3) When the RY contacts turn ON: This causes the current to flow from the starter@
Current flows from solenoid relay@ to RY, solenoid switch to oil pressure switch, thermo switch, solenoid
relay©, and the solenoid, activating the solenoid and relay@, RY holding coil H, and to ground, keeping the
starting the engine. RY contacts in ON state.
4) As the engine starts and starter switch is placed in (b) Automatic stop circuit
the ON position, voltage to the solenoid relay® is cut
When the thermo switch and oil pressure switch
off; however, TR1 and TR2 stay ON for approximately
detect an abnormal condition, each switch turns OFF
another 30 seconds by the discharge current of the
and the RY contacts open, deactivating the solenoid
capacitor C. During capacitor C's discharging, the oil
and stopping the engine.
pressure builds up as the engine speed increases,
causing the oil pressure switch to turn ON. (c) Pushbutton stop
To stop the engine during operation, operate the stop
switch, and the stop operation is performed just as
when the automatic stop is performed.
2. SPECIFICATIONS
Item Specification
I l
(Mitsubishi Electric
Corp. products! Model M3T95082 M5T50276 M5T50277 M5T50279
I
mechanism
I I I I I
rectifier
Model A2T A2T A2T A4T A4T A4T A4T A6T A6T
72987 72986 73387 57986 57987 65772 65773 75386 75387
l
Intake air Type
heater
Capacity x )6022, 22· Tl 16022-TCI
quantity 2 kW x 1 0.3 kW x 6
Fuse capacity 91 A
16-13
ENGINE ELECTRICAL - SPECIFICATIONS,
SERVICE STANDARDS
Item Specification
I
Solenoid relay Model !Energize-lo-slop lypel !Energize-to-run typel
(Nikko Denki product) 0-25000-5592 0-25000-6720
3. SERVICE STANDARDS
3.1 SERVICE STANDARD TABLE
Unit:mm
M5T50276 4 to 6
M5T50277
16-14
ENGINE ELECTRICAL - SERVICE STANDARDS
Unit:mm
°
Field coil resistance (at 20 CI Approx. 7.2 !l - Replace.
16-15
• ENGINE ELECTRICAL - SERVICE STANDARDS
Unit:mm
16-16
4. SPECIAL TOOL
ENGINE ELECTRICAL - SPECIAL TOOL,
SERVICE PROCEDURES •
Unit:mm
85021A
"-.--@
Starter
C0118A
16-17
ENGINE ELECTRICAL - SERVICE PROCEDURES
5.1.2 Disassembly
<M3T>
10
9
8 Rotating
condition
6
Roughened commutator surface,
seizure, ridge wear, worn damaged
gear
I 11
13
Worn arid
damaged gear
0
22
23
<Disassembly sequence>
CD Yoke assembly @ Overrunning clutch
2 Rear bracket 14 Packing
3 Brush holder 15 Plate
0 Brush spring 16 Spacer
® Brush 17 Lever
6 Armature 18 Collar
*7 Front bearing *19 Gear shaft bearing
*8 Rear bearing @ Ring
® Magnetic switch @ Pinion stopper
10 Center bracket 22 Front bracket
@ Gear bracket * 23 Sleeve bearing
@ Gear shaft
16-18
ENGINE ELECTRICAL - SERVICE PROCEDURES
<M5T>
,---------- -- --- - - -
--------------- ----------------- -----,
14
15
2
Worn and
19 damaged gear 3
Deposited brush power,
uneven wear, movement
1 of brush in holder
Mounted condition of
ball and field coil
<Disassembly sequence>
16-19
ENGINE ELECTRICAL - SERVICE PROCEDURES
Front bracket
assembly
Gear bracket
mounting bolt
829548
Front bracket
Gear bracket
829518
Ring
829638
82957A
16-20
ENGINE ELECTRICAL - SERVICE PROCEDURES
NOTE:
Overrunning clutch
t Gear bracket
Gear shaft
Gear shaft
82959A
84141A
(d) Remove the overrunning clutch and gear bracket
When the ring is removed, keep the gear from the gear shaft.
shaft in overhanging condition. (4) Removal of Brush Spring
Ring
�
u-
Brush spring
�'---- Pinion stopper
82958A 82549A
(c) Remove the ring from the ring groove of the gear To remove the brush spring, first release the brush
sh9ft. Remove the pinion stopper from the gear shaft. spring and remove the brush.
16-21
•
5.1.3 Inspection
ENGINE ELECTRICAL - SERVICE PROCEDURES
Item NV L
Commutator M3T 38.7 38.1
outside diameter
M5T 43.2 42.2
0 0
Coil earth test
Open circuit test
Item NV
NV Nominal Value
Limit Brush spring 25 to 34 N 18 N
tension (2.5 to 3.5 kgf) (1.8 kgf)
M5T 23 14
Insulation test
B1104E
16-22
ENGINE ELECTRICAL - SERVICE PROCEDURES
07507A
07508A
16-23
ENGINE ELECTRICAL - SERVICE PROCEDURES
82563A
075098
D7512C
16-24
ENGINE ELECTRICAL - SERVICE PROCEDURES
u
(a) Coil open circuit test
<MST>
M terminal
M terminal 8 terminal
/
D7513A S terminal
82586K
Measure the installed load of the brush spring. Using
a new brusli read the load at the moment the spring Check that there is a continuity across "S" and "M"
leaves the brush. terminals.
If the spring tension is below the limit, replace the If there isn't, replace the magnetic switch.
spring.
(5) Brush Holder Insulation Test
82586J
16-25
• ENGINE ELECTRICAL - SERVICE PROCEDURES
M terminal
(or B terminal)
829608
Check th.at there is no continuity across "B" and "M" Install the gear shaft to the overrunning clutch and
terminals. If there is, replace the magnetic switch. check to see if the gear shaft turns smoothly when
(c) Loose contact test turned clockwise (in the drive direction) and locks
when turned counterclockwise.
If any unusual condition is noted, replace the overrun
ning clutch.
(8) Adjustment of Gear Shaft Thrust Gap
825878
829648
16-26
ENGINE ELECTRICAL - SERVICE PROCEDURES
Armature
Cylindrical
block
B2576B
Bearing 07503A
Using the bearing puller, remove the bearings from
If the bearing of the gear shaft is defective, put a pin the armature.
or bolt in each of the four holes (6 mm in diameter) in (Installation)
the internal gear and press down the bearing out of
position with a press.
(Installation)
Inner ra
�
,'\
,
. .
- .
Install the rear bearing by striking its inner race
B2962A
uniformly with a soft hammer.
/� '"""' rnce
mt��
Pipe
B2578A
<M3T>
14
16
18
Apply grease *2.
21 20
8 4 5
Assembly sequence
(Recommended greases)
*1: Mystik JT-6 (Kyodo Yushi) '.2�23
or equivalent ([� 19----,@-,(1}-,@-+ _,
*2: MULTEMP MS-2 (Kyodo Yushi)
fT>--->(ll\
or equivalent
*3: MULTEMP HD-2 (Kyodo Yushi)
or equivalent
-16� ,� 1: '�®['
*4: MOLYCOAT AS-19 (Dow Coning) 6---> 7---,8
or equivalent
3___, 5---> 4---> i
D7548C
16-28
ENGINE ELECTRICAL - SERVICE PROCEDURES
<M5T>
•1 grease to
be applied
9
I
•2 grease to
be applied
17
2
•2 grease to
3 5 6 7 19 13 be applied
M5T50279 1 to 3
•2 grease to
be applied M5T50276 4 to 6
M5T50277
NV... Nominal Value Gear shaft thrust gap
NV 0.1 to 0.5
(Recommended grea.ses)
*1: Mystik JT-6 (Kyodo Yushi)
or equivalent
*2: MULTEMP MS-2 (Kyodo Yushil
or equivalent <Assembly sequence>
*3: MULTEMP HD-2 (Kyodo Yushi)
or equivalent 11 i._.16-,(i 1,-.:1 J'->lla-1.1 )'->(is
*4: MOLYCOAT AS-19 (Dow Coning) 19-,20�
l____,_
or equivalent
-,1�1�9·· ·
6--, 7-,3 5
2
3-,��11:
890738
16-29
ENGINE ELECTRICAL - SERVICE PROCEDURES
Reassembly Procedure
The reassembly procedure for the M3T95082 starter is
described. On the other starters, only the differences Ring
�
are described.
(1) Reassembly the Gear Shaft, Overrun t--��Gear shaft
Ring groove
ning Clutch, and Gear Bracket in the
Following Way
Overrunning clutch
82968A
Gear bracket
Gear shaft
(c) Fit the ring into the ring groove in the gear shaft.
Grease
(MULTEMP MS-2
or equivalent)
829598
82969A
Pinion stopper
(d) Pull hard the pinion gear toward the ring and
IEjJ �....--1���
J> secure it by fitting the ring into the ring groove in
Gear shaft pinion stopper.
(2) Installation of Lever
(a) Collar fixed type <M3T>
Front bracket
82967A
82956C
16-30
ENGINE ELECTRICAL - SERVICE PROCEDURES
B2956D
B2952C
Insert the lever in the direction shown and mount it
B terminal S terminal
with the pin· from outside the front bracket.
(3) Installation of Overrunning Clutch and
Gear Shaft
Overrunning
clutch
Front bracket
<M3T> <M5T>
B4538B
Grease
(Mystik JT-6
or equivalent) B2955E
16-31
ENGINE ELECTRICAL - SERVICE PROCEDURES
(5) Installation of Yoke Assembly (a) Wire the reassembled starter as shown above.
(b) Turn ON switches K 1 and K 2 to project the pinion.
(c) Turn OFF switch K 2 to stop pinion from rotating.
Pinion
_ ;,,.:
'r-+'l
':
I I- I
I:
�J - ,l---j ��I
I ::
1
:: :1
I' 11
I J , I I 11
rI I I , ,,
r--
82697A
NOTE:
When the yoke assembly and center brack·
Model Nominal Value
et are mounted, the locating notch should
M3T95082 1 to 3
be aligned with the projection. M5T50279
M5T50276 4 to 6
5.1.5 Inspection and Adjustment after M5T50277
Reassembly
(1) Inspection of Pinion Gap 800540
Switch K2
Battery
Switch K1
S terminal M terminal
16-32
ENGINE ELECTRICAL - SERVICE PROCEDURES
NOTE:
m
1. Use a wire as thick as possible and
Washer secure each connection firmly.
Magnetic switch 2. Apply voltage gradually from OV up to
24V.
(b) Measure the current and rotating speed when the
specified voltage is applied. If the measurement is out
of specification, replace the starter.
Measure the rotating speed by illuminating the pinion
with strobe light.
Washers
0.25, 0.5, 1.0 mm (c) Gradually increase the voltage from OV and
measure the voltage when the pinion springs out and
(2) Inspection of No-load Characteristics
turns.
and Magnetic Switch Operating Vol·
If the voltage exceeds the specification, replace the
tage
starter.
<M3T>
Ammeter Voltmeter Battery Nominal value 16V or less
(magnetic switch opera! ng voltage)
<MST> 836218
Ammeter Voltmeter Battery
B3621E
16-33
ENGINE ELECTRICAL - SERVICE PROCEDURES
�--11
Inspection Procedure
S B
L terminal . mal
l ,.,m
�
"
� :: SW
terminal
U1T07076
L
D8002A
B terminal Coil resistance
S terminal NV 10.4 n (24V, 20° c)
(1) Check for continuity between the SW and L
D8003H
terminals and check to ensure that the coil resistance
<Model \J1T06071>
is up to specification.
(2) Check to ensure that when the battery voltage
(24V) is applied across the SW and L terminals, there
is continuity between the 8 and S terminals.
D8003D
V-belt
B0104H
16-34
5.3.2
ENGINE ELECTRICAL - SERVICE PROCEDURES
Disassembly
•
�--------------·--·- ------------··----- ----------------�
-
2
<Disassembly sequence>
(1) Rear bracket assembly 11 Spacer
(2_i Stator 12 Rotor assembly
(31 Rectifier 13 Spring
@ Rectifier <80A only> *14 Rear bearing
({l Regulator assembly @ Rotor
® Brush (16) Front bracket assembly
(fl Brush spring 17 Cover
7 Rear bracket 18 Cover
8 Pully and fan *19 Front bearing
@ Pulley (2g Front bracket
@ Fan
Parts marked with • should not be removed unless defects are
evident.
For parts with an encircled number, refer to Disassembly Procedure
that follows. B3907E
16-35
ENGINE ELECTRICAL - SERVICE PROCEDURES
Disassembly Procedure
(1) Separation of Front Bracket Assembly
from Rear Bracket Assembly
D8107H
Remove the through bolt and, using a screwdriver, (2) Removal of Pulley
pry off the front bracket assembly from the rear
bracket assembly.
NOTE:
Fan
Bearing box
Front bracket
Rotor
B1029Z
Rotor 810290
16-36
ENGINE ELECTRICAL SERVICE PROCEDURES
Rectifier
Stator
B3909A
16-37
•
5.3.3 Inspection
ENGINE ELECTRICAL - SERVICE PROCEDURES
Description NV L
Ground test
NV 0.32 to 0.44 kg
L 0.2 kg
Open circuit test
Ground test
83907F
16-38
ENGINE ELECTRICAL - SERVICE PROCEDURES
081300
08058A
Check that there is no continuity between the slip ring
Check that there is continuity across stator leads. If and core.
there is no continuity indicating a broken wire, If there is, replace the rotor as it is grounded.
replace the stator. (b) Field coil resistance
(b) Continuity across stator leads and core
081310
080588
Measure the resistance across slip rings. Replace the
Check that there is continuity across the stator leads rotor if the resistance is not within the specification.
and core.
If there is, replace the stator as it is grounded.
16-39
ENGINE ELECTRICAL - SERVICE PROCEDURES
D8132C
Measure �he slip ring O.D. If the slip ring has rough
surface or is unevenly worn, correct with sandpaper
or lathe.
Correction must be made within the limit of slip ring
O.D.
(3) Inspection of Brush and Brush Spring
(a) Inspection of brush
82718A
Cl
C:
.c
V) Wear limit line
08062A
82716A
'•, I
16-40
ENGINE ELECTRICAL - SERVICE PROCEDURES
-:::==1
.-
L:c:: g I
827378
Heat sink
2) When soldering the brush, insert a pin into the
brush hole and fix to the regulator assembly. B2720A
NOTE:
1�=
�I
82722A
16-41
• ENGINE ELECTRICAL
{Installation)
Replace the bearing if defect is evident.
(a) Replacement of front bearing
Apply engine oil.
{Removal)
82728A
Front bearing
Cover
Front bracket
82724A Front bracket
Spacer
82730A
16-42
ENGINE ELECTRICAL SERVICE PROCEDURES
Rear bearing
Apply grease.
Spring
fitting groove
827320
82731 D
Apply a light coat of engine oil to the inside of the
NOTE: bearing and using a press, install with the spring
Use care not to cause damage to the slip fitting groove of the bearing facing the rotor field coil
ring by the bearing puller. side.
16-43
•
5.3.4 Reassembly
ENGINE ELECTRICAL - SERVICE PROCEDURES
135 to 160 Nm
(13.5 to 16.5 kgfm)
19
4
6
B2990L
<80A alternator>
135 to 160 Nm
(13.5 to 16.5 kgfm)
5 19
Components
1: 3, 3A <80A only>, 4, 5, 6, 7
12: 13, 14, 15
16: 17, 18, 19, 20
<Assembly sequence>
16 (20--, 19--, 18--, 17)--,@ (15-, 14-, (jj)) __, 8
(11 -> 10-> 9) --, 2-, 1 (7 _:. © --, 6 --, 5-, (:i) __, (:l)A <80A only>)
16-44
ENGINE ELECTRICAL SERVICE PROCEDURES
B2745A
(a) Push in the brush by hand and insert the pin into
When the rectifiers are to be connected together by the brush hole from the rear of the rear bracket to fix
soldering, do the soldering with the regulator as well the brush.
as the rectifiers mounted to the rear bracket. (b) Noting the spring position of the rotor bearing
mounted to the front bracket side, install the rear
NOTE:
bracket assembly.
When soldering, finish it in a short time
(less than 5 seconds). NOTE:
After completion of reassembly, be sure to
(2) Installation of Spring
remove the pin and close the hole.
Minimize spring
projection
D8099E
16-45
ENGINE ELECTRICAL - SERVICE PROCEDURES
08074A
D80728
D80738
D80768
<40A alternator>
(f) When quick-charging the battery with a quick
charger, be sure to disconnect terminal connections Terminal voltage 27V 27V
in advance. Otherwise, a damaged diode and regula Current 26A or more 37A or more
Voltmeter
B terminal Switch K1
Alter
nator �-----1o----o1�
Variable resistor
'------. Alternator
drive motor B terminal
836238
NOTE:
The on-vehicle test is an easier way of
inspection; the test bench inspection is
Ammeter
necessary for more accurate results.
(3) Inspection of Regulator
(a) Test bench inspection
16-48
5.4
ENGINE ELECTRICAL - SERVICE PROCEDURES
GOA AL TERNATOR
•
5.4.1 Removal and Installation
[Refer to 5.3.1.I
5.4.2 Disassembly
1
,
i 14
�&-
�
. t
<Disassembly sequence>
Cover 10 Stator *19 Pulley
2 Brush holder assembly 11 Plate *20 Fan
3 Brush holder 12 Lead wire assembly 21 Rotor assembly
4 Brush 13 Terminal set @ Rotor
5 Brush spring 14 Connector *23 Rear bearing
6 End cover 15 Condenser Ct}! Front bracket assembly
7 Cover 16 Heat sink set 25 Cover
8 Bolt set 17 Rear bracket *26 Front bearing
9 Rear bracket @ Pulley assembly @ Front bracket
B4539A
16-49
•
5.4.3 Inspection
ENGINE ELECTRICAL - SERVICE PROCEDURES
Description NV L
Field coil Approx. 13 !!
resistance
Open circuit test
Slip ring 0.0. 46 45.4
Ground test
Ground test
3
�
B
;
Short test
Open test
845398
16-50
ENGINE ELECTRICAL - SERVICE PROCEDURES
5.4.4 Reassembly
16
8
11 7
83 to 105 Nm
(8.5 to 11 kgfm)
6 345 to 360 Nm
(35 to 37 kgfm)
27
Components
2: 3, 4, 5
9: 11, 12, 13, 15, 16, 17
21: 22, 23
24: 25, 26, 27
<Assembly sequence>
24 (27 _, 26-, 25) _, 21 (23 _, 22) -• 18 (20-• 19) _, 10 _, 9 ( 17 _, 16
_, 15 _, 13 _, 12 _, 11) _, 14 _, 8 _, 7 _, 6 _, 2 (5 _, 4 _, 3)-, 1
B4543A
16-51
•
5.4.5
ENGINE ELECTRICAL - SERVICE PROCEDURES
F - E Tester shows continuity. No continuity (Brush in poor contact or field coil open-circuited)
Resistance O (Field coil short-circuited)
N - A Tester shows continuity when If tester shows no continuity when (black) is connected to N and
(black) is connec1ed to N and !red) connected to A, all of three ( +) diodes are open-circuited
(red) connected to A. or stator coil open-circuited.
If tester shows continuity when (black) is connected to A and
(red) connected to N, ( >) diodes are short-circuited.
N - E Tester shows continuity when If tester shows no continuity when (black) is connected to E and
(black) is connected to E and (red) connected to N, all three (-) diodes are open-circuited.
(red) connected to N. If tester shows continuity when (black) is connected to N and
(red) connected to E, (-) diodes are short-circuited.
Terminal voltage 28 V
Current 60 A or more
Connector
A�F
N�E
08078A
�-..----..---1 A 1----1-----,
A mmeter Switch
(dual Kt
.
deflection){
T
I
Boltmeter,
_l. Battery
24V
08080A
16-52
ENGINE ELECTRICAL - SERVICE PROCEDURES
------------------;==-=-====-
' ====-==--··'
Res1stanc1: between L and R
1
1
!
�V Approx 200 \! ___ J
S terminal
814538
16-53
ENGINE ELECTRICAL SERVICE PROCEDURES
Air heater
#�
IG F L
f �!\_���
�
NOTE:
This regulator uses a transistor type volt·
age regulator, so the regulated voltage
� � ��p
cannot be changed. If the regulated volt· �--� 1�--v-;--,�I
Battery
age is out of the nominal value, replace the
regulator.
D8803C
16-54
ENGINE ELECTRICAL - SERVICE PROCEDURES
Clearance
NV 0.4 to 0.5 Pointer clearance
NV 1.5 to 2.0
Stop ' :
lever .. ! Extern�l stopper
\ 'I '
Amperage
SW terminal ' r- I ':
08901A
�-1 Lock nut
marked ', -1
!(! Lock Rod
�?df-
'
-�l�\
i n_ u \
Ct�-
/
(1) Check to ensure that there is continuity between
the terminals "B" and "S" when 2.3 A exciting current Operating Stop side
is applied between terminal SW in the figure and side I
I
Before Stroke 27 to 29 mm Cover Battery
body earth. attraction (24V)
Aftere attraction
·cv:{j])·
(2) Check also the heater relay fuse and replace with P.C P.C
new one if it has been burnt out. II· Ammeter
NV 5A or less
When replacing fuses, be sure to use a fuse of H.C H.C
specified capacity.
�
B4121B
(a) Connect the stop lever and solenoid using the rod
and remove the solenoid cover.
(b) Push manually the stop lever to the stop position
and adjust the rod so that the solenoid pointer gap
becomes as specified.
(c) Check that the stop lever to external stopper
clearance is as specified when the stop lever is on the
operation side.
(d) In the state of (c) above, apply specified voltage to
solenoid "B" terminal and check that the pointer gap
and ammeter reading are as specified. (Stop lever
stop side)
(e) Tighten the lock nut of the rod.
(f) Check that the solenoid pointer color has not
changed and then install the cover.
16-55
•
(2) Solenoid Relay
ENGINE ELECTRICAL - SERVICE PROCEDURES
t
Stop timer measurement
DC 24 V B C ST W A
SW@
Terminal voltage
SW©
DC 28.5 V
Solenoic1 or
coil load
30A -, 3A
SW@
SW@
ON
18 l 5"
Oil pressure
timer
SW@
30 l 5"
Stop timer
Test schedule
Description of symbols
SW@ : Snap switch A
SW@ : Snap switch B
SW© : Push switch C D9558A
16-56
(b) On-vehicle inspection
ENGINE ELECTRICAL - SERVICE PROCEDURES
•
Check the solenoid relay according to the following
flowcharts and determine whether it is good or not on
the basis of the terminal voltage, etc. measured in the
individual states.
• The terminal symbols denote those of the sole
noid relay.
• The voltage 24V means the battery voltage.
I Yes
Alternator defective I , 24V
Stop switch defective
16-57
•
(3) Thermo Switch
ENGINE ELECTRICAL - SERVICE PROCEDURES
Engine oil
Testing oil pressure gauge
pressure gauge
Cock A ll) 5, t
"' "' 0
Oil "' "' Q.
u "'
reservoir J----"<�------t---! � "- .;
ro :=; 09562A
.... :-= ::,
UC O
Oil pressure
switch Cock B
(a) Check to ensure that there is continuity between
D9560A
the terminals (i) and @.
(b) Check to ensure that there is no continuity
between the terminals (i) and 0).
(c) Check to ensure that there is continuity between
the terminals© and® and that the coil resistance has
a nominal value.
Operating pressure
NV 69 to 98 kPa (d) Check to ensure that when the battery voltage is
(0.7 to 1.0 kgf cm') or less
applied across the terminals © and ®, there is
continuity between the terminals (i) and 0 and no
continuity between the terminals 0 and @.
09561A
16-58
ENGINE ELECTRICAL - SERVICE PROCEDURES
Eh--�
Clearance Pointer clearance 8 C H S
NV 0.4 to 0.5 NV 1.5 to 2.0
�11·
0
�II· Ammeter
a) Check if the solenoid is energized when switches
H.C H.C NV 1A or less SW1 and SW2 are turned ON.
b) Using a stop watch, measure the time required for
the solenoid to return after switch SW2 is turned OFF.
NV ... Nominal Value
2) Relay holding
84121C a) Turn ON switch SW1 and SW2 and, after the
solenoid is activated, turn ON the switch SW3.
(a) Connect the stop lever and solenoid using the rod b) Turn OFF the switch SW2 and make sure that the
and remove the solenoid cover. solenoid remains activated for more than 34 seconds.
(b) Push manually the stop lever to the operation c) After verifying 2) above, turn OFF the switch SW3
position and adjust the rod so that the solenoid to ensure that the solenoid returns.
pointer gap becomes as specified. In this state, also
ch�ck that the stop lever to external stopper clearance
is as specified.
(c) In the state of (b) above, apply specified voltage to
solenoid "B" terminal and check that the pointer gap
and ammeter reading are as specified. (Stop lever
operation side).
(d) Tighten the lock nut of the rod.
(e) Check that the solenoid pointer color has not
changed and then install the cover.
16-59
m
(b) On-vehicle inspection
ENGINE ELECTRICAL - SERVICE PROCEDURES
Is vol-
Solenoid does not tage 18V or No
operate when key Check battery. more available at Battery defective
switch is set from s terminal with key
ON to START. switch at START
No
ov Solenoid relay
defective
Solenoid defective or
Is there miswired
continuity No
>------------
between emergency --.! Emergency switch
switch termi defective
nals?
I Yes
Wiring defective
Is voltage
Solenoid operates 18V or more
when key switch is available at S Y�e=s�----
>---------- - - ----� Solenoid relay
- -
changed back from defective
START to ON.
I Battery defective
No
16-60
ENGINE ELECTRICAL - SERVICE PROCEDURES
I 24V
Thermo switch or
oil pressure switch
24V
Key switch defective I Solenoid defective
defective
16-61
ENGINE ELECTRICAL - SERVICE PROCEDURES
Engine oil
Testing oil pressure gauge
pressure gauge
Item NV
Operating 93 to 97°C
temperature
Oil pressure
NV ... Nominal Value switch Cock B
Temperature- �
sensing
portion D9560A
D95598
16-62
ENGINE ELECTRICAL - TROUBLESHOOTING
6. TROUBLESHOOTING
.
l Defective wiring
Defective starter wiring Correct
• Worn brush
• Defective rectifier
• Defective regulator
16-63
ENGINE ELECTRICAL - TROUBLESHOOTING
16-64
CLUTCH
CONTENTS
CAUTION:
When servicing clutch assemblies or components, do NOT create dust by
sanding or by cleaning clutch parts with a dry brush or with compressed
air. (A water dampened cloth should be used).
The clutch disc contains "Asbestos Fibers" which can become airborne if
dust is created during service operations. Breathing dust containing
"Asbestos Fibers" may cause serious bodily harm.
21-1
fD CLUTCH - GENERAL
1. GENERAL
Strap plate
Release lever
support
The clutch is a dry single disc type which transmits is performed, the pressure spring force causes the
and disconnects engine power through the clutch pressure plate to press the clutch disc against the
shift shaft. engine flywheel to transmit power.
When the operation for clutch disengagement is The clutch consists of a clutch disc, pressure plate and
performed, the clutch release lever is pushed. Since release lever assembly. The clutch disc has a woven
the clutch release lever pivots round the release lever facing.
pin in the release lever support provided in the clutch The drive system is the strap drive type which uses a
.cover, the pressure spring is compressed, causing the strap plate between the clutch cover and pressure
clutch disc clamped between the engine flywheel and plate to couple them. This system insures smooth
pressure plate to become free and cuts transmission engagement and disengagement of the clutch.
of power. When the operation for clutch engagement
21-2
2. SPECIFICATIONS
CLUTCH - SPECIFICATIONS, SERVICE STANDARDS
m
Clutch [Option]
Item Specification
·------+-- --------- ---�--- - -
--- -
--- -
Clutch 160221 16022-T, TCI
Type Dry single disc coil spring type Dry single disc coil spring type
Model C10W41 or C12W43 C12W43
Facing Material Woven Woven
0.0. x 1.0. mrn 410 x 250 or 430 x 250 430 X 250
Bearing case Type Direct-coupled type
Model PC12
3. SERVICE STANDARDS
3.1 SERVICE STANDARD TABLE Unit: mm
Clutch Depth from facing surface to rivet head 2.2 to 2.8 0.2 Replace.
disc
Flatness 0.6 or less - Replace.
Clearance between release lever pin and bushing 112.71 0.3 Replace.
0.06 to 0.15
Clearance between strap plate and strap bolt 112.21 0.3 Replace.
0.01 to 0.11
Pressure plate and lever assembly mounting bolt M10 x 1.5 32 to 49 (3.3 to 5.0)
21-3
fD CLUTCH - SPECIAL TOOL
4. SPECIAL TOOL
Unit:mm
E0012B
E0007A
37 ±
55
Stopper bolt 43502-39100
M10 x 1.25
30
�
E0005B
21-4
CLUTCH - SERVICE PROCEDURES
fD
5. SERVICE PROCEDURES NOTE:
5.1 REMOVAL AND INSTALLATION 1. Before removing the clutch, be sure to
install the stopper bolt and plain
(1) Removal
washer to prevent the strap plate from
�--- - ---- ---- - -----
- - --
· being damaged.
2. Use the stopper bolt (M10 x 1.25 - 85
with effective length 30 mm or morel
and plain washer (for M12 threads)
commercially available.
(2) Installation
3 1
Flywheel -- -�
Clutch Alignment
Arbor 03726-21000
E0187A
1. Bearing case assembly
2. Pressure plate & lever assembly
(a) Install the clutch disc using the special tool, Clutch
3. Clutch disc assembly
E0755A Alignment Arbor.
NOTE:
When installing the clutch disc, make sure
that it is installed in the correct direction:
install it so that· its side with the part
number stamped is visible.
21-5
fD CLUTCH - SERVICE PROCEDURES
E0756A
21-6
CLUTCH - SERVICE PROCEDURES
fD
5.2 CLUTCH PROPER
5.2.1 Disassembly and Inspection
Squareness Squareness
NV 3.5 or less NV 3.2 or less
L 5.2 L 4.8
<Disassembly sequence>
(1) Clutch disc assembly 9 Release lever pin
(2) Strap bolt 10 Return spring
°
!J l Lock bolt 11 Release lever support
(4) Lock plate 12 Release lever pin
(SJ Support nut 13 Release lever subassembly
(6) Clutch cover (with strap plate) 14 Bushing
(]) Pressure spring (15) Pressure plate
8 Spring seat
21-7
fD CLUTCH - SERVICE PROCEDURES
----�
Strap bolt
Stopper bolt
1rn
Assembled
rd:
(4 places) thickness
E0860A E0694A
(a) Compress the pressure spring with the stopper Measure the assembly thickness of facing and the
bolts and, at the same time, remove the strap bolts, depth from facing surface to rivet head or cup head. If
support nuts, and other parts. the measurement is below the limit, replace the clutch
disc assembly.
Clutch Installer
MH061331
(b) Flatness of clutch disc
Dial gauge
Clutch disc
21-8
CLUTCH - SERVICE PROCEDURES
fD
(c) Clutch disc runout (3) Inspection of Pressure Plate
(a) Measurement of thickness
E0696A
Pressure plate
E0438A
Using the runout tester, measure the clutch disc
runout. If tlie measurement exceeds specification, Measure the pressure plate thickness and, if it is
correct or replace the clutch disc. below the limit, replace.
(d) Spline play in turning direction (b) Measurement of flatness
E0697B E0439A
Using a piano wire, measure the play in the turning Measure the flatness of the pressure plate friction
direction of the clutch disc hub splines and bearing surface. Regrind or replace if the limit is exceeded.
case clutch shaft. If the limit is exceeded, replace the
clutch disc.
21-9
fD CLUTCH - SERVICE PROCEDURES
(c) Strap bolt fitting hole I.D. (5) Inspection of Pressure Spring
Pressure spring
E0440A E0487A
Measure. the 1.0. or strap bolt fitting hole in the Measure the free length, squareness, and installed
pressure plate and, if the limit is exceeded, replace. load of the pressure spring. If the measurement is
below the limit, replace the spring.
(4) Inspection of Release Lever
E0441A
21-10
5.2.2
CLUTCH - SERVICE PROCEDURES
<Assembly sequence>
IJY12]
14
--,11-9-10- a.�7-6-,5-4-,3-2--·1
15-
For parts with an encircled number, refer to Reassembly Procedure
that follows. E0754B
Reassembly Procedure
21-11
fD CLUTCH - SERVICE PROCEDURES
Stopper bolt
E0860A
(3) With the pressure spring compressed by the (4) After installing the clutch, check the clutch cover
stopper bolts, install the strap bolt, support nut, and and release lever for height using the special tool,
other parts. Clutch Lever Aligner.
Clearance
BO 30 mm
NV 0.03 to 0.08 mm
Rotating condition, L 0.2 mm
<Disassembly sequence> wear, damage, seizure
NOTE:
Parts marked * should not be removed unless they are to
be replaced.
E0760A
21-12
5.3.2 Reassembly
CLUTCH - SERVICE PROCEDURES m
Apply sealant
THREE BOND 1102C or equivalent
� -
--- -
-- --·
- -- - -
-' < Assembly sequence>
Installation of Needle Roller Bearing Using special tool, the Needle Roller Bearing Installer,
install the needle roller bearing in the housing.
The needle roller bearing should be pressed in up to
the specified dimension with the oil seal side inward
and the inscribed side outward.
NOTE:
When installing the needle roller bearing,
direct the lip in the correct direction.
Needle roller bearing
Inscribed side
(dust seal side)
Needle Roller Bearing Installer
44590-12600
Installing -
direction
Dust seal -
�/L\i;;;;;;;;;;;;�;;;;;�lj_J
3 to 5
E0762A
21-13
fD CLUTCH - TROUBLESHOOTING
6. TROUBLESHOOTING
.
disengaged
Damaged or poorly lubricated pilot bearing Replace or lubricate
• Worn facing
21-14
CLUTCH - TROUBLESHOOTING
m
Symptom Probable cause Remedy Ref. group
21-15
m
SPECIAL EQUIPMENT
CONTENTS
61-1
•
1. GENERAL
SPECIAL EQUIPMENT - GENERAL
( 1) Air Compressor
From oil
cooler
,�
84809A 84810A
� - - -- - ---- - - -
----
- - - -
- -
- - - -
- -
- - - - -- - - - - - - - - '
- -
I
The air compressor, installed at the flywheel housing
on the left side of engine, is driven at one-half the
engine speed by the timing gear train (injection pump From oil cooler
61-2
SPECIAL EQUIPMENT - GENERAL m
From
jHPss11re Snap rmq
Cylinder head
quidc
Delivery valve
Unloader volve To air tank
holder ------ sprinn
0-ring
Suction valve
spring
Delivery valve spring
Delivery valve
seat
B4812A
B4814A
B4813A
61-3
m SPECIAL EQUIPMENT - GENERAL, SPECIFICATIONS
(2)Pressure Governor
To air compressor
unloader Low pressure
..
valve
Valve body·
Diaphragm
2. SPECIFICATIONS
Item Specification
Air Compressor
Type Water-cooled 1-cylinder type Water-cooled 2-cylinder type
Cylinder diameter x stroke mm 85 X 50 80 X 50
Cylinder capacity cc 284 502
Turning direction Clockwise Clockwise
(as viewed from drive side)
Pressure governor
Type Diaphragm type
61-4
3. SERVICE STANDARDS
SPECIAL EQUIPMENT - SERVICE STANDARS
m
3.1 SERVICE STAN DARO TABLE
(1) 1-cylinder Air Compressor
Unit:m m
Suction valve spring Installed load/ 4.4 N (0.45 kgfl/5 3.5 N (0.36 kgtl/5 Replace.
installed length
Delivery valve spring 4.5 N (0.46 kgfl/9.5 3.6 N (0.37 kgfl/9.5
Piston ring groove to compression ring clearance - 0.08 Replace. (Replace piston
rings as a set.I
Fit between piston pin hole and piston pin 1181 0.08 Replace.
Piston pin to connecting rod small end clearance J18J 0.07 Replace piston pin or
connecting rod.
Crankshaft to connecting rod bearing clearance J34J 0.1 Replace. (Replace bearing
for worn plating.I
Suction valve spring Installed load/ 4.4 N (0.45 kgfl/5 3.5 N (0.36 kgfil Replace.
installed length
Delivery valve spring 4.5 N (O 46 kgtl/9.5 3.6 N (0.37 kgfl/9.5
Piston ring groove to piston ring clearance - 0.08 Replace. (Replace piston
rings as a set.I
Fit between piston pin hole and piston pin 1161 0.08 Replace.
Piston pin to connecting rod small end clearance 1161 0.07 Replace piston pin or
connecting rod.
Crankshaft to connecting rod bearing clearance 134) 0.1 Replace. (Replace bearing
for worn plating.)
61-5
ID SPECIAL EQUIPMENT - SERVICE STANDARDS
High pressure valve opening pressure MC802148 +3.4 (+0.35) - Adjust or replace
72 (7.3)
-0.5 (-0.05)
Joint PT 1/8 15 to 20
(1.5 to 2.0)
61-6
4. SPECIAL TOOL
SPECIAL EQUIPMENT - SPECIAL TOOL
m
Air Compressor
Unit: mm
.-W���, -
Suction valve tool MH0612G3 Removal and installation
of suction valve holder
V .:, )
13
B5241A
B5231A
61-7
ID SPECIAL EQUIPMENT - SERVICE PROCEDURES
5. SERVICE PROCEDURES
5.1 AIR COMPRESSOR
5.1.1 Removal and Installation
8
Water outlet pipe
2 Air outlet pipe
3 Unloader pipe A
4 Unloader pipe B (2-cylinder type only)
5 Water inlet pipe
6 Air suction hose (1-cylinder type)
Air suction pipe (2-cylinder type)
7 Oil pipe
8 Air compressor 890508 890518
NOTE:
1. To remove the air compressor, remove
the injection pump beforehand.
2. At installation, the injection pump gear
installed on the air compressor should
be in mesh as specified.
61-8
SPECIAL EQUIPMENT - SERVICE PROCEDURES
Installation of Air Compressor (2) Insert the bolt (M10 x 1.5 about 100 mm long)
from the rear end of the flywheel housing to support
the air compressor. Using the bolt as a guide, insert
the air compressor into the mounting hole of the
flywheel housing. At the position where both ends of
the injection pump gear and idler gear C have
touched each other, align the inscribed line on the
----
rear plate with that on the injection pump gear tooth
-- _,/
surface, and then push the air compressor in.
C0767A
Tachometer sensor or
plug mounting position
(1) Crank the engine to align the stamped mark "1, 6"
on the periphery of the flywheel with the pointer of
the inspection window in the flywheel housing and
put the piston in the No. 1 cylinder of the engine at top
dead center on the compression stroke.
Flywheel housing
If the piston in the No. 1 cylinder is at top dead center
on the compression stroke, the No. 1 cylinder will
have a valve clearance. If both inlet and exhaust Sensor plate projection
valves have no valve clearance, the piston in the No. 6
cylinder will be at top dead center on the compression
stroke. So let the engine rotate 360° .
NOTE:
When the engine is to be cranked, make
Threaded hole
sure that it is cranked manually more than
180° in the normal direction.
C0769A
61-9
m SPECIAL EQUIPMENT - SERVICE PROCEDURES
Sealant to be applied
to threaded portion
(THREEBOND 1211) Hexagonal portion
Sensor plate
24 to 35 Nm
(2.4 to 3.6 kgfm)
Tachometer sensor
Lock nut 24 to 35 Nm
(2.4 to 3.6 kgfm)
N2825A
C0762A
To mount the tachometer sensor, apply sealant to the
To install the tachometer sensor, apply sealant to the threaded portion of the sensor and screw it in until it
threaded portion of the sensor and screw the sensor seats on the sensor plate. Thereafter, back it off
in until the hexagonal portion of the sensor seats. two-thirds of a turn (240° ) (to make 1.0 mm clearance).
Tighten the lock nut to the specified torque.
61-10
5.1.2 Disassembly
SPECIAL EQUIPMENT - SERVICE PROCEDURES
•
[1-cylinder Type)
Settling
L Limit
wear
2 Cracks,
3 wear
Wear,
Cracks
��11;f� ,: 0
damage
2
Scratch. clogged oil hole
J� ���� �
Crankshaft end play
L 1.0
25
<Disassembly sequence>
Sensor plate 11 Spring holder '2f1 Oil ring
2 Injection pump gear 12 Delivery valve spring 22 Snap ring
3 Collar 13 Delivery valve 23 Piston pin
4 Cylinder head 14 Delivery valve seat 24 Piston
5 Stud bolt !15i Suction valve holder 25 Bearing holder
6 Snap ring 16 Suction valve spring 26 Oil seal
7 Unloader valve 17 Suction valve 27 Connecting rod
8 Valve spring 18 Suction valve seat 28 Connecting rod cap
9 Valve guide 19 Cylinder liner 29 Connecting rod bearing
10 Delivery valve holder 1201 Compression ring 30 Crankshaft
31 Crankcase
D9252A
NOTE:
Do not remove the stud bolt unless trouble is evident.
61-11
m
(2-cylinder Type I
SPECIAL EQUIPMENT - SERVICE PROCEDURES
4
Cracks. 23
scratch
Cracks. wear of
bushing, clogged
oil hole
26
Damage of
circle, wear
1
Cracks,
wear
I 30
:�28 Damage of circle. wear
�_
�27
!
29
Wear. damage Crankshaft end play
L 1.0
L Limit
<Disassembly sequence>
1 Sensor plate 11 Delivery valve spring 21 Snap ring
2 Injection pump gear 12 Delivery valve 22 Piston pin
3 Collar 13 Delivery valve seat 23 Piston
4 Cylinder head (1_41 Suction valve holder 24 Bearing holder
5 Snap ring 15 Suction valve spring 25 Oil seal
6 Unloader valve 16 Suction valve 26 Connecting rod
7 Valve spring 17 Suction valve seat 27 Connecting rod cap
8 Valve guide 18 Cylinder liner 28 Connection rod bearing
9 Valve holder (19) Compression ring 29 Crankshaft
10 Spring holder (i_o; Oil ring 30 Crankcase
09253A
The procedures for disassembly of the 1- and 2- procedures for disassembly of the 1-cylinder type are
cylinder types are much the same. So only the described below.
61-12
SPECIAL EQUIPMENT - SERVICE PROCEDURES
Disassembly Procedure
•
D9259A
D9257A
(2) Using Piston Ring Tool (special tool), remove the
(1) Using Suction Valve Tool (special tool), remove compression ring and oil ring from the piston.
61-13
m
5.1.3
SPECIAL EQUIPMENT - SERVICE PROCEDURES
Tension
Load/installed length
NV 4.5 N (0.46 kgfl/9.5
L 3.6 N (0.37 kgfl/9.5
Tension
Load/installed length
NV 4.4 N (0.45 kgf)/5
L 3.5 N (0.36 kgtl/5
Clearance
BD 18
L 0.08
Clearance
BO 18
L 0.07
Clearance
BO 34
L 0.1
Clearance
BD 42
L 0.1
D9252B
61-14
(2-cylinder Type]
SPECIAL EQUIPMENT - SERVICE PROCEDURES •
Tension Load/installed length
NV 4.5 N 10.46 kgfi/9.5
L 3.6 N 10.37 kgfi/9.5
Clearance
BO 16
L 0.08
BD . Basic Diameter
NV.. Nominal Value
L Limit
D9253B
61-15
m SPECIAL EQUIPMENT - SERVICE PROCEDURES
(1) Piston and Cylinder Liner (a) Measure the clearance between the piston ring
groove and compression ring. If the clearance is over
the limit, replace the compression ring or piston.
NOTE:
Measure the clearance all around the pis
ton.
Cylinder liner
Piston measuring direction
measuring direction
D9266A
EB
D9267A
61-16
SPECIAL EQUIPMENT - SERVICE PROCEDURES
m
(c) Measure the crankshaft journal outside diameter
[Crankshah[
Mr.asuring
and bearing inside diameter and calculate the clear
Measuring position direction ance. If the clearance is over the limit, replace parts.
End play
09270A
09269A
61-17
m SPECIAL EQUIPMENT
Unloader valve-----1
tr
Valve guide
D9272A
61-18
5.1.4 Reassembly
SPECIAL EQUIPMENT - SERVICE PROCEDURES
•
(1-cylinder Type]
98 to 115 Nm
(10 to 12 kgfm)
98 to 115 Nm
98 to 115 Nm 1
( 0 to 12 kgfm)
9 (10 to 12 kgfm)
� 10 4
15
6 � 11
"--
/
� Apply 0.2 to 0.3 cc of
THREEBOND Neji Lock
TB13238 or equivalent to
three threads
5
15 to20Nm
(1.5 to2.0 kgfm)
1 23 to25 Nm
(2.3 to2.6 kgfm)
Apply engine oil 215 Nm
to lips (22 kgfml
14 to 18 Nm
/'
(1.4 to1.8 kgfm)
31 30 29 28
<Assembly sequence>
31->30->2 9->ti&'>--.@--,25---,26->24->23->22->@--,@---,1 9_, 5--->4->
3->@--,(i) J
14->13->12->11--,10->18---,17->16->��
8---, 7-->6->9---------��
B3256C
61-19
m
[2-cylinder Type]
SPECIAL EQUIPMENT - SERVICE PROCEDURES
:tT��������19 12
20 13
15 to 20 Nm 15
(1.5 to 2.0 kgfm)
0
23 to 25 Nm
(2.3 to 2.6 kgfm)
<Assembly sequence>
30-+29-->24-->25-->28----,(27)-,�i\1---->23---,22---,21 -,120)----,(19,-.18-,4--,3--,•:i ._., 1)
13_, 12-, i 1-,10-+9_, 17_, 16-> 15-->114f--, J
8---, 7---,&-,5
For reassembly of parts with an encircled number, see procedure given in the
following.
N27538
61-20
SPECIAL EQUIPMENT - SERVICE PROCEDURES
Reassembly Procedure
m
( 1) Assembly of Connecting Rod Face side with letters
stamped lip
( /jk
2nd compression
Alignment marks .,,,.-----t_:::;,< ring ends
Approx. /
/ Jr
_,.,...-----1 Approx.
Position notch in holt head 0 1 120 120"
the connecting rod cap end �
83259A
61-21
m SPECIAL EQUIPMENT - SERVICE PROCEDURES
83251A
83262A
Stake the cylinder head at three places shown over
the suction valve holder. Install the injection pump gear, sensor plate, and nut
as instructed in the figure.
5.2 PRESSURE GOVERNOR
5.2.1 Disassembly and Inspection
Damage, corrosion
Settling, damage
61-22
5.2.2
SPECIAL EQUIPMENT - SERVICE PROCEDURES
5 840808
Testing (3) Slowly decrease the air tank pressure and check
that the air gauge reading starts to increase when the
Pressure governor Air gauge nominal pressure (low pressure valve opening pres
sure) is reached.
For adjustment, use the adjusting screw. After adjust
ment, tighten firmly with the lock nut.
(4) After tightening the lock nut, check again the high
and low pressure valve opening pressures. If they are
out of specification, adjust again.
(5) Install and seal the cover.
61-23
Notes: for 6D22 parts call: Phone: 269 673 1638
or email: [email protected]
Mitsubishi 6D22 Gasket and Seal Reference Page 1 of 28 Valve Stem Seals, Rocker Shaft Bracket Orings,
e
e
e
0 .e
I
Oring under
rC-t
Rocker Shaft Bracket @
� MH096246
I
QValve Stem Seal
CJ M E092685
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 2 of 28 - 6D22 Head Gasket , Cylinder Head Soft Plugs, Injector Tube,
M E998000 Kit
6022 Cylinder Head
Soft Plug Kit
( all soft plugs for 6
cylinder heads )
� Injector Tube
v-ME998605
c= _oring ME998607
( for injector tube )
Sealing Cap
Soft Plug ME99809 �----
g. Sealing Cap
Soft Plug ME99809
Head Gasket
ME998722
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 3 of 28 Injector Gaskets and Seals
Sealing Washer
ME997905
� Injector-Tube
v--ME998605
i
Sealing Washer
ME916490 -===:::::
� //!;'E916402
SealRing
ff
I
r L
�
sealRlog
ME916414
0
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 4 of 28 6D22 Valve Cover Gasket, Seal Grommet,
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 5 of 28 6D22 Exhaust Manifold Gaskets, Seal Rings,
www.6D22.com
Mitsubish i 6D22 Gasket and Seal Reference Page 6 of 28 6D22 Turbo Mounting Gasket, Air Intake Plug Sealing Washer
Gasket,
Turbocharger to
Exhaust Manifold
ME980061
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 7 of 28 6D22 Turbo Lines Gaskets and Sealing Washers
�
Gasket, Turbo Oil
Return Line to
Block
ME977030
�
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 8 of 28 6D22 Intake Manifold Gaskets
-www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Pag_e 9 of 28 6D22 Intake Heater Gaskets
intake heaters.
\�
Intake Manifold Spacers
ME099640 Intake
Manifold Gasket ME999601 Gaskets for
��---, Intake Manifold Spacers
I
P
o _ rHO �-,
·,' ,· 0
--ME099632 Intake
Manifold Gasket
'J
( for engines with intake
manifold heaters )
ME099608 Intake
Heater Element
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 10 of 28 6D22 Rear Crankshaft Seal, Three Types Rear Crankshaft Seal.
Mitsubishi 6D22 Rear Crankshaft Seal Reference Page, Three Types Rear Crankshaft Seal.
1. Rear Crnnkshaft Seal Combined with Four Bolt Retainer Assembly
2. Rear Crankshaft Seal - Two Seal Type
3. Rear Crankshaft Seal - One Seal Type
Gasket ME150048
-- - - --·
r-- --
l. -aI\"\,JJ
I
3092020100 Slinger
ME058232 Retainer
Slinger Assembly for One Oil Seal
www.6D22.com
Mitsubishi 6022 Gasket and Seal Reference Page 11 of 28 6022 Rear Flywheel Housing Gaskets
MF931522 Oring
ME963801 Gasket
ME963782 Gasket,
Plate to block
ME963789 Gasket,
Flywheel housing to plate
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 12 of 28 6D22 Front Crankshaft Seal, Gasket, Side Cover Gaskets.
Slinger ME971034 \
Gasket ME942608
Side Cover Gaskets (3)
ME940057
www.6D22.com
Upper Cylinder L"iner Seals
ME963597
Middle Cylinder Liner
. Seal
ME963608
Lower Cylinder Liner
. Seals
ME963610
Soft Plug
MF998847
www.6D22 .com
Mitsubishi 6D22 Gasket and Seal Reference Page 14 of 28 6D22 Oil Cooler Gaskets and Seals
MF969311 Oring
�
0/
MF969313 Oring
()
'c:JJ ME998629 Sealing Washers
@ ·,
"'5
ti
l@--
� ME998633 Sealing Washer
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 15 of 28 6D22 lntercooler Gaskets and Seals
,�
ME969904 Gasket
ME969849 Gaskets
for Inter Cooler
__,,--�·,
MF969773 Orings
MF969773 Orings
ME969904 Gasket� • .
�
� MF969704 Sealing Washers
L--1
���
�J'\.
� ME969982 Gasket
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 16 of 28 6D22 Injection Pump Oil Line Seals
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 17 of 28 6D22 Oil Pump Gaskets
Sealing Washer
( for oil pan plug )
ME998622 ----
o -sealing Washer
� ( for oil pan plug )
ME998629
www.6D22.com
Mitsubishi 6022 Gasket and Seal Reference Page 19 of 28 6022 Injection Pump Drive Gaskets and Seals
MF969800 Oring
www.6D22.com
Mitsubishi 6022 Gasket and Sea I Reference Page 20 of 28 6022 PTO Orive
. Gaskets and Seals
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 21 of 28 6D22 Water Pump Seals, Thermostat Gasket.
ME979604 Oring
MF906631 Sealing Washer
ME930669 Gasket
for thermostat
MH964114
Water Pump Seal Assy
MH661202 Sealing
Washer
www.6D22.com
Mitsubishi 6D22 Gas ket and Seal Reference Page 22 of 28 6D22 Timmg Gear Orings
MF961701 Oring
MF961694 Oring
www.6D22.com
Dip stick and Block
6D22 Gaskets and O<in gs lo<
Mitsubishi 6D22
Gasket and seal
Referenc e Page 23 of 28 @
ck
Oring, for dipsti
MF9300 06
881
Gasket ME942
g
MF921 633 Orin
m
www .6022.co
Mitsubishi 6D22 Gasket and Seal Reference Page 24 of 28 6D22 Water Manifold Gaskets and Seals.
--
Water Manifold
Oring
ME979604 Sealing Washer
I on water manifold olua \
ME979803
www.6D22.com
Mit,ubi<hl6D22Gasle!andSealRe!erenceP,>ge2�of286D220ilLineSeal,withlntercooler
Mitsubishi 6D22 Gasket and Seal Reference Page 26 of 28 6D22 Parts - Notes
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 27 of 28 6D22 Parts - Notes
www.6D22.com
Mitsubishi 6D22 Gasket and Seal Reference Page 28 of 28 6D22 Parts - Notes
www.6D22.com
Mitsubishi 6D22 Parts Description -
( Partial List ) Reference: www.HeavyEquipmentRestorationParts.com
ME052488 6D22 Bearing Set
ME052489 6D22 Bearing Set
ME052490 6D22 Bearing Set
MF140258 6D22 Bolt
MH000707 6D22 Bolt
MH000714 6D22 Bolt
ME151450 6D22 Bushing, Connecting Rod
ME051187 6D22 Cam Bushing
ME051188 6D22 Cam Bushing
ME051189 6D22 Cam Bushing
ME051190 6D22 Cam Bushing
ME051191 6D22 Cam Bushing
ME051672 6D22 Cam Bushing
ME051673 6D22 Cam Bushing
ME051674 6D22 Cam Bushing
ME051675 6D22 Cam Bushing
ME051677 6D22 Cam Bushing
ME051676 6D22 Cam Bushing
ME051678 6D22 Cam Bushing
ME052330 6D22 Connecting Rod
ME150492 6D22 Connecting Rod
ME150493 6D22 Connecting Rod
ME999365 6D22 Cylinder Head
ME999383 6D22 Cylinder Head
ME999793 6D22 Cylinder Head
ME999969 6D22 Cylinder Head
ME050502 6D22 Cylinder Liner
ME050503 6D22 Cylinder Liner
ME050504 6D22 Cylinder Liner
ME051102 6D22 Cylinder Liner
ME051103 6D22 Cylinder Liner
ME051104 6D22 Cylinder Liner
ME051105 6D22 Cylinder Liner
ME051216 6D22 Cylinder Liner
ME051217 6D22 Cylinder Liner
ME051218 6D22 Cylinder Liner
ME051219 6D22 Cylinder Liner
ME051220 6D22 Cylinder Liner
ME051221 6D22 Cylinder Liner
ME051222 6D22 Cylinder Liner
ME051229 6D22 Cylinder Liner
ME051230 6D22 Cylinder Liner
ME051231 6D22 Cylinder Liner
ME051232 6D22 Cylinder Liner
ME051500 6D22 Cylinder Liner
ME051501 6D22 Cylinder Liner
ME051502 6D22 Cylinder Liner
ME051503 6D22 Cylinder Liner
ME051632 6D22 Cylinder Liner
ME051633 6D22 Cylinder Liner
ME051634 6D22 Cylinder Liner
ME058210 6D22 Cylinder Liner
ME058211 6D22 Cylinder Liner
ME058212 6D22 Cylinder Liner
ME058272 6D22 Cylinder Liner
ME058273 6D22 Cylinder Liner
ME058274 6D22 Cylinder Liner
ME058275 6D22 Cylinder Liner
ME058277 6D22 Cylinder Liner
ME058278 6D22 Cylinder Liner
ME058279 6D22 Cylinder Liner
ME157039 6D22 Cylinder Liner
ME157040 6D22 Cylinder Liner
ME157041 6D22 Cylinder Liner
ME998042 6D22 Cylinder Liner
ME998045 6D22 Cylinder Liner
855315 6D22 Cylinder Liner Cat Excavator
948319 6D22 Cylinder Liner Cat Excavator
961274 6D22 Cylinder Liner Cat Excavator
969730 6D22 Cylinder Liner Cat Excavator
991240 6D22 Cylinder Liner Cat Excavator
994933 6D22 Cylinder Liner Cat Excavator
30922200102 6D22 Damper
ME052337 6D22 Damper
ME068269 6D22 Damper
ME051697 6D22 Exhaust Valve
3110401103 6D22 Exhaust Valve
3120470200 6D22 Exhaust Valve
3120471101 6D22 Exhaust Valve
ME051064 6D22 Exhaust Valve
ME979901 6D22 Exhaust Valve
ME979033 6D22 Front Crankshaft Seal
ME051575 6D22 Head Gasket
ME051618 6D22 Head Gasket
ME051714 6D22 Head Gasket
ME998722 6D22 Head Gasket
ME998770 6D22 Head Gasket
ME059751 6D22 Injection Pump Body
ME722342 6D22 Injection Pump Body
ME726267 6D22 Injection Pump Body
ME726298 6D22 Injection Pump Body
ME727156 6D22 Injection Pump Body
ME742794 6D22 Injection Pump Body
ME050825K 6D22 Injection Pump Rebuild Kit
ME050850K 6D22 Injection Pump Rebuild Kit
ME050861K 6D22 Injection Pump Rebuild Kit
ME059604K 6D22 Injection Pump Rebuild Kit
ME059623K 6D22 Injection Pump Rebuild Kit
ME059629K 6D22 Injection Pump Rebuild Kit
ME157069K 6D22 Injection Pump Rebuild Kit
ME157071K 6D22 Injection Pump Rebuild Kit
ME157227K 6D22 Injection Pump Rebuild Kit
ME157281K 6D22 Injection Pump Rebuild Kit
ME158009K 6D22 Injection Pump Rebuild Kit
ME158010K 6D22 Injection Pump Rebuild Kit
ME158012K 6D22 Injection Pump Rebuild Kit
ME158014K 6D22 Injection Pump Rebuild Kit
ME158241K 6D22 Injection Pump Rebuild Kit
ME158242K 6D22 Injection Pump Rebuild Kit
ME158246K 6D22 Injection Pump Rebuild Kit
ME158247K 6D22 Injection Pump Rebuild Kit
ME050883 6D22 Injector
ME056275 6D22 Injector
ME059621 6D22 Injector
ME998662 6D22 Injector
3090400302 6D22 Intake Valve
3090400401 6D22 Intake Valve
ME051063 6D22 Intake Valve
ME051567 6D22 Intake Valve
ME051696 6D22 Intake Valve
ME979902 6D22 Intake Valve
ME963597 6D22 Liner Seal
ME963608 6D22 Liner Seal
ME963610 6D22 Liner Seal
ME052038 6D22 Main Bearing
ME052045 6D22 Main Bearing
ME052053 6D22 Main Bearing
ME052054 6D22 Main Bearing
ME052055 6D22 Main Bearing
ME052056 6D22 Main Bearing
ME052057 6D22 Main Bearing
ME052069 6D22 Main Bearing
ME150453 6D22 Oil Cooler
ME150866 6D22 Oil Cooler
ME157900 6D22 Oil Cooler
ME157901 6D22 Oil Cooler
ME158045 6D22 Oil Cooler
ME158046 6D22 Oil Cooler
ME051615 6D22 Oil Jet
ME051709 6D22 Oil Jet
3090711400 6D22 Oil Jet
ME998508 6D22 Oil Pan Gasket
ME120351 6D22 Oil Pump
ME054373 6D22 Oil Pump Cover
ME052597 6D22 Piston
ME052023 6D22 Piston
ME052093 6D22 Piston
ME052094 6D22 Piston
ME052115 6D22 Piston
ME052118 6D22 Piston
ME052119 6D22 Piston
ME052120 6D22 Piston
ME052121 6D22 Piston
ME052420 6D22 Piston
ME052421 6D22 Piston
ME052422 6D22 Piston
ME052423 6D22 Piston
ME052424 6D22 Piston
ME052447 6D22 Piston
ME052448 6D22 Piston
ME052449 6D22 Piston
ME052450 6D22 Piston
ME052540 6D22 Piston
ME052541 6D22 Piston
ME052542 6D22 Piston
ME052543 6D22 Piston
ME052588 6D22 Piston
ME052589 6D22 Piston
ME052590 6D22 Piston
ME052591 6D22 Piston
ME052592 6D22 Piston
ME052593 6D22 Piston
ME052594 6D22 Piston
ME052595 6D22 Piston
ME052596 6D22 Piston
ME052598 6D22 Piston
ME052599 6D22 Piston
ME052600 6D22 Piston
ME052601 6D22 Piston
ME052664 6D22 Piston
ME052665 6D22 Piston
ME052666 6D22 Piston
ME052667 6D22 Piston
ME052668 6D22 Piston
ME052669 6D22 Piston
ME052670 6D22 Piston
ME052673 6D22 Piston
ME052674 6D22 Piston
ME052675 6D22 Piston
ME052676 6D22 Piston
ME052677 6D22 Piston
ME052678 6D22 Piston
ME052679 6D22 Piston
ME052730 6D22 Piston
ME052732 6D22 Piston
ME052733 6D22 Piston
ME052734 6D22 Piston
ME052735 6D22 Piston
ME052736 6D22 Piston
ME052791 6D22 Piston
ME052792 6D22 Piston
ME052809 6D22 Piston
ME052810 6D22 Piston
ME052811 6D22 Piston
ME052812 6D22 Piston
ME052813 6D22 Piston
ME052814 6D22 Piston
ME052815 6D22 Piston
ME052818 6D22 Piston
ME052820 6D22 Piston
ME052821 6D22 Piston
ME052822 6D22 Piston
ME052861 6D22 Piston
ME052862 6D22 Piston
ME052863 6D22 Piston
ME052864 6D22 Piston
ME052865 6D22 Piston
ME052866 6D22 Piston
ME052902 6D22 Piston
ME052903 6D22 Piston
ME052904 6D22 Piston
ME052905 6D22 Piston
ME052906 6D22 Piston
ME052907 6D22 Piston
ME052908 6D22 Piston
ME052910 6D22 Piston
ME052911 6D22 Piston
ME052912 6D22 Piston
ME052913 6D22 Piston
ME052983 6D22 Piston
ME052984 6D22 Piston
ME052985 6D22 Piston
ME052986 6D22 Piston
ME052987 6D22 Piston
ME052988 6D22 Piston
ME052989 6D22 Piston
ME052990 6D22 Piston
ME052991 6D22 Piston
ME052992 6D22 Piston
ME052993 6D22 Piston
ME052994 6D22 Piston
ME052995 6D22 Piston
ME058007 6D22 Piston
ME058008 6D22 Piston
ME058009 6D22 Piston
ME058010 6D22 Piston
ME058011 6D22 Piston
ME058012 6D22 Piston
ME058013 6D22 Piston
ME058014 6D22 Piston
ME058049 6D22 Piston
ME058050 6D22 Piston
ME058051 6D22 Piston
ME058052 6D22 Piston
ME058053 6D22 Piston
ME058054 6D22 Piston
ME058055 6D22 Piston
ME058056 6D22 Piston
ME058060 6D22 Piston
ME058061 6D22 Piston
ME058062 6D22 Piston
ME058063 6D22 Piston
ME058064 6D22 Piston
ME058065 6D22 Piston
ME058066 6D22 Piston
ME058336 6D22 Piston
ME058390 6D22 Piston
ME058391 6D22 Piston
ME058392 6D22 Piston
ME058393 6D22 Piston
ME150132 6D22 Piston
ME150134 6D22 Piston
ME150135 6D22 Piston
ME150136 6D22 Piston
ME150137 6D22 Piston
ME150138 6D22 Piston
ME150139 6D22 Piston
ME157020 6D22 Piston
ME157021 6D22 Piston
ME157022 6D22 Piston
ME157023 6D22 Piston
ME157024 6D22 Piston
ME157025 6D22 Piston
ME157026 6D22 Piston
ME158590 6D22 Piston
ME979880 6D22 Piston
ME979881 6D22 Piston
ME979882 6D22 Piston
ME979883 6D22 Piston
ME979884 6D22 Piston
ME979885 6D22 Piston
ME979886 6D22 Piston
ME979887 6D22 Piston
ME979888 6D22 Piston
ME979889 6D22 Piston
861395 6D22 Piston Cat Excavator
960212 6D22 Piston Cat Excavator
969733 6D22 Piston Cat Excavator
969734 6D22 Piston Cat Excavator
969736 6D22 Piston Cat Excavator
969737 6D22 Piston Cat Excavator
1R5828 6D22 Piston Cat Excavator
1R5906 6D22 Piston Cat Excavator
1R5907 6D22 Piston Cat Excavator
1R5908 6D22 Piston Cat Excavator
3091737100 6D22 Piston Ring
3091737101 6D22 Piston Ring
3111702100 6D22 Piston Ring
3111702101 6D22 Piston Ring
ME052029 6D22 Piston Ring
ME052770 6D22 Piston Ring
ME052778 6D22 Piston Ring
ME052794 6D22 Piston Ring
ME052827 6D22 Piston Ring
ME058000 6D22 Piston Ring
ME052124 6D22 Piston Ring Set
ME052125 6D22 Piston Ring Set
ME052126 6D22 Piston Ring Set
ME052127 6D22 Piston Ring Set
ME058128 6D22 Piston Ring Set
ME052787 6D22 Piston Ring Set
ME052790 6D22 Piston Ring Set
ME052889 6D22 Piston Ring Set
ME052890 6D22 Piston Ring Set
ME052891 6D22 Piston Ring Set
ME052892 6D22 Piston Ring Set
ME052893 6D22 Piston Ring Set
ME052894 6D22 Piston Ring Set
ME052895 6D22 Piston Ring Set
ME052896 6D22 Piston Ring Set
ME072788 6D22 Piston Ring Set
ME072789 6D22 Piston Ring Set
ME072790 6D22 Piston Ring Set
ME052750 6D22 Piston Ring Set
ME052885 6D22 Piston Ring Set
ME058004 6D22 Piston Ring Set
ME058046 6D22 Piston Ring Set
ME979870 6D22 Piston Ring Set
ME979871 6D22 Piston Ring Set
ME979872 6D22 Piston Ring Set
ME979873 6D22 Piston Ring Set
ME979874 6D22 Piston Ring Set
ME979875 6D22 Piston Ring Set
ME979876 6D22 Piston Ring Set
ME979877 6D22 Piston Ring Set
ME979878 6D22 Piston Ring Set
3091720010 6D22 Piston Ring Set
861396 6D22 Piston Ring Set Cat Excavator
962014 6D22 Piston Ring Set Cat Excavator
962015 6D22 Piston Ring Set Cat Excavator
990042 6D22 Piston Ring Set Cat Excavator
991648 6D22 Piston Ring Set Cat Excavator
991649 6D22 Piston Ring Set Cat Excavator
991650 6D22 Piston Ring Set Cat Excavator
991651 6D22 Piston Ring Set Cat Excavator
9911652 6D22 Piston Ring Set Cat Excavator
1R5909 6D22 Piston Ring Set Cat Excavator
1R5910 6D22 Piston Ring Set Cat Excavator
1R5911 6D22 Piston Ring Set Cat Excavator
ME150909 6D22 Rear Crankshaft Seal
ME963604 6D22 Rear Crankshaft Seal
ME964441 6D22 Rear Crankshaft Seal
ME979990 6D22 Rear Crankshaft Seal
ME979994 6D22 Rear Crankshaft Seal
ME058006 6D22 Ring Set
ME051051 6D22 Rocker Arm
ME940057 6D22 Side Cover Gaskets
3092020100 6D22 Slinger
ME930669 6D22 Thermostat Gasket
31109-07109 6D22 Thrust Washer
ME051120 6D22 Valve Guide
ME051122 6D22 Valve Guide
ME979603 6D22 Valve Guide
ME979607 6D22 Valve Guide
MH964114 6D22 Water Pump Seal Assembly, Internal
MH037087 Banjo Bolt 6D22
MH037254 Banjo Bolt 6D22
MH037279 Banjo Bolt 6D22
MH037716 Banjo Bolt 6D22
ME705400 Banjo Bolt 6D22 Injector
3092503800 Bearing 6D22
ME719820 Bearing 6D22 Turbocharger
ME052054 Bearing Set
ME052055 Bearing Set
ME052056 Bearing Set
ME052057 Bearing Set
ME052491 Bearing Set
ME520492 Bearing Set
MH052053 Bearing Set
MH040026 Bearing,
ME704268 Bearing, 6D22 Injection Pump
ME704282 Bearing, 6D22 Injection Pump
ME705184 Bearing, 6D22 Injection Pump
ME705283 Bearing, 6D22 Injection Pump
ME719030 Bearing, 6D22 Turbocharger
ME719336 Bearing, 6D22 Turbocharger
ME719337 Bearing, 6D22 Turbocharger
MS556005 Bearing, 6D22 Water Pump
MS556125 Bearing, 6D22 Water Pump
ME152008 Bolt
MF241222 Bolt
MH000714 Bolt
MH000733 Bolt
ME061330 Bolt
MF140260 Bolt
MH000706 Bolt 6D22 Oil Line
MH000713 Bolt 6D22 Oil Line
MH000886 Bolt 6D22 Oil Line
MF300843 Bolt, 6D22
MF303367 Bolt, 6D22
MF303374 Bolt, 6D22
3091900400 Bolt, 6D22 Connecting Rod
ME052765 Bolt, 6D22 Connecting Rod
MF300843 Bolt, 6D22 Cylinder Block
MF300845 Bolt, 6D22 Cylinder Block
MF300847 Bolt, 6D22 Cylinder Block
MF300851 Bolt, 6D22 Cylinder Block
MF303365 Bolt, 6D22 Cylinder Block
MH000706 Bolt, 6D22 Cylinder Block
MH000713 Bolt, 6D22 Cylinder Block
MH000727 Bolt, 6D22 Cylinder Block
MF300896 Bolt, 6D22 Engine Mount
MH000727 Bolt, 6D22 Engine Mount
MH000843 Bolt, 6D22 Engine Mount
MH000923 Bolt, 6D22 Engine Mount
MH000392 Bolt, 6D22 Exhaust
MH000679 Bolt, 6D22 Exhaust
ME052691 Bolt, 6D22 Flywheel
ME052693 Bolt, 6D22 Flywheel
MF100031 Bolt, 6D22 Flywheel Housing
MF240050 Bolt, 6D22 Flywheel Housing
MF300841 Bolt, 6D22 Flywheel Housing
MF300843 Bolt, 6D22 Flywheel Housing
MF300847 Bolt, 6D22 Flywheel Housing
MH000924 Bolt, 6D22 Flywheel Housing
MH000927 Bolt, 6D22 Flywheel Housing
MH000928 Bolt, 6D22 Flywheel Housing
MF243649 Bolt, 6D22 Flywheel Housing,
MH000925 Bolt, 6D22 Flywheel Housing,
MH000929 Bolt, 6D22 Flywheel Housing,
MH000999 Bolt, 6D22 Flywheel Housing,
ME704150 Bolt, 6D22 Injection Pump
ME705216 Bolt, 6D22 Injection Pump
ME705267 Bolt, 6D22 Injection Pump
ME705295 Bolt, 6D22 Injection Pump
MH000714 Bolt, 6D22 Intake
MH000835 Bolt, 6D22 Intake
MH000716 Bolt, 6D22 Intake
MH000732 Bolt, 6D22 Intake
MH000872 Bolt, 6D22 Intake
MH001419 Bolt, 6D22 Intake
MF140020 Bolt, 6D22 Intake Heater
MS146006 Bolt, 6D22 Oil Cooler
MS146008 Bolt, 6D22 Oil Cooler
MS146014 Bolt, 6D22 Oil Cooler
MS146016 Bolt, 6D22 Oil Cooler
MS146310 Bolt, 6D22 Oil Cooler
MF140011 Bolt, 6D22 Oil Line
MF140013 Bolt, 6D22 Oil Line
MF140002 Bolt, 6D22 Oil Pan
MF300841 Bolt, 6D22 Oil Pan
MF300843 Bolt, 6D22 Oil Pan
MH000707 Bolt, 6D22 Oil Pan
MH000830 Bolt, 6D22 Oil Pan
MH001103 Bolt, 6D22 Rocker Cover
MH000377 Bolt, Crankshaft Pully
MH000922 Bolt, Damper
MF000729 Bolt, Exhaust
MF101314 Bolt, Exhaust
MF101316 Bolt, Exhaust
MF140287 Bolt, Exhaust
MF241278 Bolt, Exhaust
MH000679 Bolt, Exhaust
MH000713 Bolt, Exhaust
MH000922 Bolt, Exhaust
ME051712 Bolt, for oil jet
ME061330 Bolt, Main Cap
ME150511 Bracket, 6D22 Rocker Shaft
3090402200 Bushing, 6D22
3092502901 Bushing, 6D22
ME034549 Bushing, 6D22
ME052660 Bushing, 6D22
ME052843 Bushing, 6D22
ME062905 Bushing, 6D22
ME704596 Bushing, 6D22 Governor
ME704606 Bushing, 6D22 Governor
ME704658 Bushing, 6D22 Governor
ME704981 Bushing, 6D22 Governor
ME730138 Bushing, 6D22 Governor
ME730139 Bushing, 6D22 Governor
ME704055 Bushing, 6D22 Injection Pump
ME704057 Bushing, 6D22 Injection Pump
ME051209 Camshaft,
ME151299 Camshaft,
ME704094 Camshaft, 6D22 Injection Pump
ME704147 Camshaft, 6D22 Injection Pump
3000424302 Cap
ME031518 Check Valve, Oil Jet Bolt,
ME062573 Collar
3092504400 Collar
3097521400 Compressor Piston
ME052330 Connecting Rod
ME052763 Connecting Rod
ME052825 Connecting Rod
ME052919 Connecting Rod
ME052920 Connecting Rod
ME052921 Connecting Rod
ME052922 Connecting Rod
ME052923 Connecting Rod
ME052924 Connecting Rod
ME052925 Connecting Rod
ME052925 Connecting Rod
ME052926 Connecting Rod
ME052927 Connecting Rod
ME052928 Connecting Rod
ME052929 Connecting Rod
ME052930 Connecting Rod
ME052931 Connecting Rod
ME052932 Connecting Rod
ME052933 Connecting Rod
ME052934 Connecting Rod
ME052935 Connecting Rod
ME052936 Connecting Rod
ME058044 Connecting Rod
ME058057 Connecting Rod
ME058057 Connecting Rod
ME157019 Connecting Rod
ME979975 Connecting Rod
ME157019 Connecting Rod
ME157996 Connecting Rod
3091902102 Connecting Rod Bearing, Lower
ME052334 Connecting Rod Bearing, Upper
ME056100 Coupling, 6D22 Injection Pump
ME056242 Coupling, 6D22 Injection Pump
ME058609 Coupling, Exhaust Pipe
ME150441 Cover, 6D22 Oil Cooler
ME157904 Cover, 6D22 Oil Cooler
ME158055 Cover, 6D22 Oil Cooler
ME996339 Crankshaft 6D22
ME998340 Crankshaft 6D22
ME719270 Deflector, 6D22 Turbocharger
ME062523 Director, Cylinder Head Water 6D22
MF472407 Dowel Pin, 6D22 Crankshaft
MF472405 Dowl Pin 6D22 Flywheel
ME153170 Element, 6D22 Oil Cooler
ME153172 Element, 6D22 Oil Cooler
ME964223 Exhaust Manifold Gaskets 6D22
ME964643 Exhaust Seal Rings 6D22
ME150048 Flywheel Housing Gasket
ME062828 Flywheel Ring Gear
ME942608 Gasket
ME969980 Gasket
ME977030 Gasket
ME0988209 Gasket
ME942663 Gasket
ME942881 Gasket
ME942906 Gasket
ME942907 Gasket
ME963782 Gasket
ME963789 Gasket
ME963801 Gasket
ME969303 Gasket
ME969982 Gasket
MH033077 Gasket
ME942881 Gasket, 6D22 Block
ME997610 Gasket, 6D22 Engine Oil Pump
ME998633 Gasket, 6D22 Engine Oil Pump
ME969312 Gasket, 6D22 Gear Housing
ME704586 Gasket, 6D22 Governor
ME704618 Gasket, 6D22 Governor
ME704772 Gasket, 6D22 Governor
ME705323 Gasket, 6D22 Governor
ME727391 Gasket, 6D22 Governor
ME727491 Gasket, 6D22 Governor
375117000 Gasket, 6D22 Injection Pump
375124001 Gasket, 6D22 Injection Pump
3126106400 Gasket, 6D22 Injection Pump
ME704044 Gasket, 6D22 Injection Pump
ME704083 Gasket, 6D22 Injection Pump
ME704096 Gasket, 6D22 Injection Pump
ME704101 Gasket, 6D22 Injection Pump
ME705151 Gasket, 6D22 Injection Pump
ME705209 Gasket, 6D22 Injection Pump
ME705218 Gasket, 6D22 Injection Pump
ME705289 Gasket, 6D22 Injection Pump
ME727376 Gasket, 6D22 Injection Pump
ME727378 Gasket, 6D22 Injection Pump
ME970401 Gasket, 6D22 Injection Pump Drive
ME969962 Gasket, 6D22 Intake Heater
ME969849 Gasket, 6D22 Intercooler
ME969904 Gasket, 6D22 Intercooler
ME969501 Gasket, 6D22 Oil Cooler
ME998604 Gasket, 6D22 Oil Pump
ME969310 Gasket, 6D22 PTO Drive
ME977028 Gasket, 6D22 Turbo Oil Return Line
ME980061 Gasket, 6D22 Turbocharger to Manifold
ME977602 Gasket, 6D22 Water Manifold to Head
3003232100 Gasket, Exhaust Pipe
ME063680 Gasket, Exhaust Pipe
ME063737 Gasket, Exhaust Pipe
ME068375 Gasket, Exhaust Pipe
ME120385 Gear and Case 6D22 Oil Pump
3123500044 Gear, 6D22 Oil Pump
ME054703 Gear, 6D22 Oil Pump
ME150506 Gear, Cam Idler
ME151298 Gear, camshaft
ME091034 Gear, Crankshaft
ME052996 Gear, Inj Pump Drive
ME150689 Gear, Inj Pump Idler
ME051515 Head Bolt 6D22
ME051516 Head Bolt 6D22
ME962515 Head Bolt 6D22
ME962516 Head Bolt 6D22
ME704011 Holder, 6D22 Injection Pump
ME704041 Holder, 6D22 Injection Pump
ME705431 Holder, 6D22 Injector
ME705432 Holder, 6D22 Injector
ME705441 Holder, 6D22 Injector
ME055398 Impeller, 6D22 Water Pump
ME157062 Impeller, 6D22 Water Pump
ME059655 Injection Pump Body
ME059669 Injection Pump Body
ME998605 Injector Tube, 6D22
ME098201 Intake Elbow Gasket 6D22
ME099649 Intake Elbow Gasket with screen 6D22
ME999603 Intake Gasket
ME999601 Intake Gasket 6D22
ME099608 Intake Heater Element 6D22
ME999602 Intake Heater Elemment 6D22
ME999612 Intake Manifold Gasket
ME099644 Intake Manifold Gasket 6D22
ME099632 Intake Manifold Gasket for 6D22 Intake Heater
ME099649 Intake Manifold Gasket with screen
ME099640 Intake Manifold Gasket with screen 6D22
ME099640 Intake Manifold Gasket with screen 6D22
MS476135 Key,
ME996464 Kit
ME997089 Kit
ME997284 Kit
ME997802 Kit
ME998000 Kit, 6D22 Cylinder Head Soft Plug Kit
ME997018 Liner & Piston Kit
ME997031 Liner & Piston Kit
ME998905 Liner & Piston Kit
ME998906 Liner & Piston Kit
ME998907 Liner & Piston Kit
ME998908 Liner & Piston Kit
ME999594 Liner & Piston Kit
ME999905 Liner & Piston Kit
3120434200 Lock , valve keeper 6D22
ME051705 Mitsubishi 6D22 Washer
ME705429 Nozzle, 6D22 Injector
ME705435 Nozzle, 6D22 Injector
ME705903 Nozzle, 6D22 Injector
ME705905 Nozzle, 6D22 Injector
ME032042 Nut
MF430122 Nut
MF430007 Nut, 6D22 Exhaust
MF434105 Nut, 6D22 Exhaust
MH004054 Nut, 6D22 Exhaust
MH004054 Nut, 6D22 Exhaust
MH004073 Nut, 6D22 Exhaust
MH004073 Nut, 6D22 Exhaust
MS430007 Nut, 6D22 Exhaust
MS446185 Nut, 6D22 Exhaust
ME051197 Oil Jet 6D22
ME051706 Oil Jet 6D22
ME150482 Oil Jet 6D22
MC850069 Oil Pressure Gauge
ME924665 Oil Seal, 6D22 Injection Pump Drive
ME972338 Oil Seal, 6D22 PTO
MF969804 Oring
MD000523 Oring
MF921633 Oring
MF930006 Oring
MF931522 Oring
MF969640 Oring
MH096246 Oring
ME979604 Oring 6D22 Thermostat Housing
ME701153 Oring, 6D22 Injection Pump
ME705152 Oring, 6D22 Injection Pump
ME705278 Oring, 6D22 Injection Pump
ME705280 Oring, 6D22 Injection Pump
ME705281 Oring, 6D22 Injection Pump
ME705287 Oring, 6D22 Injection Pump
ME717732 Oring, 6D22 Injection Pump
ME748413 Oring, 6D22 Injection Pump
ME748414 Oring, 6D22 Injection Pump
ME748415 Oring, 6D22 Injection Pump
MF969591 Oring, 6D22 Injection Pump Drive
MF969800 Oring, 6D22 Injection Pump Drive
MF969773 Oring, 6D22 Intercooler
3110702401 Oring, 6D22 Liner
ME051375 Oring, 6D22 Liner
MF969623 Oring, 6D22 Oil Cooler
MF969628 Oring, 6D22 Oil Cooler Element
MF969630 Oring, 6D22 Oil Cooler Element
ME997625 Oring, 6D22 pressure regulator
ME150992 Oring, 6D22 Rear Crankshaft Seal
MF961694 Oring, 6D22 Timing Gear Shaft
MF961701 Oring, 6D22 Timing Gear Shaft
ME979604 Oring, 6D22 Water Pump
MF969305 Oring, 6D22 Water Pump
MF969332 Oring, 6D22 Water Pump
ME998607 Oring, for Injector Tube
ME061399 Outer Valve Spring 6D22
ME051094 Packing
3090722300 Packing, 6D22 Liner
MH012026 Pin, Crankshaft
MF472405 Pin, cylinder block 6D22
MF472406 Pin, cylinder block 6D22
MF474204 Pin, cylinder block 6D22
MH007011 Pin, cylinder block 6D22
3003233030 Pipe, Exhaust
3003233040 Pipe, Exhaust
ME157305 Pipe, Exhaust
32261002 Piston Connecting Rod Assembly 6D22
ME052149 Piston Pin
ME052149 Piston Pin 6D22
3031900600 Piston Pin Bushing 6D22
3031900690 Piston Pin Bushing 6D22
ME052158 Piston Pin Bushing 6D22
ME052159 Piston Pin Bushing 6D22
ME052159 Piston Pin Bushing 6D22
ME052603 Piston Pin Bushing 6D22
ME052660 Piston Pin Bushing 6D22
3121733100 Piston Pin Retainer
ME062326 Plate
ME062660 Plate
MH037725 Plug
MH037137 Plug
ME031088 Plug, threaded
ME704144 Plunger, 6D22 Injection Pump
ME704257 Plunger, 6D22 Injection Pump
ME704374 Plunger, 6D22 Injection Pump
ME704396 Plunger, 6D22 Injection Pump
ME741405 Plunger, 6D22 Injection Pump
ME743406 Plunger, 6D22 Injection Pump
ME743408 Plunger, 6D22 Injection Pump
ME743409 Plunger, 6D22 Injection Pump
ME743410 Plunger, 6D22 Injection Pump
ME051180 Push Rod, 6D22
ME051199 Push Rod, 6D22
ME705406 Push Rod, 6D22 Injector
ME705410 Push Rod, 6D22 Injector
ME705414 Push Rod, 6D22 Injector
3093194010K Rebuild Kit for 6D22 Turbocharger
ME050738K Rebuild Kit for 6D22 Turbocharger
ME058448K Rebuild Kit for 6D22 Turbocharger
ME058724K Rebuild Kit for 6D22 Turbocharger
ME157213K Rebuild Kit for 6D22 Turbocharger
ME157215K Rebuild Kit for 6D22 Turbocharger
ME995231K Rebuild Kit for 6D22 Water Pump
ME995234K Rebuild Kit for 6D22 Water Pump
MEO95645 Retainer
3121733100 Retainer Ring, 6D22 Piston
ME058232 Retainer, 6D22 Rear Crankshaft Seal, specify one or two seal type
3112100201 Ring Gear
4480102200 Ring Gear
ME062696 Ring Gear
ME053951 Ring Seal
ME719056 Ring, 6D22 Turbocharger
ME719290 Ring, 6D22 Turbocharger
ME719339 Ring, 6D22 Turbocharger
ME719383 Ring, 6D22 Turbocharger
ME719832 Ring, 6D22 Turbocharger
ME719864 Ring, 6D22 Turbocharger
3097502050 Rings, Compressor Piston
ME051584 Screw,
ME041001 Screw, Valve Adjust
MF669804 Seal
MF669805 Seal
MF669902 Seal
MF669909 Seal
MF669912 Seal
MF669913 Seal
MF669914 Seal
MF669916 Seal
MF669919 Seal
ME962485 Seal Grommet, 6D22 Valve Cover
ME916402 Seal Ring, 6D22 Injector
ME916414 Seal Ring, 6D22 Injector
ME063946 Seal Ring, 6D22 Turbocharger
ME034997 Seal Ring, Exhaust Pipe
ME034998 Seal Ring, Exhaust Pipe
ME063946 Seal Ring, Exhaust Pipe
ME705228 Seal, 6D22 Governor
ME705333 Seal, 6D22 Governor
ME705210 Seal, 6D22 Injection Pump
ME722347 Seal, 6D22 Injection Pump
ME7605286 Seal, 6D22 Injection Pump
ME998801 Seal, 6D22 pressure regulator
MF969311 Sealing Ring
MF969313 Sealing Ring
ME979803 Sealing Washer
ME998622 Sealing Washer
MF969704 Sealing Washer
ME998629 Sealing Washer
ME998629 Sealing Washer
ME998633 Sealing Washer
ME998633 Sealing Washer
MF891182 Sealing Washer
MF971174 Sealing Washer
MF998874 Sealing Washer
MH946199 Sealing Washer
MF906631 Sealing Washer 6D22 Thermostat Housing
MH661202 Sealing Washer 6D22 Water Pump
ME051374 Sealing Washer,
ME051705 Sealing Washer,
ME998629 Sealing Washer, 6D22 Air Compressor
ME998551 Sealing Washer, 6D22 Injection Pump
ME998601 Sealing Washer, 6D22 Injection Pump
ME916490 Sealing Washer, 6D22 Injector
ME997905 Sealing Washer, 6D22 Injector
MH942197 Sealing Washer, 6D22 Oil Jet
ME977020 Sealing Washer, 6D22 Turbo Oil Line
ME051353 Seat Exhaust
ME051354 Seat Exhaust
ME051214 Seat Intake
3093615300 Seat, 6D22 Oil Pump
ME051034 Seat, Exhaust
ME051354 Seat, Exhaust
ME051300 Seat, Intake
ME051083 Seat, Valve Spring
ME719350 Shaft & Turbine, 6D22 Turbocharger
ME719756 Shaft & Turbine, 6D22 Turbocharger
3123500501 Shaft, 6D22 Oil Pump
ME054372 Shaft, 6D22 Oil Pump
3092504100 Shaft, Cam Idler
ME150519 Shaft, Cam Idler
ME150520 Shaft, Cam Idler
ME151333 Sleeve
ME704024 Sleeve, 6D22 Injection Pump
ME704079 Sleeve, 6D22 Injection Pump
ME704409 Sleeve, 6D22 Injection Pump
ME722346 Sleeve, 6D22 Injection Pump
ME723409 Sleeve, 6D22 Injection Pump
ME060125 Slinger
ME971034 Slinger
ME999101 Slinger
MF522236 Snap Ring
ME704404 Snap Ring, 6D22 Injection Pump
MF998840 Soft Plug
MF998847 Soft Plug
ME998007 Soft Plug Kit, 6D22 Block
ME99809 Soft Plug, Sealing Cap
ME998804 Soft Plug, Sealing Cap
ME998807 Soft Plug, Sealing Cap
ME998810 Soft Plug, Sealing Cap
MH012037 Spring pin
ME704668 Spring, 6D22 Governor
ME704748 Spring, 6D22 Governor
ME716095 Spring, 6D22 Governor
ME717321 Spring, 6D22 Governor
ME705405 Spring, 6D22 Injector
ME705409 Spring, 6D22 Injector
ME705411 Spring, 6D22 Injector
ME705451 Spring, 6D22 Injector
3093615200 Spring, 6D22 Oil Pump
ME054393 Strainer
ME054526 Strainer
ME157586 Strainer
ME157587 Strainer
MF407035 Stud, 6D22 Exhaust
MF407728 Stud, 6D22 Exhaust
MF401931 Stud, 6D22 Flywheel Housing
MF402541 Stud, 6D22 Flywheel Housing
MH002113 Stud, 6D22 Flywheel Housing
MF406288 Stud, cylinder block 6D22
MH002131 Stud, cylinder head 6D22
MC840219 Switch 6D22 Oil Pressure
ME049107 Switch 6D22 Oil Pressure
ME049261 Switch 6D22 Oil Pressure
ME049262 Switch 6D22 Oil Pressure
ME951940 Switch 6D22 Oil Pressure
ME951943 Switch 6D22 Oil Pressure
ME061021 Tappet
ME704062 Tappet, 6D22 Injection Pump
ME722244 Tappet, 6D22 Injection Pump
ME151300 Thrust Plate
3090401600 Thrust Plate, 6D22 Rocker Shaft
3120978101 Thrust Washer Set 6D22
3120978101 Thrust Washer Set 6D22
3120978201 Thrust Washer Set 6D22
3120978201 Thrust Washer Set 6D22
3120978301 Thrust Washer Set 6D22
3120978301 Thrust Washer Set 6D22
3120978401 Thrust Washer Set 6D22
3120978401 Thrust Washer Set 6D22
ME056097 Timer, 6D22 Injection Pump
ME059662 Timer, 6D22 Injection Pump
ME723117 Timer, 6D22 Injection Pump
ME723861 Timer, 6D22 Injection Pump
ME726300 Timer, 6D22 Injection Pump
ME730855 Timer, 6D22 Injection Pump
3003291300 Turbine Seal
ME051410 Upper Valve Spring Retainer 6D22
ME061746 Upper Valve Spring Retainer 6D22
ME051694 Valve Cover
ME051372 Valve Cover
ME051373 Valve Cover Gasket 6D22
ME962499 Valve Cover Gasket 6D22
ME051208 Valve Spring
ME061398 Valve Spring
ME092685 Valve Stem Seal 6D22
ME704008 Valve, 6D22 Injection Pump
ME704032 Valve, 6D22 Injection Pump
ME704145 Valve, 6D22 Injection Pump
ME704262 Valve, 6D22 Injection Pump
ME704315 Valve, 6D22 Injection Pump
ME084527 Valve, Oil Cooler Bypass
ME074455 Valve, Oil Pressure Regulator
ME719360 Wheel Compressor 6D22
ME719843 Wheel Compressor 6D22
MB110315
MC000039
MC000241
MC000325
MC010080
MC010186
MC011294
MC011362
MC012759
MC041272
MC251843
MC420083
MC429036
MC513075
MC521036
MC840100
MC840110
MC840182
MC840219
ME052868
ME052886
ME052887
ME052888
602
ENGINE
Shop Manual
364 MAR. 1989
200 IHI