Escolar Documentos
Profissional Documentos
Cultura Documentos
FE series
FE6,FE6T & FE6TA
Pub.No. SMEFES2E01
ENGINE
SERVICE MANUAL
MODEL
FE6 series
GENERAL
GE
MAINTENANCE
MA
TROUBLE DIAGNOSIS
TD
ENGINE PROPER
EP
FOREWORD
This manual describes the service, by system, of the
engine of FE6A, FE6B, FE6T and FE6TA models.
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be performed
properly. Also, overhaul and repair should be
effected in accordance with prescribed service standards.
This manual should be kept readily available in the
workshop as a helpful reference for those engaged in
servicing vehicles.
Nissan Diesel Motor Co., Ltd. reserves the right to
make changes for improvement at any time without
notice.
This manual is based on vehicles that were manufactured on or before April.1, 1998. Revisions, if any, will
be introduced in the Technical Bulletin.
LUBRICATION SYSTEM
LB
COOLING SYSTEM
EC
FUEL SYSTEM
EF
IE
ELECTRICAL SYSTEM
EE
AUXILIARY EQUIPMENT
EA
A quick reference index, a black tab is provided on the first page, so you can quickly find the first
page of each chapter by mating it to the chapters black tab.
Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major components, items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]
-1-
Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part
name, and the number is determined according to the operation sequence.
No. 1, 2, 3
Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks + and , affixed to the part name number indicate that the key points of operation (precautions, technique, use of special tools, and other maintenance information) are explained in the text.
+: Key points of disassembly
Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.
4. Ball
5. Cover
6. Gasket
Marks , and + indicate that the key points of operation are explained in the text.
-2-
If there are no + and , marks affixed to the parts, general explanation is given for those
parts.
X The following marks and abbreviations are used in this manual.
Marks:
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.
: Should be lubricated with oil.
: Sealing point
: Always replace after every disassembly.
z
Abbreviations
T.D.C.:
I.D.:
Inside diameter
B.T.D.C.:
Dia.:
Diameter
A.T.D.C.:
S.T.D.:
Standard
B.B.D.C.:
O.S.:
Oversize
A.B.D.C.:
U.S.:
Undersize
O.D.:
Outside diameter
Assy:
Assembly
Engine position:
Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
The captions WARNING and CAUTION warn you about procedures that must be followed to prevent personal injury and/or damage to some parts of the vehicle.
-3-
Engine model:
Engine model
For TAIWAN
118 {160}/3,000
FE6A
119 {162}/3,000
FE6B
FE6
132 {180}/3,000
FE6B
135 {183}/3,000
FE6T
FE6T
151 {205}/2,800
FE6T
FE6T-Z
162 {220}/2,800
FE6T
157 {213}/2,800
FE6TA
173 {235}/2,800
FE6TA
FE6TA
Engine models specified for TAIWAN are different from those for general markets. Hereinafter, engine models will be described by specifications for general markets. For TAIWAN specifications, use the above table to
identify the engine model specification for TAIWAN when reading this service manual.
NOTE
z
Only maintenance interval information includes information for TAIWAN engine models.
-4-
- MEMO -
-5-
GE
GENERAL
CONTENTS
SPECIFICATIONS .................................. GE-1-1
ENGINE SPECIFICATIONS ............................. GE-1-1
ENGINE NUMBERS ......................................... GE-1-9
LUBRICATION ........................................ GE-2-1
PRECAUTIONS ...................................... GE-3-1
SPECIFICATIONS
SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine models FE6A and FE6B
Engine model
Item
Max. gross output (JIS)
kW {PS}/rpm
FE6A
FE6B
118 {160}/3,000
Type
Water cooled
6, in-line
Stroke cycle
Combustion chamber
Valve mechanism
Overhead valve
Cylinder liner
Dry
Bore x stroke
mm (in)
Compression ratio
18.0
kPa {kgf/cm2, psi}/rpm
Cylinder compression
Idling speed
600
Intake
Valve timing
Exhaust
Valve clearance mm (in)
Open (B.T.D.C.)
15
Closed (A.B.D.C.)
40
Open (B.B.D.C.)
53
Closed (A.T.D.C.)
Intake
Exhaust
Lubrication system
Lubrication
system
132 {180}/3,000
Diesel
Cooling method
Forced-circulation type
Oil pump
Gear pump
Oil filter
Cartridge type
Oil cooler
Cooling system
Cooling system
119 {162}/3,000
Radiator type
Cooling fan
Corrugated fin
Outside diameter - Number of fins
mm (in)
480 (18.90) - 6
485 (19.09) - 8
510 (20.08) - 6
485 (19.09) - 8
530 (20.87) - 6
510 (20.08) - 7
530 (20.87) - 6
Water pump
Thermostat
GE-1-1
SPECIFICATIONS
Engine model
Item
FE6A
FE6B
Ignition system
Compression ignition
14
15
Ignition order
1-4-2-6-3-5
Plunger type
Fuel filter
Bosch
Plunger diameter
mm (in)
9.5 (0.374)
9.0 (0.354)
Fuel system
Plunger lead
Fuel injection
pump
Cam lift
mm (in)
Governor
8.0 (0.315)
6.0 (0.236)
Type
Centrifugal
Type name
RAD/RLD/RFD
RLD
Type name
Conventional type
Flange type
Nozzle
Multi-jet
Identification mark
D2
Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter
Air cleaner
mm (in)
Direction of rotation
Air volume
kg (lb)/min
Compression ratio
Exhaust brake
SA (RAD, RLD)
/SAG (RFD)
SA
Turbocharger
RAD/RLD/RFD
Centrifugal
Nozzle holder
9.0 (0.354)
Feed pump
Type
Injection pressure
9.5 (0.374)
Right lead
Injection pump
Type
Timer
Fuel injection
nozzle
12
Type
Chamber type
Cylinder type
Operating method
Vacuum type
Air type
GE-1-2
SPECIFICATIONS
Engine model
Item
Electrical system
Starting motor
FE6A
Type
Shift type
Model
Output
V-kW
24-4.5
Type
Alternator
AC, diode-rectified
0202 152 0310
Model
Output
V-A
IC-transistor type
Type
Ribbon
V-A
22 x 85 - 1
Type
Air compressor
Reciprocating type
85 x 40 - 1 (3.35 x 1.57 - 1)
Cooling system
Water cooled
Direction of rotation
Regulator
Air heater
Auxiliary equipment
FE6B
Type
Vane
Model
VD-120
GE-1-3
SPECIFICATIONS
FE6T
Item
Max. gross output (JIS)
Type
Water cooled
6, in-line
Stroke cycle
Combustion chamber
Valve mechanism
Overhead valve
Cylinder liner
Dry
Bore x stroke
mm (in)
Compression ratio
Cylinder compression
kPa
{kgf/cm2,
17.5
2,942 {30, 427}/200
psi}/rpm
Idling speed
600
Intake
Valve timing
Exhaust
Valve clearance mm (in)
Open (B.T.D.C.)
15
Closed (A.B.D.C.)
30
Open (B.B.D.C.)
53
Closed (A.T.D.C.)
Intake
Exhaust
Lubrication system
Lubrication
system
162 {220/2,800}
Diesel
Cooling method
Forced-circulation type
Oil pump
Gear pump
Oil filter
Cartridge type
Oil cooler
kPa
{kgf/cm2,
psi}
Cooling system
Cooling system
151 {205/2,800}
Radiator type
Cooling fan
Corrugated fin
Outside diameter - Number of fins
mm (in)
510 (20.08) - 7
510 (20.08) - 7
580 (22.83) - 6
580 (22.83) - 7
580 (22.83) - 7
Water pump
Thermostat
GE-1-4
SPECIFICATIONS
Engine model
FE6T
Item
Ignition system
Compression ignition
12
10
Ignition order
1-4-2-6-3-5
Plunger type
Fuel filter
Bosch
Plunger diameter
mm (in)
9.0 (0.354)
Fuel system
Plunger lead
Fuel injection
pump
Cam lift
mm (in)
Governor
Timer
Right lead
Injection pump
9.0 (0.354)
6.0 (0.236)
Type
Centrifugal
Type name
RLD
Type
Centrifugal
Type name
SA
SAG
Conventional type
Nozzle holder
Flange type
Nozzle
Multi-jet
Identification mark
D3
A5
19,614
{200, 2,844}
19,614
{200, 2,844}
Model
Air intake and exhaust system
21,575
{220, 3,128}
157 {1.6, 23}
Air cleaner
External dimensions
(Length x Width x Height)
mm (in)
Air volume
T04B
RHC62E
138,000
150,000
Direction of rotation
kg (lb)/min
Compression ratio
Exhaust brake
A6
Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter
Turbocharger
10.0 (0.394)
Feed pump
Type
Fuel injection
nozzle
21 (46)
18.8 (41.5)
3.2
Type
Cylinder type
Operating method
Air type
GE-1-5
SPECIFICATIONS
Engine model
FE6T
Item
Type
Starting motor
Shift type
Model
Electrical system
Output
V-kW
24-4.5
Type
AC, diode-rectified
Model
Alternator
Output
V-A
Regulator
Auxiliary equipment
24-80
Ribbon
V-A
22 x 85 - 1
Type
Air compressor
IC-transistor type
Type
24-50
Air heater
Reciprocating type
408738-5600
408738-5601
85 x 40 - 1 (3.35 x 1.57 - 1)
408738-5611
408738-5741
85 x 40 - 1
(3.35 x 1.57 - 1)
85 x 60 - 1 (3.35 x 2.36 - 1)
Cooling system
Water cooled
Direction of rotation
GE-1-6
SPECIFICATIONS
FE6TA
Item
Max. gross output (JIS)
kW {PS}/rpm
157 {213}/2,800
Type
Diesel
Cooling method
Water cooled
6, in-line
Stroke cycle
Combustion chamber
Valve mechanism
Overhead valve
Cylinder liner
Dry
Bore x stroke
mm (in)
Compression ratio
17.5
Cylinder compression
kPa
{kgf/cm2,
psi}/rpm
Idling speed
600
Intake
Valve timing
Exhaust
Valve clearance mm (in)
Open (B.T.D.C.)
Closed (A.B.D.C.)
Lubrication
system
15
30
40
Open (B.B.D.C.)
53
Closed (A.T.D.C.)
Intake
Exhaust
Lubrication system
Forced-circulation type
Oil pump
Gear pump
Oil filter
Cartridge type
Oil cooler
kPa
{kgf/cm2,
psi}
Cooling system
Cooling system
173 {235}/2,800
Forced-circulation type
Radiator type
Cooling fan
510 (20.08) - 7
580 (22.83) - 6
580 (22.83) - 7
580 (22.83) - 7
Water pump
Thermostat
GE-1-7
SPECIFICATIONS
Engine model
FE6TA
Item
Ignition system
Compression ignition
12
Ignition order
1-4-2-6-3-5
Plunger type
Fuel filter
mm (in)
TC-MD
Bosch
11.0 (0.433)
9.0 (0.354)
Fuel system
Plunger lead
Fuel injection
pump
Cam lift
mm (in)
Governor
Timer
Right lead
Injection pump
10.0 (0.394)
Feed pump
6.0 (0.236)
Type
Centrifugal
Type name
RLD
Type
Centrifugal
Type name
SAG
Electronic (MD-TICS)
Conventional type
Nozzle holder
Fuel injection
nozzle
Flange type
Nozzle
Multi-jet
Identification mark
F4 or C1
Injection pressure
Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter
Air cleaner
A3
Model
External dimensions
(Length x Width x Height)
Turbocharger
mm (in)
kg (lb)/min
Compression ratio
Exhaust brake
RHC6V
125,000
150,000
Direction of rotation
Air volume
T04E
20 (44)
19.4 (42.8)
3.2
Type
Cylinder type
Operating method
Air type
GE-1-8
SPECIFICATIONS
Engine model
FE6TA
Item
Type
Electrical system
Starting motor
Shift type
Model
Output
V-kW
24-4.5
Type
Alternator
AC, diode-rectified
Model
V-A
24-50
Regulator
IC-transistor type
Type
Ribbon
V-A
22 x 85 - 1
Type
Reciprocating type
Auxiliary equipment
408738-5610
408738-5611
Air compressor
85 x 40 - 1
(3.35 x 1.57 - 1)
85 x 40 - 1
(3.35 x 1.57 - 1)
80 x 40 - 1
(3.15 x 1.57 - 1)
Cooling system
Water cooled
Direction of rotation
Output
Air heater
Type
Vane
Model
VD-30
ENGINE NUMBERS
The engine serial number is stamped on the right side of the cylinder block.
FE6-XXXXXXC*
Engine serial number
Engine model
*Engine specification
A: Natural aspirated engine
B: Natural aspirated engine
C: Turbocharged engine
D: Turbocharged engine with intercooler
GE-1-9
LUBRICATION
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant
Specifications
Remarks
Engine oil
API CC or CD
DEXRON or DEXRON II
GM ATF type
Bearing grease
NLGI No. 2
Antifreeze
Fuel
Above 7C (20F) 2-D Diesel fuel or equivalent blended diesel fuel Check with the service establishment to
Below 7C (20F) 1-D Diesel fuel or equivalent blended diesel fuel be sure you get the properly blended fuel.
NOTE
z
It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged
engines.
CAPACITIES (APPROXIMATELY)
Item
Engine oil pan (H-level)
Engine oil
Total
Power steering system
12 (2-5/8 gal)
FE6TA*
14 (3-1/8 gal)
15 (3-1/4 gal)
FE6TA*
17 (3-3/4 gal)
MK and LK series
PK series
3 (2-5/8 qt)
5.5 (4-7/8 qt)
Cooling system
22 (4-7/8 gal)
Square type
Round type
Fuel tank
NOTE
Capacities shown are for reference only. When filling, observe the specified level.
z * Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).
z
GE-2-1
PRECAUTIONS
PRECAUTIONS
PREPARATION
Observe the following when servicing the vehicle.
z
Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle
may move abruptly.
z
Engage the parking brake and chock the wheels securely.
z
If the engine is hot, wait until it cools off.
z
Set the transmission gear shift lever to NEUTRAL.
z
Turn the key switch to OFF. Disconnect the ground cable when servicing the electrical system.
z
Do not touch rotating parts of the engine if servicing requires engine operation. Always operate the
engine in a well-ventilated area.
z
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.
GE-3-1
PRECAUTIONS
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
z
If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts
should be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent
that the specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limit
from preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the red (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,
the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
Abnormalities
z
Uneven wear
z
Graded wear
z
Scratches
z
Cracks
z
Deformity
z
Fatigue or weakness (for springs and rubbers, etc.)
z
Bends
z
Loose fit
z
Unusual noise (for bearings)
z
Discoloration or jamming
z
Rust formation
z
Deterioration (for brake linings, etc.)
GE-3-2
All bolts and nuts are sized using the metric system. Do not use parts other than those designated.
Nominal
size
Bolt dia.
mm
Pitch
mm
M6
6.0
M8
8.0
M10
10.0
M12
12.0
M14
7T
9T
Nm
kgfm
ftlbf
Nm
kgfm
ftlbf
Nm
kgfm
ftlbf
1.0
5.1
0.52
3.8
8.4
0.86
6.2
12
1.2
1.25
13
1.3
21
2.1
15
29
3.0
22
1.0
13
1.3
22
2.2
16
31
3.2
23
1.5
25
2.5
18
41
4.2
30
59
6.0
43
1.25
25
2.6
19
43
4.4
32
62
6.3
46
1.75
42
4.3
31
71
7.2
52
98
10.0
72
1.25
46
4.7
34
77
7.9
57
108
11.0
80
14.0
1.5
74
7.5
54
127
13.0
94
177
18.0
130
M16
16.0
1.5
108
11.0
80
186
19.0
137
275
28.0
203
M18
18.0
1.5
167
17.0
123
275
28.0
203
392
40.0
289
M20
20.0
1.5
226
23.0
166
382
39.0
282
549
56.0
405
M22
22.0
1.5
304
31.0
224
510
52.0
376
736
75.0
542
NOTE
Item
Nm
kgfm
4.76 (0.1874)
13 - 18
1.3 - 1.8
9 - 13
6.35 (0.2500)
16 - 24
1.6 - 2.4
12 - 17
8.0 (0.315)
29 - 39
3.0 - 4.0
22 - 29
10.0 (0.394)
39 - 49
4.0 - 5.0
29 - 36
12.0 (0.472)
59 - 78
6.0 - 8.0
43 - 58
15.0 (0.591)
69 - 93
7.0 - 9.5
51 - 69
21 - 28
2.1 - 2.9
15 - 21
42 - 57
4.3 - 5.8
31 - 42
Flared nut
GE-4-1
ftlbf
- MEMO -
- MEMO -
MA
MAINTENANCE
CONTENTS
SERVICE DATA ...................................... MA-1-1
SERVICE DATA ............................................... MA-1-1
TIGHTENING TORQUE ................................... MA-1-2
TOOLS .................................................... MA-2-1
PERIODIC MAINTENANCE
SCHEDULES .......................................... MA-3-1
MAINTENANCE INTERVALS........................... MA-3-2
PERIODIC PARTS REPLACEMENT ............... MA-3-4
MA-4-1
MA-4-4
MA-4-9
MA-4-17
MA-4-27
MA-4-32
SERVICE DATA
SERVICE DATA
SERVICE DATA
Maintenance
standard
Service limit
Intake
0.3 - 0.4
(0.012 - 0.016)
Exhaust
0.3 - 0.4
(0.012 - 0.016)
Less than
392 {4, 57}
Open
15 B.T.D.C.
Closed
40 A.B.D.C.
Open
53 B.B.D.C
Closed
9 A.T.D.C.
Open
15 B.T.D.C.
Closed
30 A.B.D.C.
Open
53 B.B.D.C
Closed
9 A.T.D.C.
10 - 15 (0.39 - 0.59)
7 - 12 (0.28 - 0.47)
39 - 59
{0.4 - 0.6, 6 - 9}
Pressure side
74.5 - 78.5
(166 - 173)
71.5 - 81.5
(161 - 179)
82 (180)
80 - 84 (176 - 183)
77 - 87 (171 - 189)
88 (190)
86 - 90 (187 - 194)
85 - 93 (185 - 199)
76.5 (170)
82 (180)
88 (190)
Item
Valve clearance
mm (in)
Valve
timing
FE6A
FE6B
FE6TA
173 kW
{235 PS}
Intake
FE6T
FE6TA
157 kW
{213 PS}
Intake
Exhaust
Exhaust
76.5 (170)
MA-1-1
Remarks
SERVICE DATA
Maintenance
standard
Service limit
14
15
12
12
10
12
600
650
Item
FE6A
FE6B
Fuel system
FE6T
FE6TA
FE6A, FE6B, FE6T
Idle speed
rpm
FE6TA
550
Maximum speed
3,200
rpm
3,600
Remarks
MD-TICS system
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Lubrication
system
Cooling
system
MA-1-2
SERVICE DATA
Item
Fuel
system
FE6TA
157 kW {213 PS}
FE6TA
157 kW {213 PS}
FE6TA
157 kW {213 PS}
Air intake
and exhaust
system
Tightening torque
Type I
Type II
T04B
Compressor housing and back
T04E
plate mounting bolt
Nm {kgfcm, inlbf} RHC62E
RHC62V
T04B
Turbine housing and center hous- T04E
ing mounting bolt
Nm {kgfcm, inlbf} RHC62E
RHC62V
MA-1-3
TOOLS
TOOLS
Tool name and number
Description
Feeler gauge
99541 Z5000
Timing plate
99646 Z5001
Compression gauge
99640 Z5500
*Plate
157944-9520
MA-2-1
Shape
TOOLS
Description
Pin vice
99727 Z5005
Nozzle cleaner
99726 Z5000
MA-2-2
Shape
The maintenance or lubrication service shown below are to be performed at the indicated intervals (km, miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be continued at the same intervals as before except the initial maintenance.
z Under the following severe operating conditions, more frequent servicing will be required.
Operation in heavy dust conditions
Operation at extremely low or high ambient temperature
Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight)
Extended low-speed operation
Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine
Nissan Diesel parts.
z
Do not modify, alter, disconnect or remove any part of the vehicle which could affect, directly or
indirectly, vehicle emissions.
MA-3-1
MAINTENANCE INTERVALS
Maintenance intervals
Items
Kilometers x 1,000
Miles x 1,000
Daily
Months
10
15
20
25
30
35
40
45
50
55
60
0.6
12
15
18
21
24
27
30
33
36
10
11
12
Valve clearance
T
I : After 200,000 km (125,000 miles)
Crank damper
Oil leakage
Remarks
Full-flow type
(1)
(1)
Coolant leakage
Coolant level
I
I
I
I
I
I
I
R
(3)
(4)
Radiator cap
Fan clutch
V-belt
I
I
Thermostat
Injection timing
Fuel leakage
R
I
I
I
I
I
I
I
I
I
I
I
I
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Fuel strainer
Fuel level
I
Drain
I
Drain
I
Drain
I
Drain
I
Drain
I/C
Drain
I/C
I/C
I/C
I/C
I/C
I/C
(2)
(2)
Turbocharger
I
I
(5)
Remarks:
(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the scheduled replacement.
(2) If the warning light comes on even before the scheduled replacement, clean or replace element.
(3) Service every 6 months.
(4) Service every 12 months.
(5) With turbocharger engine equipped vehicles only.
MA-3-2
Kilometers x 1,000
Miles x 1,000
Daily
Months
10
15
20
25
30
35
40
45
50
55
60
0.6
12
15
18
21
24
27
30
33
36
10
11
12
*Idle speed
I/C
I/C
I/C
I/C
I/C
R
I
*Valve clearance
Oil CC or CD class
*Engine oil and
oil filters
Oil CD class
*Engine oil and
bypass oil filter Oil CD class
(if equipped)
Oil level and contamination
I
I
FE6 engine
FE6T, FE6T-Z
and FE6TA
engines
Oil pressure
I
I
I
I
I
Drain Drain Drain Drain Drain
I
I
I
I
I
Drain Drain Drain Drain Drain
*Injection timing
Fuel tubing
Accelerator linkage
Crank damper
Every 24 months : I
Engine coolant
Thermostat
Fan clutch
Alternator
Starter
*PCV valve
*PCV system
*Turbocharger
Remarks
I
I
(piping)
Every 240,000 km (145,000 miles) : C
MA-3-3
FE6 engine
FE6 engine
FE6 engine
FE6T, FE6T-Z
and FE6TA
engines
10
Remarks
ENGINE
Fuel hose (engine side)
R
R
MA-3-4
R
R
(1)
MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
z
1.
2.
3.
4.
5.
Service
limit
Intake
Exhaust
Item
Valve
clearance
Remarks
When
engine is
cold
MA-4-1
MAINTENANCE PROCEDURE
3.
4.
If the valve clearance is not correct, loosen the lock nut for
the adjusting screw and adjust the screw until the specified
clearance is obtained.
After adjusting the valve clearance, hold the adjusting
screw and tighten the lock nut.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}
Recheck the valve clearance.
Rotate the flywheel one complete turn until the mark 16 is
aligned with the pointer. Next, check and adjust the remaining valve clearances.
If the engine operates erratically or vibrates even though
the valve clearances are properly adjusted, problems may
be due to improperly adjusted valve timing which results
from incorrect assembling of the timing gear train, etc. If
erratic operation is noticed, check the valve timing as
described below.
3.
4.
MA-4-2
MAINTENANCE PROCEDURE
5.
Item
Valve
timing
FE6A
Intake
FE6B
FE6TA
173 kW
Exhaust
{235 PS}
FE6T
Intake
FE6TA
157 kW
{213 PS} Exhaust
Service
Remarks
limit
Open
15 B.T.D.C.
(1)
Closed
40 A.B.D.C.
(2)
Open
53 B.B.D.C.
(3)
Closed
9 A.T.D.C.
(4)
Open
15 B.T.D.C.
(1)
Closed
30 A.B.D.C.
(2)
Open
53 B.B.D.C.
(3)
9 A.T.D.C.
(4)
Closed
CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting
bolts for looseness. Replace faulty parts if necessary.
Crank damper mounting bolt
: 59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}
MA-4-3
MAINTENANCE PROCEDURE
3.
Maintenance standard
Service limit
Remarks
1,961
{20, 284}
At 200 rpm
with engine
warm
NOTE
z
The above engine rpm range refers to that when the battery is fully charged and the starting motor is in good
condition.
LUBRICATION SYSTEM
OIL LEAKAGE
Check the cylinder head, timing gear case cover, oil pan, oil filters
and other related parts for sign of leakage. If necessary, replace
gaskets. After replacing the gasket, check that point to ensure there
is no leakage.
MA-4-4
MAINTENANCE PROCEDURE
Check the engine oil level and for contamination of engine oil
before driving the vehicle each day and when you stop for fuel.
Check the oil level with the engine off. When checking the oil level
after stopping the engine, wait at least 15 minutes to allow the oil to
return to the oil pan.
3.
If oil level is low, add engine oil of the proper viscosity for
the anticipated temperature range during the service interval through the oil filler port located on the valve cover on
top of the engine. Do not add oil above the H mark on the
dipstick.
CAUTION
z Use care to keep dirt and debris from entering the crankcase through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills accidentally.
4.
MA-4-5
MAINTENANCE PROCEDURE
NOTE
z
Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner
as soon as possible.
The engine oil and oil filter change interval varies with the type of
engine oil used and vehicle driving conditions. If the vehicle is
driven for extended periods of time at high or low speeds, in dusty
areas, with frequent idling or carrying heavy loads, engine oil will
deteriorate faster and require more frequent changing.
As the temperature rises, the engine oils viscosity decreases,
reducing its lubricating effect. To choose an oil with the proper viscosity for the anticipated ambient temperature range, refer to the
viscosity chart in the GE section of this manual.
To change the engine oil
1. Loosen the oil filler cap.
2.
3.
Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
Place a container under the drain plugs in the bottom of the
oil pan and oil filter. Remove the plugs and drain the oil into
the container.
MA-4-6
MAINTENANCE PROCEDURE
4.
5.
6.
7.
8.
When all the oil has been drained from the oil pan and oil filter, replace the drain plugs in the drain hole and tighten the
drain plug.
Oil pan drain plug
: 59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}
Replace the oil filter. See the instructions under the caption
OIL FILTER.
Add engine oil through the oil filler port to the specified
level.
After refilling the engine oil, wait for at least 6 minutes, then
using the dipstick check the oil level. If the oil level is low,
add additional oil. Wait 6 minutes, then recheck the oil level.
Repeat this procedure until the engine oil reading on the
dipstick is between H and L.
Install the engine undercover (if equipped).
Oil filter
WARNING
WARNING
z
Do not handle hot oil filter without hand protection. Failure to do so may result in burn injury.
NOTE
MA-4-7
MAINTENANCE PROCEDURE
To replace the oil filter
1. Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
2. Place a container under the oil filter and remove the drain
plug in the bottom of the oil filter. Drain oil from the filter.
3. Remove the filter with a filter wrench and drain all oil into
the container.
4.
5.
Run the engine. Check the filter and seal for leaks.
After checking, install the under cover.
MA-4-8
MAINTENANCE PROCEDURE
COOLING SYSTEM
The engine cooling system was filled at the factory with a high-quality, year-round, coolant solution with a 50/50 antifreeze/water mixture. The antifreeze solution contains rust and corrosion inhibitors.
The solution provides protection against freezing to approximately 30C (-22F). The solution must remain in the system year round to
provide protection against freezing, boiling, rust and corrosion. Do
not use additional cooling system additives or inhibitors. They may
interfere with the proper operation of the cooling system.
Check the engine, radiator, hoses and pipes daily. Repair any
leaks. Replace swollen and worn hoses and tighten loosen clamps.
Check the OVERHEATING AND COOLANT LEVEL warning light
daily to be sure that it does not operate.
WARNING
WARNING
COOLANT LEAKAGE
Check the cooling system for leakage, especially at tube and hose
connections. Also check piping for fractures, cracks or damage.
Replace parts if faulty.
If water leaks through the small hole in the water pump body, the
water seal may be faulty.
Disassemble and repair the water pump.
MA-4-9
MAINTENANCE PROCEDURE
COOLANT LEVEL
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the radiator filler cap while the engine cooling system is hot; wait until it cools.
z Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
z If the coolant is accidentally ingested, force the person to
vomit and secure medical help immediately. If the coolant gets in the eye, flood the eye with lots of water and
get medical attention immediately.
Open the front lid.
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located behind
the front lid.
The coolant level should be between the HIGH and LOW lines. If
the coolant level is below the LOW line, add the proper coolant
solution to the HIGH line.
Be sure to use an ethylene glycol antifreeze with water at the
proper mixture ratio. To ensure the proper mixture ratio, carefully
read the instructions on the container or obtain the instructions from
the antifreeze manufacturer. Examples are shown below.
Outside temperature
down to
Antifreeze
Soft water
-10 (14)
30%
70%
-20 (-4)
40%
60%
-30 (-22)
50%
50%
C (F)
MA-4-10
MAINTENANCE PROCEDURE
CAUTION
CHANGING COOLANT
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the radiator filler cap while the engine cooling system is hot. Wait until it cools down.
z Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen to allow
a reduction in pressure in the cooling system.
MA-4-11
MAINTENANCE PROCEDURE
Once a year the cooling system should be drained and thoroughly
flushed.
Unless the cooling system is treated with a corrosion preventive,
rust and scale will eventually clog up passages in the radiator and
water jackets. This condition is aggravated in some localities by formation of insoluble salts from the water used.
CAUTION
z
4.
5.
Open the radiator drain cock and the cylinder block drain
cock.
Drain all coolant solution from the system into the containers.
Shut the drain cocks. Fill the cooling system with a proper
mixture of water and a good quality cooling system detergent. (Refer to the additional instructions on the detergent
container.)
Start the engine and run it at a high idling speed until the
indicator points to the middle region of the coolant temperature gauge. Maintaining the above coolant temperature with
the thermostat open, run the engine and allow the detergent
to circulate throughout the cooling system for at least 15
minutes.
Stop the engine. Open the drain cocks and completely drain
the detergent from the system.
6.
7.
8.
9.
MA-4-12
MAINTENANCE PROCEDURE
10. Shut the drain cocks and fill the cooling system with plain
water. Start the engine and run it at a moderate speed in
the same manner as described in step 8.
11. Stop the engine. Open the drain cocks and drain the rinsing
water.
12. Repeat rinsing procedure 2 or 3 times until the discharged
rinsing water appears clean.
13. Drain the coolant from the coolant reservoir tank as necessary.
14. Close the drain cocks and remove the drain hose from the
radiator drain cock.
Never get your hand near the fan, when the engine is
operated.
z If fan clutch is equipped, the fan rotating speed may
seem to slow when the coolant is cool, but never try to
touch the fan and other rotating parts while the engine is
running.
z
MA-4-13
MAINTENANCE PROCEDURE
RADIATOR CAP
Attach the radiator cap to a cap tester, and measure the operating
pressure of the radiator cap valve. If the measured value exceeds
the maintenance standard, replace.
Unit: kPa {kgf/cm2, psi}
Maintenance standard
Service limit
39 - 59 {0.4 - 0.6, 6 - 9}
FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1. Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2. Check the fan clutch for proper operation:
z
Rotate the cooling fan by hand (adjacent parts should be
cool) to ensure it moves smoothly without binding.
z
Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the H range. Stop
the engine to ensure that the cooling fan no longer rotates
by hand.
NOTE
z
Unit: C (F)
Item
FE6A
FE6B 119 kW {162 PS}
FE6B 132 kW {180 PS}
FE6B 132 kW {180 PS}
FE6T 135 kW {183 PS}
FE6T 151 kW {205 PS}
FE6TA 157 kW {213 PS}
FE6T 151 kW {205 PS}
FE6T 162 kW {220 PS}
FE6TA 157 kW {213 PS}
FE6TA 173 kW {235 PS}
FD1300L
ON - OFF
type
Run the
engine
continuously
Operating
temperature (T)
3,000
rpm
755
(1679)
FDL1700
Linear
type
FDL2000
3,400
rpm
6510 805
(14918 1769)
5010 805
(12218 1769)
MA-4-14
MAINTENANCE PROCEDURE
V-BELT
Be sure the engine is off and the transmission is in Neutral.
Engage the parking brake securely.
1. Visually check the V-belt daily for cracks and damage. If the
belt is cracked or damaged excessively, replace it. Also
check that the belt does not come in contact with the bottom
of the pulley groove. Replace the belt if necessary.
2.
Maintenance standard
Service limit
10 - 15 (0.39 - 0.59)
7 - 12 (0.28 - 0.47)
2.
3.
Cooler belt
1. Loosen the lock nut.
2. Adjust the belt tension to the specified value by the adjusting bolt.
3. Tighten the lock nut.
: 35 - 47 Nm {3.6 - 4.8 kgfm, 26 - 35 ftlbf}
MA-4-15
MAINTENANCE PROCEDURE
THERMOSTAT
1.
2.
3.
z
Thermostat
88 (190)
76.5 (170)
Valve lift/ temperature
82 (180)
mm/C (in/F)
88 (190)
Maintenance
standard
Service limit
74.5 - 78.5
(166 - 173)
71.5 - 81.5
(161 - 179)
80 - 84
(176 - 183)
77 - 87
(171 - 189)
86 - 90
(187 - 194)
85 - 93
(185 - 199)
NOTE
z
4.
5.
MA-4-16
MAINTENANCE PROCEDURE
FUEL SYSTEM
WARNING
WARNING
Observe the following when removing parts of the fuel system:
z Post a placard that reads: CAUTION: FLAMMABLE.
z Prepare a fire extinguisher.
z Disconnect the ground terminal from the battery.
GOVERNOR SETTING
Make sure that the parts shown in the figure below are secured with
sealing caps and wires. If the cap or wire is broken, check and
adjust the injection pump and governor.
CAUTION
z
INJECTION TIMING
1.
2.
Remove the pointer cover. Secure the pointer to the flywheel housing using bolts.
Crank the engine in the standard direction by turning the flywheel with a lever until the pointer is aligned with the timing
mark.
Maintenance
standard
Service
limit
14
15
12
12
10
12
Item
FE6A
FE6B
Fuel
injection
timing
FE6T
FE6T
A
Remarks
MD-TICS
system
NOTE
z
If the mark goes past the pointer, move it back past the
pointer and turn again in the standard direction until
alignment is made.
MA-4-17
MAINTENANCE PROCEDURE
3.
4.
FE6A
FE6B
FE6T
FE6TA
Timing mark
Remarks
13 - 15
119 kW {162 PS}
14 - 16
11 - 13
11 - 13
9 - 11
8 - 10
2 - 4
11 - 13
MD-TICS system
MA-4-18
MAINTENANCE PROCEDURE
z
3.
4.
5.
6.
FE6A
FE6B
FE6T
FE6TA
Timing mark
Remarks
13 - 15
119 kW {162 PS}
14 - 16
11 - 13
11 - 13
9 - 11
8 - 10
2 - 4
11 - 13
MD-TICS system
NOTE
z
Perform this measurement at least three times, and calculate the average value.
MA-4-19
MAINTENANCE PROCEDURE
IDLE SPEED
NOTE
z
1.
2.
3.
Idle
speed
Item
Maintenance
standard
Service limit
600
650
550
FE6T
A
NOTE
MA-4-20
MAINTENANCE PROCEDURE
NOTE
z
3.
No-load maximum
engine speed
Maintenance standard
Service limit
3,600
ACCELERATOR LINKAGE
Check accelerator linkage for bent rods, interference with nearby
parts or looseness.
Remove carbon from around the openings by using the corner of a hard piece of wood. Do not use waste or any other
material to push carbon into the openings.
MA-4-21
MAINTENANCE PROCEDURE
6.
Injection nozzle
hole diameter
Wire diameter
Z
D3
0.29 (0.0114)
0.26 (0.0102)
D2
A5
A6
A3
0.30 (0.0118)
0.29 (0.0114)
C1
0.245 (0.0096)
0.23 (0.0091)
7.
FUEL LEAKAGE
Check the fuel system for leakage at tube or hose connections.
MA-4-22
MAINTENANCE PROCEDURE
Cartridge type
1.
2.
3.
Apply a thin coat of clean engine oil to the gasket of the new
filter.
WARNING
WARNING
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in loss of fuel
and fire hazard due to spilled fuel.
4.
Install the new fuel filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an additional 3/4 of a turn.
CAUTION
z When installing the fuel filter, tighten by hand. Do not
use a wrench or other tools which could result in overtightening and damage to the filter.
5.
After installing the filter, purge air from the fuel system and
check for fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.
MA-4-23
MAINTENANCE PROCEDURE
3.
Loosen the center bolt and remove the filter case, set
spring, element and other parts.
4. Check the element for clogging and contamination.
5. Clean the filter parts in light oil.
6. Replace the packings.
7. Reassemble the parts correctly.
Center bolt
: 20 - 29 Nm {2.0 - 3.0 kgfm, 14 - 22 ftlbf}
WARNING
WARNING
z Make sure fuel leaks are not present after installing
parts. Leaks will not only waste fuel but also create a fire
hazard.
NOTE
z
8.
1.
Drain plug
6.
Seat spring
2.
Packing
7.
Retainer
3.
Center bolt
8.
Element
4.
Packing
9.
Packing
5.
Filter case
10.
Filter cover
After installing the filter, purge air from the fuel system and
check for fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.
Place a receiver under the filter, then loosen the drain plug to drain
sediment.
Put the drained precipitates in a glass container such as a test tube.
If there is fuel on top of the water, dust and precipitates, it indicates
that the precipitates have been removed.
Bleed air from the fuel system after draining sediments.
MA-4-24
MAINTENANCE PROCEDURE
3.
Loosen the center bolt, and remove the filter case, set sprig
and element.
4. Clean each part in light oil.
5. Replace the element packings.
6. Reassemble each part correctly.
Center bolt
: Type I
20 - 29 Nm {2.0 - 3.0 kgfm, 14 - 22 ftlbf}
: Type II
59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}
Drain plug (Type II only)
: 16 - 22 Nm {1.6 - 2.2 kgfm, 12 - 16 ftlbf}
z
Do not excessively tighten the bolts and plugs.
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
Type I
1.
Plug
7.
Set spring
2.
Packing
8.
Retainer
3.
Drain cock
9.
Element
4.
Center bolt
10.
Packing
5.
Packing
11.
Filter cover
6.
Filter case
Type II
7.
1.
Drain plug
7.
Seat
2.
Packing
8.
Element
3.
Center bolt
9.
Packing
4.
Packing
10.
Filter cover
5.
Filter case
11.
Filter plug
6.
Spring
12.
O-ring
After installing the filter, purge air from the fuel system and
check fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.
MA-4-25
MAINTENANCE PROCEDURE
FUEL STRAINER
Draining sediment from fuel strainer
1.
2.
3.
Cleaning procedure
1.
Place a suitable oil can under the drain plug, and drain the
fuel and sediment.
2. Loosen the center bolt, and remove the case, set spring
baffle and other parts.
3. Clean each part in light oil.
4. Replace the packings.
5. Reassemble each part correctly.
Center bolt
: 15 - 20 Nm {1.5 - 2.0 kgfm, 11 - 14 ftlbf}
NOTE
z
Strainer cover
6.
Spring retainer
2.
Packing
7.
Strainer case
3.
Screen
8.
Packing
4.
Baffle
9.
Center bolt
5.
Set spring
10.
Drain plug
NOTE
z
6.
After installing the filter, purge air from the fuel system and
check fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.
MA-4-26
MAINTENANCE PROCEDURE
1.
2.
3.
4.
MA-4-27
MAINTENANCE PROCEDURE
Cover assembly
4.
Inner element
2.
Packing
5.
Evacuator valve
3.
Outer element
6.
Body assembly
1.
2.
3.
MA-4-28
MAINTENANCE PROCEDURE
Wing nut
7.
Outer element
2.
Packing
8.
Wing nut
3.
Cover assembly
9.
Packing
4.
Packing
10.
Inner element
5.
Wing nut
11.
Evacuator valve
6.
Packing
12.
Body assembly
1.
2.
3.
4. First remove the wig nut and then the inner element.
NOTE
z Do not remove the inner element until the specified
replacement time. In other words, the inner element need
not be checked between replacements.
MA-4-29
MAINTENANCE PROCEDURE
CONDITION OF EXHAUST
Warm up the engine sufficiently, then visually inspect exhaust
smoke during idling, acceleration and deceleration with the vehicle
at a stop.
Color of smoke
Judgment standard
Normal
Black
Abnormal
Incomplete combustion
White
Abnormal
Engine oil is also burning. However,
exhaust gases are often white when either
the air or engine temperature is low.
3.
MA-4-30
MAINTENANCE PROCEDURE
5.
5.
PCV VALVE
Point of inspection
Cover the hole at the center of the bottom of the valve with
masking tape and suck on the valve outlet to check that air
is sucked into the inlet hole on the bottom of the valve.
z
Next, cover the inlet hole on the bottom of the valve and
suck on the outlet pipe to check that the diaphragm opens
and closes properly. This can be confirmed by the operating
sound which the diaphragm makes when opening and closing.
If there are any abnormalities, replace the valve.
NOTE
z When sucking on the valve, be careful not to get any oil
in mouth. First remove the oil from inside the valve.
z
MA-4-31
MAINTENANCE PROCEDURE
PCV SYSTEM
Hose and clamp
Check hose connections for signs of chafing, leaks or deterioration.
Replace faulty hoses or tighten clamps, as necessary.
Piping
Check piping and connections for improper installation, cracks or
damage. Remove the hose when the PCV valve is replaced and
clean the inside of the hose with compressed air.
Replace faulty hoses or retighten clamps, as necessary.
OTHERS
ALTERNATOR
Check the ball bearings for proper rotation and abnormal noise.
STARTING MOTOR
Inspect the moving contactor of the magnetic switch.
MA-4-32
- MEMO -
TROUBLE DIAGNOSIS
TD
CONTENTS
DIAGNOSIS ............................................ TD-1-1
DIFFICULT ENGINE STARTING .....................
BLACK EXHAUST SMOKE ..............................
WHITE EXHAUST SMOKE ..............................
IRREGULAR ENGINE OPERATION................
TD-1-2
TD-1-3
TD-1-3
TD-1-4
TD-1-5
TD-1-6
TD-1-7
TD-1-8
TD-1-9
DIAGNOSIS
DIAGNOSIS
DIAGNOSIS GUIDE
The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling
the engine on the basis of the symptoms of the problem complained of by the user and the result of checks
performed in the shop with the engine mounted in the body.
Open the page of the guide corresponding to the trouble symptom complained of by the user.
Check all of the points listed in the page.
If there is any applicable item in the checking points, the cause of the trouble may be assumed in the
following manner.
z
Each item in the Symptoms and checking points section corresponds to one or more items in the
Cause of trouble section through the dot mark z. If there are more than one applicable Cause of
trouble items, the item having the largest number of dot marks should be regarded as the central
cause of the trouble.
z
The cause items having no dot mark can be regarded as not being the cause of the trouble.
NOTE
z If more than one cause is assumed, the repair should begin with the simplest operation.
TD-1-1
Faulty starter
Electrical system
Fuel system
Engine proper and others
Cause of trouble
Discharged battery
DIAGNOSIS
z
z
Lack of fuel
Faulty nozzle
z
z
z
z
z
z
z
z
z
z
z
TD-1-2
Engine knocks
Irregular idling
Intake
system
Fuel system
Faulty nozzle
z
z
Cause of trouble
DIAGNOSIS
z
z
Engine proper
and others
z
z
TD-1-3
Fuel system
z
z
z
z
Others
z
z
z
z
z
z
z
z
TD-1-4
z
z
z
z
z
z
Malfunction of governor
Irregular idling
Engine knock
Cause of trouble
IRREGULAR ENGINE
OPERATION
DIAGNOSIS
z
z
Fuel system
Intake and exhaust
system
Engine proper
Others
z
z
z
z
z
z
z
z
z
Seized piston
z
z
TD-1-5
Engine overheats
Irregular idling
Engine knock
Cause of trouble
DIAGNOSIS
Turbocharger
Engine proper
z
z
z
Engine knock
Cause of trouble
EXCESSIVE OIL
CONSUMPTION
DIAGNOSIS
z
z
TD-1-6
Others
Engine
proper
Fuel system
Irregular idling
z
z
TD-1-7
Clutch slip
Prolonged idling
z
z
Dragged brake
Chassis
Driving
habits
Engine overheats
Engine knock
Cause of trouble
DIAGNOSIS
Others
Fuel system
TD-1-8
z
z
z
z
z
Engine overheats
z
z
z
Cause of trouble
NOISY ENGINE
DIAGNOSIS
Water pump
Coolant
passage
Radiator
Coolant leakage
z
z
z
z
Air bubbles appear in water tank only when water temperature is high
Damaged impeller
Coolant leakage from engine coolant passage
Malfunction of thermostat
Others
Cause of trouble
ENGINE OVERHEATS
DIAGNOSIS
TD-1-9
- MEMO -
- MEMO -
ENGINE DISASSEMBLY
AND REASSEMBLY
DR
CONTENTS
SERVICE DATA ...................................... DR-1-1
TIGHTENING TORQUE ................................... DR-1-1
TOOLS .................................................... DR-2-1
CONSTRUCTION.................................... DR-3-1
ENGINE ............................................................ DR-3-1
GEAR TRAIN.................................................... DR-3-5
ENGINE REAR PTO ........................................ DR-3-6
DISASSEMBLY AND
REASSEMBLY ........................................ DR-4-1
OUTSIDE OF ENGINE .....................................
CYLINDER HEAD.............................................
ENGINE PROPER ............................................
ENGINE REAR PTO.........................................
DR-4-1
DR-4-11
DR-4-17
DR-4-27
SERVICE DATA
SERVICE DATA
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Front side
Rear side
2nd
3rd
1st
98 {10.0, 72}
2nd
Bracket
29 {3.0, 22}
Cushion
49 {5.0, 36}
Cushion
49 {5.0, 36}
M8
M12
10 - 12 {1.0 - 1.2, 7 - 9}
Remarks
FE6TA
157 kW {213 PS}
FE6TA
157 kW {213 PS}
DR-1-1
Tighten diagonally.
SERVICE DATA
Unit: Nm {kgfm, ftlbf}
Item
Injection pump drive gear mounting nut
Injection pump mounting bolt
Injection pump stay
mounting bolt
Tightening torque
147 - 167 {15.0 - 17.0, 108 - 123}
20 - 25 {2.0 - 2.5, 14 - 18}
21 - 26 {2.1 - 2.7, 15 - 20}
29 - 39 {3.0 - 4.0, 22 - 29}
21 - 26 {2.1 - 2.7, 15 - 20}
177 - 196 {18.0 - 20.0, 130 - 145}
25 {2.5, 18}
25 {2.5, 18}
20 {2.0, 14}
20 {2.0, 14}
Remarks
98 {10.0, 72}
Do not overtighten.
10 - 13 {1.0 - 1.3, 7 - 9}
DR-1-2
TOOLS
TOOLS
Tool name and number
Description
Socket wrench
99535 Z5007
Guide bolt
99687 97001
Engine stand
99550 96001
DR-2-1
Shape
TOOLS
Description
Engine jack
99890 Z0001
DR-2-2
Shape
CONSTRUCTION
CONSTRUCTION
ENGINE
ENGINE MODEL FE6
DR-3-1
CONSTRUCTION
DR-3-2
CONSTRUCTION
DR-3-3
CONSTRUCTION
DR-3-4
CONSTRUCTION
GEAR TRAIN
DR-3-5
CONSTRUCTION
DR-3-6
4. Alternator
5. Hydraulic pump
, 6. Thermostat housing
7. Water pump
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-1
DR-4-2
DR-4-3
, 7. Oil pipe
, 8. Oil filter
9. Oil cooler
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-4
7 Oil pipe
Connect the oil pipe using an O-ring.
NOTE
z
6 Exhaust manifold
Install the exhaust manifold using a gasket.
NOTE
z
These nuts are heat-resistant and should not be confused with other types.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}
DR-4-5
6. Intake manifold
7. Nozzle assembly
, 8. Timer coupling
, 9. Injection pump assembly and stay
10. Starting motor
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-6
1.
2.
Align the scribe mark on the injection pump drive gear tooth
with the pointer at the check window on the upper side of
the timing gear case. Then, install the compressor or injection pump support.
2.
DR-4-7
4.
5.
6.
Equally tighten the bolts (1), (2), (3) and (4) in that order so
that the dial gauge pointer stays in the 00.05 mm
(00.0020 in) range. Then tighten these bolts to the specified torque.
NOTE
z Be sure to equally tighten the bolts in the order enumerated above.
:20 - 25 Nm {2.0 - 2.5 kgfm, 14 - 18 ftlbf}
DR-4-8
8.
9.
10. Rotate the flywheel so that the pointer is aligned with the
specified fuel injection timing mark. If the timing marks on
the injection pump body and injection pump timer are not
close each other, rotate the flywheel an additional turn until
the No. 1 cylinder is set at TDC on the compression stroke.
Maintenance
standard
Service
limit
14
15
12
12
10
12
Item
FE6A
FE6B
Fuel
injection
timing
FE6T
FE6T
A
Remarks
MD-TICS
system
DR-4-9
13. Tighten the coupling half cotter bolts to the specified torque.
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}
: FE6TA 157 kW {213 PS}
83 - 93 Nm {8.5 - 9.5 kgfm, 61 - 69 ftlbf}
DR-4-10
CYLINDER HEAD
DISASSEMBLY AND REASSEMBLY
Step 1
3. Gasket
4. O-ring
5. Breather adapter
6. O-ring
DR-4-11
Step 2
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-12
Step 3
23. O-ring
24. Valve guide
25. Push rod pipe
26. Front engine slinger
27. Stay
28. Rear engine slinger
,+ 29. Cylinder head
30. Head gasket
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-13
29 Cylinder head
Remove the cylinder head assembly. Attach chains or cables to the
engine lifters and lift the cylinder head away from the cylinder block
using a hoist.
NOTE
z
DR-4-14
Be sure to align the end of the rocker arm with that of the
push rod.
Tighten the middle bolt first and move toward the outer
ones.
DR-4-15
- MEMO -
DR-4-16
ENGINE PROPER
DISASSEMBLY AND REASSEMBLY
DR-4-17
DR-4-18
DR-4-19
Marks + and , indicate that the key points of operation are explained in the text.
Lift the engine with a hoist and attach it to the engine stand
(99550 96001).
1 Flywheel
1. Measure and record the surface runout of the flywheel that
engages with the clutch disc. (Manual transmission model
only)
DR-4-20
22 Piston assembly
1. Measure the side clearance of the large end of the connecting rod.
DR-4-21
23 Crankshaft assembly
1. Measure and record the end play of the crankshaft.
2.
24 Idler gear
Measure and record the end play of the idler gear.
26 Camshaft assembly
Remove the camshaft gear and camshaft.
NOTE
z Turn the oil pan sideways so that the cam follower cannot drop into the oil pan when removing the camshaft.
DR-4-22
22 Crankshaft
1. Install upper main bearing shells.
NOTE
z Be sure to reinstall all shells in their original positions.
2.
3.
Install the main bearing cap with the arrow mark facing
the front of the engine in the order of embossed numbers.
4.
DR-4-23
Service limit
0.40 (0.0157)
22 Piston assembly
1. Insert the piston assembly (including the connecting rod,
upper bearing shell and bolts) into the cylinder liner using
the piston insert tool (99631 Z5502).
NOTE
z When installing the piston rings, ensure that their gaps
are 180 opposite of each other and are not positioned in
the direction of the piston pin and at a right angle to it.
z Face the arrow mark on the piston toward the front of the
engine when inserting the piston assembly.
z Ensure that the number stamped on the large end of
each connecting rod is the same as that on the cylinder
when installing the piston assembly.
Engine model
FE6T
FE6TA
FE6A
FE6B
FE6T
Type II
135 kW {183 PS}
162 kW {220 PS}
Type III
DR-4-24
3.
Measure the side clearance of the large end of the connecting rod.
Unit: mm (in)
Maintenance standard
Service limit
24 Idler gear
1. Install the idler gear.
NOTE
z Align the timing mark on the camshaft gear with that on
the crank gear.
: 34 - 39 Nm {3.5 - 4.0 kgfm, 25 - 29 ftlbf}
2.
Service limit
0.3 (0.012)
DR-4-25
Service limit
0.30 (0.0118)
10 Hydraulic pump
Using grease, affix a fuse to a tooth of the hydraulic pump gear and
install the hydraulic pump on the timing gear case. Rotate the pump
gear and measure the thickness of the smashed fuse to determine
the backlash.
Unit: mm (in)
Maintenance standard
Service limit
0.30 (0.0118)
16 Flywheel housing
Install the flywheel housing using a gasket.
NOTE
z On models equipped with the PTO, remove the idler gear
bracket in advance.
1 Flywheel assembly
1. Install the flywheel using the two guide bolts (99687 97001),
and tighten the bolts.
: 235 - 255 Nm {24.0 - 26.0 kgfm, 174 - 188 ftlbf}
2.
Service limit
0.18 (0.0071)
DR-4-26
13. Tray
14. PTO holder
15. O-ring
16. Ball bearing
17. Retaining ring
18. O-ring
19. Retaining ring
, 20. Sub gear
21. Retaining ring
, 22. PTO gear
23. Ball bearing
Marks + and , indicate that the key points of operation are explained in the text.
DR-4-27
Service limit
0.3 (0.012)
NOTE
z
When installing the sub gear, face the F mark toward the
outside and lock it with a retaining ring.
2.
Secure the PTO gear and turn the sub gear in the direction
where the spring opens. When the 8 mm (0.31 in) diameter
hole in the PTO gear aligns with that in the sub gear, insert
an 8 mm (0.31 in) diameter pin.
DR-4-28
Assemble the PTO gear, aligning the oil hole of the drive
shaft with the oil hole of the PTO gear.
4.
Align the pin position with the M24 threaded hole in the
PTO holder and install the pin.
5. Install the holder assembly into the flywheel housing and
extract the pin.
NOTE
z Be sure to extract the pin.
6.
7.
Make sure that the backlash between the PTO gear and
idler gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard
Service limit
0.3 (0.012)
DR-4-29
- MEMO -
- MEMO -
ENGINE PROPER
EP
CONTENTS
SERVICE DATA ...................................... EP-1-1
TOOLS .................................................... EP-2-1
INSPECTION........................................... EP-3-1
CYLINDER BLOCK ..........................................
CRANKSHAFT .................................................
MAIN BEARING SHELL ...................................
CYLINDER LINER ............................................
PISTON AND CONNECTING ROD..................
CAMSHAFT ......................................................
GEAR TRAIN....................................................
FLYWHEEL ......................................................
FLYWHEEL HOUSING AND
TIMING GEAR CASE .......................................
CRANK PULLEY AND DAMPER .....................
EP-3-1
EP-3-2
EP-3-4
EP-3-4
EP-3-5
EP-3-10
EP-3-11
EP-3-12
EP-3-13
EP-3-13
EP-4-1
EP-4-2
EP-4-3
EP-4-4
EP-4-4
EP-4-5
EP-4-5
EP-4-6
EP-4-6
EP-4-7
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
Longitudinal
direction
Transverse direction
0.02 (0.0008)
0.05T - 0.02L
(0.0020T - 0.0008L)
77.930 - 77.950
(3.0681 - 3.0689)
77.82 (3.0638)
64.925 - 64.945
(2.5561 - 2.5569)
64.80 (2.5512)
Item
Crankshaft
Journal out-of-roundness
0.02 (0.0008)
0.02 (0.0008)
Taper of journal
Journal
End play
0.06 - 0.14
(0.0024 - 0.0055)
0.40 (0.0157)
0.03 - 0.09
(0.0012 - 0.0035)
0.15 (0.0059)
Runout
Cylinder
liner
108.00 - 108.03
(4.2520 - 4.2531)
Taper
0 - 0.07
(0 - 0.0028)
0.03 (0.0012)
FE6A
FE6B
FE6T 135 kW {183 PS}
107.825 - 107.855
(4.2451 - 4.2463)
107.940 - 107.970
(4.2496 - 4.2508)
FE6A
FE6B
FE6T 135 kW {183 PS}
0.145 - 0.205
(0.0057 - 0.0081)
0.050 - 0.070
(0.0020 - 0.0028)
36.00 - 36.02
(1.4173 - 1.4181)
Outside
diameter
Piston
Clearance
to cylinder
liner
EP-1-1
T = Tight
L = Loose
Refinishing allowance:
1.0 (0.039)
Indicator reading
Measuring position
From top
108.23 (4.2610)
25, 50, 75, 100, 150, 200
(0.98, 1.97, 2.95, 3.94, 5.91,
7.87)
Out-of-roundness
Remarks
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
2nd
0.04 - 0.08
(0.0016 - 0.0031)
0.4 (0.016)
Oil
0.02 - 0.06
(0.0008 - 0.0024)
0.2 (0.008)
1st
2nd
0.30 - 0.45
(0.0118 - 0.0177)
1.5 (0.059)
FE6A
FE6B
FE6T 135 kW
{183 PS}
0.15 - 0.35
(0.0059 - 0.0138)
1.5 (0.059)
FE6T 151 kW
{205 PS}
FE6T 162 kW
{220 PS}
FE6TA
0.25 - 0.45
(0.0098 - 0.0177)
1.5 (0.059)
35.993 - 36.000
(1.4170 - 1.4173)
0 - 0.03L
(0 - 0.0012L)
0.05 (0.0020)
36.025 - 36.041
(1.4183 - 1.4189)
0.03 - 0.05
(0.0012 - 0.0020)
0.10 (0.0039)
0.10 - 0.30
(0.0039 - 0.0118)
0.035 - 0.095
(0.0014 - 0.0037)
0.15 (0.0059)
No. 1
57.33 - 57.35
(2.2571 - 2.2579)
No. 2
57.13 - 57.15
(2.2492 - 2.2500)
No. 3
56.93 - 56.95
(2.2413 - 2.2421)
No. 4
56.73 - 56.75
(2.2335 - 2.2342)
FE6A
FE6B
FE6TA 173 kW
{235 PS}
IN
48.47 - 48.51
(1.9083 - 1.9098)
47.99 (1.8894)
EXH
48.41 - 48.45
(1.9059 - 1.9075)
47.93 (1.8870)
FE6T
FE6TA 157 kW
{213 PS}
IN
48.79 - 48.83
(1.9209 - 1.9224)
48.31 (1.9020)
EXH
48.41 - 48.45
(1.9059 - 1.9075)
47.93 (1.8870)
0.02 - 0.10
(0.0008 - 0.0039)
0.15 (0.0059)
0.06 (0.0024)
End play
0.08 - 0.28
(0.0031 - 0.0110)
0.3 (0.012)
0.06 - 0.16
(0.0024 - 0.0063)
0.3 (0.012)
0.03 - 0.12
(0.0012 - 0.0047)
0.3 (0.012)
0.02 - 0.06
(0.0008 - 0.0024)
0.2 (0.008)
Item
Piston ring
Joint gap
Oil
Outside diameter
Piston pin
Clearance to piston pin hole
Connecting Twist
rod
Bend
Camshaft
Height of
cam profile
Journal-to-bushing clearance
Gear train
EP-1-2
Remarks
L = Loose
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
Remarks
0.18 (0.0071)
20.5 (0.807)
18.5 (0.728)
21.5 (0.846)
19.5 (0.768)
FE6B, FE6T,
FE6TA
23.0 (0.906)
21.0 (0.827)
FE6B, FE6T,
FE6TA
43.0 (1.693)
45.0 (1.772)
FE6T 162 kW
{220 PS}
FE6TA 157 kW
{213 PS}
48.0 (1.890)
50.0 (1.969)
10 - 15 (0.39 - 0.59)
7 - 12 (0.28 - 0.47)
0.05 - 0.15
(0.0020 - 0.0059)
0.3 (0.012)
0.06 - 0.14
(0.0024 - 0.0055)
0.3 (0.012)
Item
Clutch disc contact surface runout
Type I
Thickness (A)
Flywheel
Type II
Reduced
size of worn
surface
Height (H)
V-belt
Engine rear
PTO
Type II
FE6A, FE6B
FE6T 135 kW
{183 PS}
Deflection
EP-1-3
TOOLS
TOOLS
Tool name and number
Description
Straightedge
99645 Z5001
EP-2-1
Shape
TOOLS
Description
Puller assembly
99718 Z5502
Puller assembly
99718 Z5503
EP-2-2
Shape
INSPECTION
INSPECTION
z
CYLINDER BLOCK
Upper surface warpage
Measure using the straightedge (99645 Z5001).
Unit: mm (in)
Item
Maintenance standard
Service limit
Longitudinal direction
Transverse direction
Service limit
0.02 (0.0008)
EP-3-1
INSPECTION
Service limit
0.05T - 0.02L
(0.0020T - 0.0008L)
Remarks
T: Tight
L: Loose
CRANKSHAFT
Journal outside diameter
When the journal outside diameter exceeds the service limit, it must
be corrected by grinding and undersized main bearing shells must
be installed.
Unit: mm (in)
Maintenance standard
77.930 - 77.950
(3.0681 - 3.0689)
Service limit
Remarks
77.82 (3.0638)
Refinishing allowance:
1.0 (0.039)
Journal out-of-roundness
When the journals exceeds the service limit in out-of-roundness,
they must be corrected by grinding. Install new undersized main
bearing shells.
Unit: mm (in)
Maintenance standard
Service limit
0.02 (0.0008)
Taper of journal
When the journals exceeds the service limit in taper, they must be
corrected by grinding. Install new undersized main bearing shells.
Unit: mm (in)
Maintenance standard
Service limit
Service limit
Remarks
64.925 - 64.945
(2.5561 - 2.5569)
64.80 (2.5512)
Refinishing allowance:
1.0 (0.039)
EP-3-2
INSPECTION
Service limit
0.02 (0.0008)
Service limit
Runout
Support the crankshaft at No. 2 and 6 journals, and measure the
runout of each part.
Unit: mm (in)
Maintenance
standard
Service limit
Journal A
Item
Remarks
Indicator reading
End play
When end play measured at the time of engine disassembly
exceeds the service limit, replace the thrust washers selectively as
a set.
Unit: mm (in)
Maintenance standard
Service limit
0.40 (0.0157)
Thickness mm (in)
0.20 OS
0.40 OS
Remarks
STD: Standard
OS: Oversize
EP-3-3
INSPECTION
Service limit
0.15 (0.0059)
CYLINDER LINER
Measure the cylinder liners with installed in the cylinder block. [The
measuring positions are 25, 50, 75, 100, 150 and 200 mm (0.98,
1.97, 2.95, 3.94, 5.91 and 7.87 in) from the block upper surface.]
Inside diameter
Unit: mm (in)
Maintenance standard
Service limit
108.23 (4.2610)
Out-of-roundness
Unit: mm (in)
Maintenance standard
Service limit
Taper
Unit: mm (in)
Maintenance standard
Service limit
Service limit
0 - 0.07 (0 - 0.0028)
Service limit
0.03 (0.0012)
EP-3-4
INSPECTION
1st ring
8.
Bolt
2.
2nd ring
9.
Connecting rod
3.
Oil ring
10.
4.
Piston
11.
5.
Snap ring
12.
6.
Piston pin
13.
Nut
7.
Bushing
Remove the piston rings using the piston ring tool (99630
Z5001).
EP-3-5
INSPECTION
PISTON
Outside diameter
The piston outside diameter should be checked at 18.5 mm (0.728
in) from the piston bottom and perpendicular to the piston pin.
Unit: mm (in)
Item
Maintenance standard
Service limit
FE6A, FE6B,
FE6T 135 kW {183 PS}
107.825 - 107.855
(4.2451 - 4.2463)
107.940 - 107.970
(4.2496 - 4.2508)
Maintenance standard
Service limit
FE6A, FE6B,
FE6T 135 kW {183 PS}
0.145 - 0.205
(0.0057 - 0.0081)
0.050 - 0.070
(0.0020 - 0.0028)
Service limit
EP-3-6
INSPECTION
PISTON RING
Clearance between piston ring and ring groove
NOTE
z
Maintenance standard
Service limit
2nd
0.4 (0.016)
Oil
0.2 (0.008)
Joint gap
Unit: mm (in)
Item
Maintenance standard
Service limit
0.30 - 0.45
(0.0118 - 0.0177)
1.5 (0.059)
FE6A
FE6B
FE6T 135 kW {183 PS}
0.15 - 0.35
(0.0059 - 0.0138)
1.5 (0.059)
0.25 - 0.45
(0.0098 - 0.0177)
1.5 (0.059)
1st
2nd
Oil
PISTON PIN
Outside diameter
Unit: mm (in)
Maintenance standard
Service limit
EP-3-7
INSPECTION
Service limit
0 - 0.03L (0 - 0.0012L)
0.05 (0.0020)
Remarks
L = Loose
CONNECTING ROD
Small-end bushing inside diameter
Unit: mm (in)
Maintenance standard
Service limit
Service limit
0.10 (0.0039)
Service limit
0.15 (0.0059)
EP-3-8
INSPECTION
200 (7.87)
Unit: mm (in)
Maintenance
standard
Service limit
Remarks
Bend
Twist
Distance between
pins: 200 (7.87)
Item
Service limit
Install the piston rings using the piston ring tool (99630
Z5001).
NOTE
Type I
Type II
2nd ring
Oil ring
Engine model
Type II
Type III
EP-3-9
INSPECTION
2.
CAMSHAFT
End play
Unit: mm (in)
Maintenance standard
Service limit
0.3 (0.012)
Nut
5.
Locating plate
2.
Lock washer
6.
Key
3.
Plain washer
7.
Camshaft
4.
Camshaft gear
Maintenance standard
Service limit
No. 1
No. 2
No. 3
No. 4
EEP3-025
Journal-to-bushing clearance
Calculate the clearance from the journal outside diameter and
bushing inside diameter.
Unit: mm (in)
Maintenance standard
Service limit
0.15 (0.0059)
EP-3-10
INSPECTION
Maintenance standard
Service limit
Runout
Support the camshaft at No. 2 and 3 journals and measure the
runout of No. 1 and 4 journals.
Unit: mm (in)
Maintenance standard
Service limit
Remarks
0.06 (0.0024)
Indicator reading
GEAR TRAIN
Front gear train backlash
Unit: mm (in)
Maintenance standard
Service limit
0.3 (0.012)
EP-3-11
INSPECTION
Service limit
0.2 (0.008)
Service limit
0.3 (0.012)
FLYWHEEL
Clutch disc contact surface runout
Unit: mm (in)
Maintenance standard
Service limit
0.18 (0.0071)
Be careful since dimension A may exceed service limits. Dimension H is within service limits on type II flywheel where the clutch contacting surface was ground to
the specification.
Unit: mm (in)
Item
FE6A, FE6B
Type I FE6TA 135 kW
{183 PS}
Thickness (A)
FE6B, FE6T
Type II
FE6TA
FE6B, FE6T
FE6TA
Height (H)
Maintenance
standard
Service limit
20.5 (0.807)
18.5 (0.728)
21.5 (0.846)
19.5 (0.768)
23.0 (0.906)
21.0 (0.827)
43.0 (1.693)
45.0 (1.772)
48.0 (1.890)
50.0 (1.969)
EP-3-12
INSPECTION
V-BELT
Check the V-belt for cracks or damage. Also check if it is out of contact with the pulley grooves.
Unit: mm (in)
Maintenance
standard
Service limit
Remarks
10 - 15 (0.39 - 0.59)
7 - 12 (0.28 - 0.47)
When midpoint is
pressed with
98 N {10 kgf, 22 lbf}
Item
Deflection
EP-3-13
2.
EP-4-1
After press-fitting the cylinder liners, check the inside diameter, out-of-roundness, taper and flange protrusion.
NOTE
z The main bearing caps should be tightened to the specified torque.
: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
Unit: mm (in)
Item
Inside diameter
Maintenance
standard
Service
limit
Measuring position
From top
108.00 - 108.03 108.23
25, 50, 75, 100, 150,
(4.2520 - 4.2531) (4.2610)
200 (0.98, 1.97, 2.95,
3.94, 5.91, 7.87)
Out-of-roundness
Taper
0 - 0.07
(0 - 0.0028)
0.03 (0.0012)
Remarks
EP-4-2
Installing bushings
1.
2.
NOTE
z
CRANKSHAFT CORRECTION
Journals
When correcting the crankshaft journals by grinding, they must be
ground undersized so that the clearance between the new undersized bearing shell and the journal is within the maintenance standard.
Crank pins
When correcting the crank pins by grinding, they must be ground
undersized so that the clearance between the new undersized
bearing shell and the crank pin is within the maintenance standard.
NOTE
EP-4-3
Size symbol
STD
0.25US
0.50US
0.75US
1.00US
US: Undersized
Size symbol
STD
0.25US
0.50US
0.75US
1.00US
US: Undersized
FE6A
FE6B
FE6T 135 kW {183 PS}
FE6T 151 kW {205 PS}
FE6TA
Type I
Type II
EP-4-4
3.
Service limit
0.10 (0.0039)
Press-fit the bushing so that the end face of the boss on the
front of the engine is level with the end face of the bushing.
NOTE
z The fitted face of the boss at the front should be 1.5 mm
(0.059 in) lower than the rear end face (H).
2.
Service limit
0.2 (0.008)
EP-4-5
FLYWHEEL CORRECTION
The runout of the surface which contacts the clutch disc should be
corrected to the maintenance standard by grinding and/or cutting.
NOTE
Unit: mm (in)
Item
FE6A, FE6B
Type I FE6TA 135 kW
{183 PS}
Thickness (A)
FE6B, FE6T
Type II
FE6TA
FE6B, FE6T
FE6TA
Height (H)
Maintenance
standard
Service limit
20.5 (0.807)
18.5 (0.728)
21.5 (0.846)
19.5 (0.768)
23.0 (0.906)
21.0 (0.827)
43.0 (1.693)
45.0 (1.772)
48.0 (1.890)
50.0 (1.969)
EP-4-6
Injection pump
bracket setting
tool
Tool number
Remarks
99720 Z5500
99720 Z5501
3.
4.
After reaming, driven in the dowel pin and caulk the dowel
pin hole. The dowel pin should be driven in so that it is
slightly below 1 mm (0.04 in) or so the bracket surface.
99718 Z5500
99687
99718 Z5501 97002
Outside diameter
of the rear edge of
the crankshaft
135 (5.31)
110 (4.33)
145 (5.71)
148 (5.83)
120 (4.72)
EP-4-7
3.
4.
Outside diameter of
sleeve
Outside diameter of
the rear edge of the
crankshaft
99718 Z5502
115 (4.53)
110 (4.33)
99718 Z5503
125 (4.92)
120 (4.72)
5.
6.
Guide bolt
No.
99687 97002
Outside
diameter of
sleeve
Outside
diameter of
the rear edge
of the crankshaft
115 (4.53)
110 (4.33)
125 (4.92)
120 (4.72)
Guide bolt
No.
99687 97002
Outside
diameter of
oil seal
Outside
diameter of
the rear edge
of the crankshaft
135 (5.31)
110 (4.33)
145 (5.71)
120 (4.72)
EP-4-8
- MEMO -
CONTENTS
SERVICE DATA ...................................... HV-1-1
SERVICE DATA ............................................... HV-1-1
TIGHTENING TORQUE ................................... HV-1-3
TOOLS .................................................... HV-2-1
CONSTRUCTION.................................... HV-3-1
REMOVAL............................................... HV-4-1
DISASSEMBLY....................................... HV-5-1
CYLINDER HEAD ............................................ HV-5-1
ROCKER SHAFT ............................................. HV-5-2
INSPECTION........................................... HV-6-1
CYLINDER HEAD ............................................ HV-6-1
VALVE INSERT ................................................ HV-6-1
VALVE .............................................................. HV-6-1
VALVE GUIDE.................................................. HV-6-2
VALVE SPRING ............................................... HV-6-2
HV
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
Remarks
89.9 - 90.1
(3.539 - 3.547)
89.7 (3.531)
Max. allowable
grinding limit:
0.3 mm (0.012 in)
Longitudinal
direction
0.2 (0.008)
Transverse direction
0.2 (0.008)
Intake
50.0 - 50.02
(1.9685 - 1.9693)
Exhaust
41.0 - 41.02
(1.6142 - 1.6150)
1.25 - 1.35
(0.0492 - 0.0531)
Intake
30 - 3030
Exhaust
45 - 4530
Intake
2.2 - 2.4
(0.087 - 0.094)
3.5 (0.138)
Exhaust
2.0 - 2.3
(0.079 - 0.091)
3.5 (0.138)
Intake
2930 - 30
Exhaust
4430 - 45
Intake
8.96 - 8.98
(0.3528 - 0.3535)
Exhaust
8.92 - 8.94
(0.3512 - 0.3520)
Intake
2.16 (0.0850)
1.8 (0.071)
Exhaust
1.65 (0.0650)
1.3 (0.051)
Intake
1.33 - 1.83
(0.0524 - 0.0720)
2.8 (0.110)
Exhaust
1.03 - 1.53
(0.0406 - 0.0602)
2.3 (0.091)
Intake
0.3 - 0.4
(0.012 - 0.016)
Exhaust
0.3 - 0.4
(0.012 - 0.016)
Item
Cylinder head
Flatness
Valve insert
Valve
Outside diameter of
valve stem
Valve clearance
HV-1-1
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
Intake
9.00 - 9.02
(0.3543 - 0.3551)
Exhaust
9.00 - 9.02
(0.3543 - 0.3551)
Intake
0.02 - 0.05
(0.0008 - 0.0020)
0.15 (0.0059)
Exhaust
0.05 - 0.09
(0.0020 - 0.0035)
0.20 (0.0079)
15 (0.59)
Outer
62.8 (2.472)
55.0 (2.165)
Inner
60.9 (2.398)
58.0 (2.283)
Outer
246.2 - 271.7
{25.1 - 27.7,
55.3 - 61.1}
Inner
126.5 - 140.2
{12.9 - 14.3,
28.4 - 31.5}
19.98 - 20.00
(0.7866 - 0.7874)
19.90 (0.7835)
0.06 (0.0024)
0.1 (0.004)
20.02 - 20.04
(0.7882 - 0.7890)
20.10 (0.7913)
0.02 - 0.06
(0.0008 - 0.0024)
0.2 (0.008)
60.0 (2.362)
49.0 (1.929)
21.6 - 31.4
{2.2 - 3.2,
4.9 - 7.1}
Outside diameter
19.96 - 19.98
(0.7858 - 0.7866)
19.85 (0.7815)
0.02 - 0.06
(0.0008 - 0.0024)
0.12 (0.0047)
Item
Valve guide
Valve spring
Free length
Tension
N {kgf, lbf}
Squareness
Free length
Inside spring
Tension
N {kgf, lbf}
Cam follower
HV-1-2
Remarks
SERVICE DATA
Maintenance
standard
Item
Service limit
Remarks
Other
Valve arrangement
No. 1 piston at TDC on compression stroke
No. 6 piston at TDC on compression stroke
10
11
12
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Nozzle sleeve
1st
98 {10.0, 72}
2nd
HV-1-3
Remarks
TOOLS
TOOLS
Tool name and number
Description
HV-2-1
Shape
TOOLS
Description
Reamer
99662 Z5500
HV-2-2
Shape
CONSTRUCTION
CONSTRUCTION
HV-3-1
REMOVAL
REMOVAL
1.
3.
HV-4-1
DISASSEMBLY
DISASSEMBLY
CYLINDER HEAD
Marks + and , indicate that the key points of operation are explained in the text.
HV-5-1
DISASSEMBLY
2 Split collar
Remove the split collar using the split collar tool (99624 Z5001).
ROCKER SHAFT
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1.
Stopper bolt
6.
Inside spring
2.
Shaft bracket
7.
3.
Adjusting screw
8.
Bushing
4.
9.
Rocker shaft
5.
Bushing
HV-5-2
INSPECTION
INSPECTION
z
CYLINDER HEAD
Flatness
Unit: mm (in)
Item
Maintenance standard
Service limit
Longitudinal direction
0.2 (0.008)
Transverse direction
0.2 (0.008)
VALVE INSERT
Contact width of valve and valve insert
Unit: mm (in)
Item
Maintenance standard
Service limit
Intake
3.5 (0.138)
Exhaust
3.5 (0.138)
VALVE
Depth of valve below lower surface of cylinder head
Check that the depth is the same as that measured before disassembly.
Unit: mm (in)
Item
Maintenance standard
Service limit
Intake
2.8 (0.110)
Exhaust
2.3 (0.091)
Maintenance standard
Service limit
Intake
2.16 (0.0850)
1.8 (0.071)
Exhaust
1.65 (0.0650)
1.3 (0.051)
HV-6-1
INSPECTION
Maintenance standard
Service limit
Intake
Exhaust
VALVE GUIDE
Clearance to valve stem
Unit: mm (in)
Item
Maintenance standard
Service limit
Intake
0.15 (0.0059)
Exhaust
0.20 (0.0079)
VALVE SPRING
Free length
Unit: mm (in)
Item
Maintenance standard
Service limit
Remarks
Outer
62.8 (2.472)
55.0 (2.165)
Inner
60.9 (2.398)
58.0 (2.283)
Intake and
exhaust
Tension
Unit: N {kgf, lbf}
Item
Maintenance standard
Service limit
Remarks
Outer
246.2 - 271.7
{25.1 - 27.7, 55.3 - 61.1}
When compressed to
44.6 mm (1.756 in)
Inner
126.5 - 140.2
{12.9 - 14.3, 28.4 - 31.5}
When compressed to
41.6 mm (1.638 in)
Squareness
For the outer spring, measure clearance at points A and B shown in
the figure.
Unit: mm (in)
Maintenance standard
Service limit
Remarks
HV-6-2
INSPECTION
Service limit
19.90 (0.7835)
Service limit
0.06 (0.0024)
0.1 (0.004)
Service limit
20.10 (0.7913)
Service limit
0.2 (0.008)
Inside spring
Unit: mm (in)
Item
Maintenance standard
Service limit
Free length
60.0 (2.362)
49.0 (1.929)
Tension
N {kgf, lbf}
21.6 - 31.4
{2.2 - 3.2, 4.9 - 7.1}
16.7
{1.7, 3.7}
Remarks
When compressed
to 33.5 mm
(1.319 in)
HV-6-3
INSPECTION
PUSH ROD
Runout
Measure push rod runout while supporting the center of the spherical surface at each end of the push rod as shown.
Unit: mm (in)
Maintenance standard
Service limit
CAM FOLLOWER
Outside diameter
Unit: mm (in)
Maintenance standard
Service limit
19.85 (0.7815)
Service limit
0.12 (0.0047)
HV-6-4
89.7 (3.531)
Maintenance standard
Service limit
Valve face
angle
Intake
2930 - 30
Exhaust
4430 - 45
Valve head
thickness
Intake
2.16 (0.0850)
1.8 (0.071)
Exhaust
1.65 (0.0650)
1.3 (0.051)
2.
Dress the end of the valve stem using a valve refacer or oil
stone.
NOTE
z Ensure that the end of the valve stem is dressed at a
right angle to the axis and is free from roughness or
damage.
3.
Dress the surface (A) of the valve insert using a valve seat
grinder.
NOTE
z Ensure that the surface (A) is free from stepped wear,
etc.
Item
Seat face
angle
Maintenance standard
Service limit
Intake
30 - 3030
Exhaust
45 - 4530
HV-7-1
Cold-fit procedure
a.
Immerse the valve inserts in dry ice for at least five minutes
before fitting. Some alcohol may be added to the dry ice for
better results.
WARNING
WARNING
z Do not touch the valve insert or dry ice with bare hands
to prevent injury.
b.
c.
Remove the valve inserts and the cylinder head. Using the
valve insert replacer (99665 Z5002), press the inserts into
place on the cylinder head.
3.
Tool number
99675 Z5002
99676 Z5000
81-20616-1A
HV-7-2
2.
3.
4.
Apply engine oil to the valve stem and insert the valve into
the valve guide. Attach a suction cup to the top of the valve
head and turn the valve while lightly tapping the insert with
the valve.
After properly lapping these parts, thoroughly clean the
compound off the parts. Then apply oil to the mating surfaces of the parts and relap.
Clean oil from the mating surfaces. Apply Prussian blue and
repeat lapping both parts until they are lapped properly.
Unit: mm (in)
Item
Contact
width of valve
and valve
insert
Maintenance standard
Service limit
Intake
3.5 (0.138)
Exhaust
3.5 (0.138)
Drive the valve guide from the lower surface of the cylinder
head using the valve guide remover (99667 Z5000).
2.
HV-7-3
Press the valve guide into place. Ream it using the reamer
(99662 Z5500) so that the inside diameter is within the
maintenance standard.
Unit: mm (in)
Item
Inside
diameter
Maintenance standard
Service limit
Intake
9.00 - 9.02
(0.3543 - 0.3551)
Exhaust
9.00 - 9.02
(0.3543 - 0.3551)
3.
Service limit
HV-7-4
Drive the nozzle tube form the lower surface of the cylinder
head using the nozzle tube remover (99655 Z5500).
Remove the O-ring from the nozzle tube.
7.
8.
9.
HV-7-5
REASSEMBLY
REASSEMBLY
CYLINDER HEAD
Key point of reassembly
Before assembling parts, apply engine oil to the sliding surfaces.
9 Exhaust valve, 8 Intake valve
Install the intake and exhaust valves.
NOTE
z
2 Split collar
1. Install the split collar using the split collar tool (99624
Z5001).
2.
Check that the depth of the valve below the lower surface of
the cylinder head is correct.
Unit: mm (in)
Item
Maintenance standard
Service limit
Intake
2.8 (0.110)
Exhaust
2.3 (0.091)
HV-8-1
REASSEMBLY
ROCKER SHAFT
Key point of reassembly
Before assembling parts, apply engine oil to the sliding surfaces.
Assemble the rocker shaft assembly.
NOTE
z
Stopper bolt
6.
Inside spring
2.
Shaft bracket
7.
3.
Adjusting screw
8.
Bushing
4.
9.
Rocker shaft
5.
Bushing
HV-8-2
INSTALLATION
INSTALLATION
1. Install the cylinder head gasket and cylinder head.
NOTE
z Ensure that the stamped part number side faces upward
when installing the gasket.
2.
Tightening torque
Spill tube
6.
HV-9-1
- MEMO -
- MEMO -
LUBRICATION SYSTEM
CONTENTS
SERVICE DATA ...................................... LB-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
LUBRICATION SYSTEM..................................
TOOLS ....................................................
OIL PUMP ...............................................
CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................
LB-1-1
LB-1-1
LB-1-2
LB-1-3
LB-2-1
LB-3-1
LB-3-1
LB-3-1
LB-3-2
LB-3-3
LB-3-4
OIL FILTER..............................................
CONSTRUCTION .............................................
REPLACING OIL FILTER .................................
INSPECTION ....................................................
OIL JET....................................................
CONSTRUCTION .............................................
REMOVAL ........................................................
LB-4-1
LB-4-2
LB-4-2
LB-4-3
LB-5-1
LB-5-1
LB-5-2
LB-5-3
LB-6-1
LB-6-1
LB-6-1
LB
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Lubrication type
Forced-circulation type
Oil pump
Gear pump
Cartridge type
(Full flow only type and full flow & by pass combination type)
Oil filter
Oil cooler
Total
FE6A, FE6B,
FE6T, FE6TA
12 (2-5/8)
FE6TA*
14 (3-1/8)
FE6A, FE6B,
FE6T, FE6TA
15 (3-1/4)
FE6TA*
17 (3-3/4)
NOTE
z
*Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
Side clearance
0.04 - 0.10
(0.0016 - 0.0039)
0.15 (0.0059)
Tip clearance
0.04 - 0.10
(0.0016 - 0.0039)
0.20 (0.0079)
0.16 - 0.27
(0.0063 - 0.0106)
0.50 (0.0197)
0.03 - 0.08
(0.0012 - 0.0031)
0.20 (0.0079)
Relief pressure
kPa {kgf/cm2, psi}
1,030
{10.5, 149}
40.0 (1.575)
Spring tension
N {kgf, lbf}
260.9 - 288.3
{26.6 - 29.4,
58.7 - 64.8}
Item
Oil pump
Relief valve
Oil cooler
LB-1-1
Remarks
SERVICE DATA
Unit: mm (in)
Maintenance
standard
Service limit
275 - 314
{2.8 - 3.2, 40 - 46}
58.5 (2.303)
Spring tension
N {kgf, lbf}
47.515 - 52.516
{4.845 - 5.355,
10.683 - 11.808}
Relief pressure
kPa {kgf/cm2, psi}
98 - 137
{1.0 - 1.4, 14 - 20}
62.0 (2.441)
Spring tension
N {kgf, lbf}
28.882 - 31.922
{2.945 - 3.255,
6.494 - 7.177}
Relief pressure
kPa {kgf/cm2, psi}
422 - 461
{4.3 - 4.7, 61 - 67}
61.0 (2.402)
Spring tension
N {kgf, lbf}
102.48 - 113.27
{10.45 - 11.55,
23.04 - 25.47}
Relief pressure
kPa {kgf/cm2, psi}
275 - 314
{2.8 - 3.2, 40 - 46}
58.5 (2.303)
Spring tension
N {kgf, lbf}
Relief pressure
kPa {kgf/cm2, psi}
98 - 137
{1.0 - 1.4, 14 - 20}
97.0 (3.819)
Spring tension
N {kgf, lbf}
Relief pressure
kPa {kgf/cm2, psi}
422 - 461
{4.3 - 4.7, 61 - 67}
62.0 (2.441)
Spring tension
N {kgf, lbf}
Item
Relief pressure
kPa {kgf/cm2, psi}
Oil cooler
short valve
Type I
Regulating
valve
Oil filter
Oil
pipe
Type II
Oil
cooler
short
valve
Regulating
valve
Remarks
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Location
Tightening torque
20 {2.0, 14}
25 {2.5, 18}
LB-1-2
SERVICE DATA
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION CIRCUIT
LB-1-3
TOOLS
TOOLS
Tool name and number
Description
Hydraulic pump
99570 Z5000
LB-2-1
Shape
OIL PUMP
OIL PUMP
CONSTRUCTION
REMOVAL
Key point of removal
Remove the drain plug from the oil pan and drain engine oil into a
container.
WARNING
WARNING
z
NOTE
z
LB-3-1
OIL PUMP
DISASSEMBLY
4. Ball
5. Cover
6. Gasket
Marks , and + indicate that the key points of operation are explained in the text.
2.
LB-3-2
OIL PUMP
3.
INSPECTION
z
Side clearance
Unit: mm (in)
Maintenance standard
Service limit
0.15 (0.0059)
Tip clearance
Unit: mm (in)
Maintenance standard
Service limit
0.20 (0.0079)
Service limit
0.50 (0.0197)
Service limit
0.20 (0.0079)
Relief valve
Item
Maintenance
standard
Service limit
Relief pressure
kPa {kgf/cm2, psi}
1,030
{10.5, 149}
Free length of
spring
mm (in)
40.0 (1.575)
Spring tension
N {kgf, lbf}
260.9 - 288.3
{26.6 - 29.4,
58.7 - 64.8}
Remarks
Fully opening
pressure 1,765
{18, 256}
When spring is
compressed to
46.0 mm (1.811 in)
LB-3-3
OIL PUMP
REASSEMBLY
Key point of reassembly
8 Pump gear assembly
Attach the driven gear to the pump gear assembly. Measure the
clearances and backlash to ensure that they do not exceed the
maintenance standard.
Unit: mm (in)
Item
Maintenance standard
Service limit
Side clearance
0.15 (0.0059)
Tip clearance
0.20 (0.0079)
Backlash between
pump gears
0.50 (0.0197)
LB-3-4
OIL COOLER
OIL COOLER
CONSTRUCTION
Type I
Type II
Type I: Former
Type II: New
LB-4-1
OIL COOLER
REMOVAL
Key point of removal
Remove the drain plug from the oil pan and drain engine oil into a
container.
WARNING
WARNING
z
DISASSEMBLY
Type I and Type II
3. Cooler element
LB-4-2
4. Housing gasket
OIL COOLER
INSPECTION
z
Service limit
LB-4-3
OIL FILTER
OIL FILTER
CONSTRUCTION
Type I (Full flow only type)
LB-5-1
OIL FILTER
LB-5-2
OIL FILTER
7. Packing
8. Short valve spring
9. Oil filter short valve
10. Clog warning switch
11. Packing
12. Short valve spring
INSPECTION
z
Service
limit
Type I
Type II
58.5 (2.303)
Type I
47.515 - 52.516
{4.845 - 5.355,
10.683 - 11.808}
When compressed to
42.0 mm (1.654 in)
When compressed to
42.0 mm (1.654 in)
Item
Free length of
spring
Spring tension
N {kgf, lbf}
Remarks
LB-5-3
OIL FILTER
Service
limit
Type I
62.0 (2.441)
Type II
97.0 (3.819)
Type I
28.882 - 31.922
{2.945 - 3.255,
6.494 - 7.177}
When compressed to
38.0 mm (1.496 in)
When compressed to
40.5 mm (1.594 in)
Item
Free length of
spring
Spring tension
N {kgf, lbf}
Remarks
Regulating valve
Unit: mm (in)
Maintenance
standard
Service
limit
Type I
61.0 (2.402)
Type II
62.0 (2.441)
Type I
102.48 - 113.27
{10.45 - 11.55,
23.04 - 25.47}
When compressed to
47.25 mm (1.8602 in)
Type II
115.7
{11.8, 26.0}
When compressed to
47.25 mm (1.8602 in)
Item
Free length of
spring
Spring tension
N {kgf, lbf}
Remarks
LB-5-4
OIL JET
OIL JET
CONSTRUCTION
1.
Straight pin
2.
Oil jet
3.
NOTE
z
REMOVAL
Key point of removal
Remove the oil jet bolt, being careful not to drop the gasket into the
cylinder block.
LB-6-1
- MEMO -
COOLING SYSTEM
CONTENTS
SERVICE DATA ...................................... EC-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
COOLING SYSTEM .........................................
EC-1-1
EC-1-2
EC-1-3
EC-1-4
TOOLS .................................................... EC-2-1
WATER PUMP ........................................ EC-3-1
CONSTRUCTION............................................. EC-3-1
EXTERNAL APPEARANCE CHECK AND CORRECTION
EC-3-1
DISASSEMBLY ................................................ EC-3-2
INSPECTION.................................................... EC-3-4
REASSEMBLY.................................................. EC-3-4
EC
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Cooling system
Forced-circulation type
Water pump
Thermostat
Fan clutch
Type I
Type IV
Type II
Type V
Type III
100 (3.94)
116 (4.57)
80 (3.15)
96 (3.78)
36 (1.42)
55 (2.17)
Provided
Packed grease
None
Provided
None
General specification
Provided
Type VI
None
OK
NG
OK
NG
OK
NG
Former
New
Former
New
Former
New
Packed
grease
differs from
that for
Type II.
Packed
grease
differs from
that for
Type V.
Remarks
Type of thermostat
Unit: mm (in)
Item
Type I
Type III
Type IV
Type V
51 (2.01)
46 (1.81)
27 (1.06)
33 (1.30)
10 (0.39)
15 (0.59)
Type II
76.5 (170)
82 (180)
Former
EC-1-1
88 (190)
76.5 (170)
82 (180)
New
Type VI
88 (190)
SERVICE DATA
Fan clutch
Item
FE6A
FE6B 119 kW {162 PS}
FE6B 132 kW {180 PS}
FD1300L
FDL1700
FDL2000
Operating temperature
C (F)
3,000 rpm
755 (1679)
ON-OFF type
6510 - 805
(14918 - 1769)
Linear type
3,400 rpm
5010 - 805
(12218 - 1769)
SERVICE DATA
Unit: mm (in)
Item
Maintenance standard
Service limit
Type I
Type II
Type III
13.03 - 13.05
(0.5130 - 0.5138)
0.03T - 0.06T
(0.0012T - 0.0024T)
45 (1.77)
74.5 - 78.5
(166 - 173)
71.5 - 81.5
(161 - 179)
80 - 84
(176 - 183)
77 - 87
(171 - 189)
86 - 90
(187 - 194)
85 - 93
(185 - 199)
76.5C
(170F)
Less than
9/90 (0.35/194)
82C
Valve lift/temperature
(180F)
mm/C (in/F)
Less than
9/95 (0.35/203)
88C
(190F)
Less than
9/100 (0.35/
212)
39 - 59 {0.4 - 0.6, 6 - 9}
10 - 15 (0.39 - 0.59)
7 - 12 (0.28 - 0.47)
Water pump
(Type I, Type
II and Type
III only)
Clearance between
housing and impeller
Thermostat
V-belt deflection
EC-1-2
Remarks
Side clearance
T: Tight
Pressure side
SERVICE DATA
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
10 - 13 {1.0 - 1.3, 7 - 9}
10 - 12 {1.0 - 1.2, 7 - 9}
EC-1-3
SERVICE DATA
COOLING SYSTEM
EC-1-4
TOOLS
TOOLS
WATER PUMP
Type I
Tool name and number
Description
Bearing replacer
99759 Z5503
EC-2-1
Shape
TOOLS
Description
Bearing replacer
99759 Z5505
Bearing replacer
99759 Z5506
EC-2-2
Shape
WATER PUMP
WATER PUMP
CONSTRUCTION
EC-3-1
WATER PUMP
DISASSEMBLY
Type I, Type II and Type III
9. Washer
, 10. Drive shaft
,+ 11. Water seal*
EC-3-2
WATER PUMP
Tool number
Type I
99749 Z5503
99749 Z5504
3 Flange
Drive out the flange using the pulley hub puller.
Tool name
Pulley hub puller
Tool number
Type I
99749 Z5503
99749 Z5504
6, 8 Ball bearing
Drive out the ball bearing together with the spacer and washer
using the bearing replacer.
Tool name
Bearing replacer
Tool number
Type I
99759 Z5503
99759 Z5505
EC-3-3
WATER PUMP
10 Water seal
Drive out the water seal using the water seal replacer.
Tool name
Water seal replacer
Tool number
Type I
99759 Z5504
99759 Z5507
INSPECTION
z
Service limit
Service limit
0.03T - 0.06T
(0.0012T - 0.0024T)
Remarks
T = Tight
REASSEMBLY
Key point of reassembly
10 Drive shaft
Attach the drive shaft guide to the pump body, and press the drive
shaft assembly into place.
Tool name
Drive shaft guide
Tool number
Type I
99789 Z5500
99789 Z5501
8 Ball bearing
Install the washer and press the ball bearing into place on the
impeller side using the bearing replacer.
NOTE
z Apply bearing grease to the rolling surface of the bearing.
Tool name
Bearing replacer
Tool number
Type I
99759 Z5503
99759 Z5506
EC-3-4
WATER PUMP
6 Ball bearing
Install the spacer and press the ball bearing into place on the flange
side using the bearing replacer.
NOTE
z
Bearing replacer
Tool number
Type I
99759 Z5503
99759 Z5506
3 Flange
Press the flange onto the drive shaft using the fan pulley hub
replacer.
Tool name
Fan pulley hub replacer
Tool number
Type I
99788 Z5501
99788 Z5503
11 Water seal
Apply a coat of THREE BOND #1702 to the outer periphery of the
water seal. Press the water seal into the pump body using the water
seal replacer.
Tool name
Water seal replacer
Tool number
Type I
99759 Z5504
99759 Z5507
2 Impeller
Press the impeller into place so that the clearance between the
pump housing and impeller is within maintenance standards.
Unit: mm (in)
Item
Clearance between
pump housing and
impeller
Maintenance standard
Service limit
Type II,
0.3 - 2.1 (0.012 - 0.083)
Type III
Type I
1 Grease nipple
Pour bearing grease into the grease nipple.
Unit: g (oz)
Item
Amount of grease
Type I
38 (1.34)
42 (1.48)
EC-3-5
THERMOSTAT
THERMOSTAT
REMOVAL
INSPECTION
Check thermostat operation as shown in the figure on the right.
Item
76.5C
(170F)
Valve opening
82C
temperature
(180F)
C (F)
88C
(190F)
76.5C
(170F)
Valve lift/
82C
temperature
(180F)
mm/C (in/F)
88C
(190F)
Maintenance
standard
Service limit
74.5 - 78.5
(166 - 173)
71.5 - 81.5
(161 - 179)
80 - 84 (176 - 183)
77 - 87 (171 - 189)
86 - 90 (187 - 194)
85 - 93 (185 - 199)
INSTALLATION
Install a new gasket so that it covers the periphery of the thermostat
as shown in the figure.
EC-4-1
Drain approximately 5% of the engine coolant from the cooling system and replenish with the same amount of cleaning
solvent (genuine product. Cooling Mate). Allow the engine
to idle for approximately 30 minutes.
NOTE
z Engine coolant temperature should be maintained at
approximately 80C (176F).
2. Drain the cooling system and replenish with tap water.
WARNING
WARNING
z Do not remove the radiator cap quickly. Otherwise, you
may be sprayed and scalded with hot flashing fluid.
Cover the cap with a thick and heavy rag, and remove it
gradually.
3.
4.
Start the engine again and continue to flush the cooling system. Repeat the flushing operation until drained water is
clean.
Remove dust, leaves, and other foreign matter from the
radiator core fins, water tubes, etc.
INSPECTION
Check the radiator and coolant reservoir tank for cracks or damage.
If necessary, repair or replace.
Service limit
39 - 59 {0.4 - 0.6, 6 - 9}
Remarks
Pressure side
EC-5-1
Engine coolant
Check density of anti-freeze solution or LLC (Long Life Coolant)
using a tester. If it is low, add anti-freeze solution or LLC as
required to suit the areas where the vehicle is to be operated.
EC-5-2
FAN CLUTCH
FAN CLUTCH
CONSTRUCTION
FD1300L
FDL1700
EC-6-1
FAN CLUTCH
FDL2000
INSPECTION
After removing the fan clutch, inspect it visually, and if there are any
cracks or oil leakage (silicone oil), replace the fan clutch assembly.
EC-6-2
FAN CLUTCH
Unit: C (F)
Item
FE6A
ON-OFF
FE6B 119 kW {162 PS} FD1300L
type
FE6B 132 kW {180 PS}
FE6B 132 kW {180 PS}
FE6T 135 kW {183 PS}
FDL1700
FE6T 151 kW {205 PS}
FE6TA 157 kW {213 PS}
Linear
type
FE6T 151 kW {205 PS}
FE6T 162 kW {220 PS}
FDL2000
FE6TA 157 kW [213 PS}
FE6TA 173 kW {235 PS}
Run the
Operating
engine
temperature
continuously
(T)
3,000 rpm
755
(1679)
6510 - 805
(14918 1769)
3,400 rpm
5010 - 805
(12218 1769)
EC-6-3
- MEMO -
FUEL SYSTEM
CONTENTS
SERVICE DATA ...................................... EF-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
FUEL SYSTEM.................................................
TOOLS ....................................................
EF-1-1
EF-1-2
EF-1-4
EF-1-6
EF-2-1
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
ADJUSTMENT..................................................
INSTALLATION ................................................
EF-5-1
EF-5-1
EF-5-2
EF-5-3
EF-5-4
EF-5-4
EF-5-5
= TWO-SPRING TYPE =
= CONVENTIONAL TYPE =
EF-4-1
EF-4-11
EF-4-12
EF-4-15
EF-4-16
EF-5-1
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
ADJUSTMENT..................................................
INSTALLATION ................................................
EF-5-6
EF-5-6
EF-5-7
EF-5-8
EF-5-9
EF-5-9
EF-5-16
FUEL FILTER .......................................... EF-6-1
CONSTRUCTION ............................................. EF-6-1
REPLACING FUEL FILTER ELEMENT............ EF-6-3
ENGINE CONTROL SYSTEM................. EF-7-1
EF
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
FE6A
kW {PS/}rpm
FE6B
FE6T
118 {160}/ 119 {162}/ 132 {180}/ 135 {183}/ 151{205}/ 162 {220}/ 173 {235}/
3,000
3,000
3,000
3,000
2,800
2,800
2,800
14
15
12
10
Ignition order
12
Plunger diameter
mm (in)
9.5
(0.374)
Injection
pump
Cam lift
mm (in) Feed
pump
8.0
(0.315)
9.0
(0.354)
9.5
(0.374)
11.0
(0.433)
9.0 (0.354)
9.0 (0.354)
10.0 (0.394)
6.0 (0.236)
Type
Centrifugal
RAD-B
RLD-E
RFD-B
RLD-E
RAD-B
RLD-E
RFD-B
RLD-E
Type
Timer
Bosch
(TC-MD type)
Governor Type
name
RLD-F
RLD-J
SAG
Centrifugal
Type
name
SA
SA/SAG
SA
Electronic
(MD-TICS)
Nozzle holder
Flange type
Nozzle
Multi-jet
Identification mark
Fuel injection
nozzle
157 {213}/
2,800
1-4-2-6-3-5
Type
Fuel injection
pump
FE6TA
D2
Number of nozzle
holes
Injection opening
pressure
D3
A5
A6
A3
19,614
{200,
2,844}
1st stage:
16,672
{170,
2,417}
2nd stage:
21,575
{220,
3,128}
*1
C1/F4
*2
C1
NOTE
EF-1-1
21,575
{220,
3,128}
19,614
{200, 2,844}
SERVICE DATA
SERVICE DATA
INJECTION PUMP ASSEMBLY
FE6A, FE6B, FE6T AND FE6TA [173 KW {235 PS}]
Unit: mm (in)
Housing and
associated parts
Camshaft
Item
Maintenance standard
Service limit
24.00 - 24.03
(0.9449 - 0.9461)
24.15 (0.9508)
0.03 - 0.07
(0.0012 - 0.0028)
0.2 (0.008)
0.01 - 0.05
(0.0004 - 0.0020)
0.1 (0.004)
20.0 (0.787)
19.8 (0.780)
Runout
Less than
0.05 (0.0020)
0.15 (0.0059)
0 - 0.02
(0 - 0.0008)
0.1 (0.004)
23.95 - 23.97
(0.9429 - 0.9437)
23.9 (0.941)
0.2 (0.008)
Tappet O.D.
Tappet
0.2 (0.008)
0.15 (0.0059)
0.3 (0.012)
0.03 - 0.08
(0.0012 - 0.0031)
0.12 (0.0047)
3.00.05
(0.11810.0020)
0.5
0.01 - 0.09
(0.0004 - 0.0035)
0.2
(0.008)
0.02 - 0.05
(0.0008 - 0.0020)
0.08
(0.0031)
0.03 - 0.08
(0.0012 - 0.0031)
0.15
(0.0059)
0.04 - 0.08
(0.0016 - 0.0031)
0.02 - 0.07
(0.0008 - 0.0028)
Roller I.D.
14.98 - 15.00
(0.5898 - 0.5906)
14.6 (0.575)
Housing-to-piston clearance
0.03 - 0.06
(0.0012 - 0.0024)
0.15 (0.0059)
Governor
Feed pump
Remarks
When static
Total play
0.3 (0.012)
Discharge pressure
Overflow valve
opening pressure
Priming pump
108 - 147
{1.1 - 1.5, 16 - 21}
EF-1-2
SERVICE DATA
Housing and
associated parts
Camshaft
Tappet
Item
Maintenance standard
Service limit
28.000 - 28.021
(1.1024 - 1.1032)
28.15 (1.1083)
0.020 - 0.062
(0.0008 - 0.0024)
0.2 (0.008)
0 - 0.06
(0 - 0.0024)
0.1 (0.004)
25.0 (0.984)
19.8 (0.780)
Runout
Less than
0.05 (0.0020)
0.15 (0.0059)
0.02 - 0.06
(0.0008 - 0.0024)
0.1 (0.004)
Tappet O.D.
27.959 - 27.980
(1.1007 - 1.1016)
27.9 (1.098)
0.2 (0.008)
0.2 (0.008)
0 - 0.056
(0 - 0.0022)
0.3 (0.012)
0.025 - 0.083
(0.0010 - 0.0033)
0.12 (0.0047)
1.275 N
{130 g, 4.59 oz}
1.471 N
{150 g, 5.29 oz}
5.60.03
(0.22050.0012)
0.25
0.01 - 0.09
(0.0004 - 0.0035)
0.2 (0.008)
0.018 - 0.039
(0.0007 - 0.0015)
0.08 (0.0031)
0.031 - 0.075
(0.0012 - 0.0030)
0.15 (0.0059)
0.003 - 0.018
(0.0001 - 0.0007)
0.1 (0.004)
0.014 - 0.056
(0.0006 - 0.0022)
0.15 (0.0059)
Governor
Remarks
At standstill
Overflow valve
opening pressure
kPa {kgf/cm2,
psi}
Discharge pressure
Priming pump
108 - 147
{1.1 - 1.5, 16 - 21}
EF-1-3
SERVICE DATA
Maintenance standard
Service limit
Z, D2, A5
A6, C1, F4
20,104 - 20,595
{205 - 210, 2,915 - 2,986}
D3, F4
22,066 - 22,556
{225 - 230, 3,200 - 3,271}
17,162 - 17,947
{175 - 183, 2,489 - 2,602}
23,046 - 23,537
{235 - 240, 3,342 - 3,413}
24,321 - 24,910
{248 - 254, 3,527 - 3,612}
1st
stage
Two-spring
type
A3
2nd
stage
Remarks
TIGHTENING TORQUE
INJECTION PUMP ASSEMBLY
Unit: Nm {kgfm, ftlbf}
Item
Injection pump
assembly
Tightening torque
PE-A type
M20
M24
TC-MD type
SA type
RAD-B
RLD-E, F
RFD-B
Governor
RLD-J
Actuator housing
Governor housing
mounting bolt
M8
EF-1-4
SERVICE DATA
Two-spring
type
Cap nut
Tightening torque
Z, D2, D3, A5, A6
C1, F4
Retaining nut
Inlet connector
Cap nut
Retaining nut
Inlet connector
Nut
Set screw
FUEL FILTER
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Type II
EF-1-5
SERVICE DATA
FUEL SYSTEM
EF-1-6
TOOLS
TOOLS
Injection pump (Part numbers designated by ZEXEL)
Tool name and number
Description
Measuring device
105782-4080
Measuring device
105782-4330
Adjusting device
105782-6170
Adjusting device
105782-6220
Measuring device
105782-6280
Timing checker
157830-3320
Sensor
157830-3420
EF-2-1
Shape
TOOLS
Tool name and number
Description
Lamp
157830-3520
Holder
157842-5220
Reflection plate
157951-1100
Handle
157910-1120
Socket wrench
157914-0500
Wrench
157915-0100
Socket wrench
157914-0300
EF-2-2
Shape
TOOLS
Description
Wrench
157915-0300
Spanner
157916-4620
Extractor
157926-6210
Seal guide
157920-5400
Tappet insert
157921-0120
Plunger insert
157921-5620
Extractor
157925-0520
Extractor
157925-6520
EF-2-3
Shape
TOOLS
Tool name and number
Description
Extractor
157926-5120
Holder
157931-2500
Holder
157931-4100
Tappet inserter
157931-6120
Lock
157976-3100
Wrench
157916-2620
EF-2-4
Shape
TOOLS
Description
Wrench
157913-3520
Wrench
157913-3620
Wrench
157913-5320
Wrench
157913-5400
Rod
157923-5800 [18 mm,
(0.71 in)] dia.
157923-5900 [22 mm,
0.87 in)] dia.
157923-6000 [26 mm,
(1.02 in)] dia.
Plug
029111-4050
Measuring device
105782-6030
EF-2-5
Shape
TOOLS
Description
Measuring device
105782-6090
Coupling
105784-0510
Coupling
157842-4420
Box wrench
157916-2800
Spanner
157916-5420
Extractor
157926-5110
EF-2-6
Shape
TOOLS
Description
Shape
Description
Base
157924-2520
Spring compressor
157921-9820
Shape
SA type
Tool name and number
Description
Block
157924-0800
Thrust bushing
157924-0500
EF-2-7
Shape
TOOLS
Description
Guide
157924-0900
Guide bolt
157924-1100
Guide bushing
157924-1200
Guide bushing
157924-1300
or
157924-1400
Supporter
157932-0100
Bolt
029001-2220
Washer
029301-2260
Band spanner
157916-6120
EF-2-8
Shape
TOOLS
Description
Base
157924-0110
Guide bolt
157924-0300
Guide
157924-0400
Thrust bushing
157924-1500
Shape
Description
Pin vise
99727 Z5005
Nozzle cleaner
99726 Z5000
* Nozzle tester
105785-0960
* Nozzle tester
105785-1010
EF-2-9
Shape
TOOLS
Description
* Plate
157944-9520
Retaining nut
157892-2020
(1) 157892-2000
(2) 026508-1140
(3) 157892-1600
Dial gauge
157954-3800
Pin
157892-1100
Pin
157892-1200
Base
157892-1800
Adjusting device
105789-0560
(1) 157892-0220
(2) 157892-1320
EF-2-10
Shape
- MEMO -
,+ 13. Camshaft
+ 14. Ball bearing
15. Shim
16. Ring
17. Gasket
18. Center bearing
,+ 19. Tappet assembly
20. Shim
21. Spring seat
22. Plunger spring
23. Upper spring seat
Marks + and , indicate that the key points of operation are explained in the text.
EF-3-1
2 Cover
Remove the pump cover plate and, using the special wrench
(157916-4620), turn the camshaft. When the tappet reaches top
dead center, insert the tappet holder (157931-7320) into the tappet
hole, so that the tappet can be released from the cam.
9 Plug
Remove the screw plug at bottom of the housing using the handle
(157910-1120).
13 Camshaft
Rotate the camshaft until its drive side key groove is facing vertically upward. Then attach the seal guide (157920-5400) to the
camshaft.
14 Ball bearing
1. Use the extractor (159725-0520) and remove the outer race
from the bearing cover. Install the outer race extractor and
tighten the nut to force the flared portion of the tool between
the outer race and the oil seal. Hold the bearing cover and
tap the tool with a hammer.
EF-3-2
19 Tappet assembly
1. Insert the tappet insert (157921-0120) from the screw plug
hole, compress the plunger spring by pushing the tappet up
and pull the plunger spring holder out.
2.
3.
After removing the tappet, insert the plunger insert (1579215620) from the screw plug hole and pull the plunger with the
lower spring seat.
EF-3-3
35 Control rack
Tilt the pump housing onto its side and set the punch mark at both
sides of the control rack to the same dimension from the ends of
the pump housing.
32 Plunger assembly
Install the plunger to the special tool plunger insert (157921-5620)
and assemble to the barrel.
At this time, the lower spring seat must be installed to the plunger.
NOTE
z Since the plunger and barrel are precision manufactured
as pair, they must not be matched with those of another
cylinder.
z Assemble the plunger with the matching mark facing the
front (cover side) of the pump housing.
19 Tappet assembly
Assemble the tappet to the pump housing using the tappet inserter
(157931-6120) and tappet insert (157921-0120) the same as when
disassembling. Push the tappet itself forcefully and install the tappet holder.
13 Camshaft
1. Install the camshaft, together with the center bearing, to the
pump housing so that the assembly mark is at the timer
side. (This work can be facilitated by coating the center
bearing with a small amount of grease and sticking it to the
camshaft.)
EF-3-4
3.
4.
Maintenance standard
Service limit
0 - 0.02 (0 - 0.0008)
0.1 (0.004)
Maintenance
standard
Service limit
Sliding resistance
of control rack
Remarks
When static
5.
EF-3-5
FEED PUMP
CONSTRUCTION
7. Adapter
8. Gasket
9. Spring
10. Valve
11. Plug
12. Gasket
13. Piston spring
14. Piston
15. Straight pin
16. Housing
EF-3-6
TIMER
CONSTRUCTION
SAG type
SA type
EF-3-7
,+
,+
,
,
1. Plug
2. Gasket
3. Screw
4. Cover
5. Flange
6. Eccentric cam (large)
7. Eccentric cam (small)
+ 8. Snap ring
9. Seat
10. Shim
11. Shim
12. Spring
13. Spring
14. Seat
15. Pilot pin
16. Spacer
, 17. Flyweight
18. O-ring
19. Housing
Marks + and , indicate that the key points of operation are explained in the text.
Using a socket wrench (157915-0300), handle (1579101120) and special wrench (157916-4620), remove the
round nut and then remove the timer assembly, using an
extractor (157926-6210).
EF-3-8
3.
4 Cover
Remove the six screws holding the cover and then remove the
cover.
NOTE
z At this time, be careful not to damage the lip of the oil
seal.
5 Flange
Remove the holder together with the flyweight assembly from the
housing.
NOTE
z Sometimes large and small cams may be left in the housing.
Do not change the order of those cams at this time.
Install them in the holder correctly, and note the directions and locations of the key groove and cams.
8 Snap ring
Compress springs using the spring compressor (157921-9820) and
draw out the snap ring.
EF-3-9
17 Flyweight
Install the flyweight as shown in the figure so that the holder key
groove faces the upper portion, and the right-hand flyweight pin
faces the upper portion. (The left-hand flyweight pin will face the
bottom portion.)
6, 7 Eccentric cam
1. Install the large and small cams in each specified position.
Large cams: t1 is wider than t2
Small cams: t3 is narrow
2.
3.
Set the pitch of the small cam housing pin hole to the measured value found in step 2.
EF-3-10
Make sure that the distance between both the small cam
hole and holder center is the same.
NOTE
z If not, repeat step 2.
5 Flange
1. With both housing punch mark and holder key groove in
position, install the housing into the holder. At this time, be
careful not to damage the oil seal.
NOTE
z If the housing pin cannot be inserted into the small cam
hole, repeat step 1 and subsequent steps.
2.
4 Cover
Lubrication of timing device.
Lubricating oil: Mobil oil #20
Oil level: Approximately 1 mm (0.04 in) below the upper surface of
flyweights.
EF-3-11
SA type
5. O-ring
, 6. Flange
7. Timer spring
, 8. Adjusting shim
9. Flyweight
, 10. Oil seal
11. Flyweight holder
Marks + and , indicate that the key points of operation are explained in the text.
EF-3-12
2.
3.
2.
3.
Fit the oil seal to the flange hole. With the guide bushing
(157924-1200) intervening, thread in the thrust bushing
(157924-1500) to force in the oil seal.
EF-3-13
3.
8 Adjusting shim
1. Clamp the base (157924-0110) in a vise and install the
guide bolt (157924-0300).
2. Place the flyweight holder over the pin of the base (1579240110) and fit the rubber ring.
3.
6 Flange
Mount the flange, apply a special wrench (157916-4620) to the
flange claw, and fit the thrust bushing (157924-0500), washer
(029301-2260), and bolt (029001-2220) to the flange.
EF-3-14
EF-3-15
GOVERNOR
DISASSEMBLY AND REASSEMBLY
RAD type
EF-3-16
Marks + and , indicate that the key points of operation are explained in the text.
Remove the idling spring plate plug (2) then loosen the
lock nut with the wrench (157913-5400).
Next, use a Phillips screwdriver to remove the idling
spring assembly.
EF-3-17
Using a Phillips screwdriver, remove the seven bolts to separate the governor cover from the governor housing. Then
remove the governor cover.
NOTE
z Be sure to keep an oil pan under the governor to receive
lubricating oil.
2.
EF-3-18
- MEMO -
RLD type
EF-3-20
Marks + and , indicate that the key points of operation are explained in the text.
EF-3-21
RFD type
EF-3-22
21. O-ring
22. Snap ring
23. Lever
24. Woodruff key
25. Collar
26. Shim
27. Oil seal
28. Bushing
29. O-ring
30. Snap ring
31. Plug
32. Tension lever shaft
33. Governor cover
34. Gasket
35. Governor spring
36. Swivel lever
,+ 37. Idling spring assembly
38. Stroke adjusting bolt
39. Tension lever
40. Guide lever assembly
Marks + and , indicate that the key points of operation are explained in the text.
53 Flyweight assembly
1. Using a box wrench (157916-2800) and handle (1579101120), remove the round nut and then remove timer assembly using an extractor (157926-6210).
2. Attach the coupling (151842-4420) for disassembly and
reassembly to the pump camshaft.
3.
EF-3-23
2.
ADJUSTMENT
When the injection pump has been disassembled, plungers or
plunger springs have been replaced, or other reasons exist, use a
pump tester and adjust the injection pump.
EF-3-24
EF-3-25
7.
8.
Set the tappet to top dead center of the camshaft and set
the scale of the dial gauge to 0.
Loosen the bleeder screw of the pump and bleed the air
from the fuel system.
When the drive shaft of the tester is slowly turned in the
drive direction while feeding fuel to the fuel inlet of the
pump, the fuel will stop flowing from the pipe of the test use
nozzle holder. This is the injection start position. The injection timing is normal if the tappet has risen by the specified
value from bottom dead center.
When the flow of fuel does not stop when the tappet has
been lifted within 3.35 to 3.45 mm (0.1319 to 0.1358 in)
from bottom dead center, adjust the adjusting shim using
the plunger spring holder (157931-4100).
When the fuel flow stops before the tappet is raised 3.45
mm (0.1358 in), add adjusting shims until the fuel flow stops
at a life of 3.35 mm (0.1319 in).
2.
Injection interval........................
|
|
|
60
|
|
|
60
|
|
|
60
|
|
|
60
|
|
|
60
|
|
|
60
|
|
|
EF-3-26
Test condition
Nozzle
Nozzle holder
mm (in)
Test oil
C (F)
40 - 45 (104 - 113)
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
8.2 (0.323)
600
421 (1.480.04)
3.5
Lever
8.0 (0.315)
1,000
531 (1.90.04)
10
Lever
Approx. 7.0
(0.276)
300
91.8 (0.320.06)
10
Rack
100
Above 80 (2.8)
Lever
D
z
Remarks
Basic
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
9.8 (0.386)
600
58.91 (2.070.04)
3.5
Lever
R1 [10.0
(0.394)]
1,500
80.61 (2.840.04)
Lever
Approx. 7.9
(0.311)
300
8.31.8 (0.290.06)
10
Rack
100
Above 80 (2.8)
Lever
EF-3-27
Remarks
Basic
RLD governor
z
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
11.3 (0.445)
600
48.21.6 (1.700.06)
3.5
Rack
Basic
Approx. 9.8
(0.386)
300
91.8 (0.320.06)
10
Rack
R1 [11.3
(0.445)]
600
48.21 (1.700.04)
Lever
R1 0.2
(0.008)
1,000
Lever
100
80+10 (2.8+0.4)
Lever
Adjusting
point
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.6 (0.496)
1,500
77.51.6 (2.730.06)
3.5
Rack
Basic
Approx. 9.7
(0.382)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.6
(0.496)]
1,500
77.51 (2.730.04)
Lever
Basic
R1 1.65
(0.0650)
600
Lever
150
77.5+20 (2.73+0.7)
Lever
Adjusting
point
Remarks
Remarks
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
11.8 (0.465)
600
66.31.6 (2.330.06)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [11.8
(0.465)]
600
66.31 (2.330.04)
Lever
R1 0.2
(0.008)
900
[71.4 - 74.6
(2.51 - 2.63)]
Lever
R1 [11.8
(0.465)]
1,500
[81.9 - 85.9
(2.88 - 3.02)]
Lever
100
84+10 (3.0+0.4)
Lever
Adjusting
point
EF-3-28
Remarks
Basic
Basic
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.5 (0.492)
1,500
83.71.6 (2.950.06)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.5
(0.492)]
1,500
83.71 (2.950.04)
Lever
R1 0.55
(0.0217)
900
68.72 (2.420.07)
Lever
150
85+20 (3.0+0.7)
Lever
Adjusting
point
Remarks
Basic
Basic
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.5 (0.492)
1,500
83.71.6 (2.950.06)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.5
(0.492)]
1,500
83.71 (2.950.04)
Lever
R1 0.55
(0.0217)
900
68.72 (2.420.07)
Lever
150
85+20 (3.0+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
Remarks
Basic
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.4 (0.488)
700
77.52 (2.730.07)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.4
(0.488)]
700
77.51 (2.730.04)
Lever
R1 +0.15
(+0.0059)
1,400
Lever
R2 [R1 0.3
(0.012)]
550
Lever
R2 0.9
(0.035)
550
Lever
Boost press.
0
150
85+20 (3.0+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
EF-3-29
Remarks
Basic
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.4 (0.488)
700
77.52 (2.730.07)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.4
(0.488)]
700
77.51 (2.730.04)
Lever
R1 +0.15
(+0.0059)
1,400
Lever
R2 [R1 0.3
(0.012)]
550
Lever
R2 0.6
(0.024)
550
Lever
Boost press.
0
150
84+20 (3.0+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
Remarks
Basic
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.5 (0.492)
1,500
83.71.6 (2.950.06)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.5
(0.492)]
1,500
83.71 (2.950.04)
Lever
R1 0.55
(0.0217)
900
68.72 (2.420.07)
Lever
150
85+20 (3.0+0.7)
Lever
Adjusting
point
Remarks
Basic
Basic
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.3 (0.524)
700
97.52 (3.430.07)
3.5
Rack
Basic
Approx.
10.1 (0.398)
275
101.8 (0.350.06)
10
Rack
R1 [13.3
(0.524)]
700
97.51 (3.430.04)
Lever
R1 +0.1
(+0.004)
1,400
Lever
R1 2.0
(0.079)
700
Lever
Boost press.
0
150
85+20 (3.0+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
EF-3-30
Remarks
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.3 (0.524)
700
97.52 (3.430.07)
3.5
Rack
Basic
Approx.
10.1 (0.398)
275
101.8 (0.350.06)
10
Rack
R1 [13.3
(0.524)]
700
97.51 (3.430.04)
Lever
R1 +0.1
(+0.004)
1,400
Lever
R1 2.0
(0.079)
700
Lever
Boost press.
0
150
85+20 (2.8+0.7)
Lever
Boost press.
0
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
Adjusting
point
Remarks
RFD governor
z
Rack
position
mm (in)
8.1 (0.319)
600
42.21 (1.490.04)
3.5
Lever
7.8 (0.307)
1,000
53.31 (1.880.04)
10
Lever
Approx. 7.0
(0.276)
300
91.8 (0.320.06)
10
Rack
100
Above 80 (2.8)
Lever
D
z
Remarks
Basic
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
9.8 (0.386)
600
58.91 (2.070.04)
3.5
Lever
R1 [10.0
(0.394)]
1,500
80.61 (2.840.04)
Lever
Approx. 7.9
(0.311)
300
8.31.8 (0.290.06)
10
Rack
100
Above 80 (2.8)
Lever
EF-3-31
Remarks
Basic
RLD governor
z
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
11.8 (0.465)
600
66.31.6 (2.330.06)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [11.8
(0.465)]
600
66.31 (2.330.04)
Lever
R1 0.2
(0.008)
900
[731.6 (2.570.06)]
Lever
R1 [11.8
(0.465)]
1,500
[83.92 (2.950.07)]
Lever
100
84+10 (3.0+0.4)
Lever
Adjusting
point
Remarks
Basic
Basic
Rack limit
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
12.4 (0.488)
700
86.42 (3.040.07)
3.5
Rack
Approx. 9.5
(0.374)
300
9.51.8 (0.330.06)
10
Rack
R1 [12.4
(0.488)]
700
86.41 (3.040.04)
Lever
R1 +0.15
(+0.0059)
1,400
[86.51.6
(3.040.06)]
Lever
R2 [R1 0.3
(0.012)]
550
[761.6 (2.680.06)]
Lever
R2 0.6
(0.024)
550
[651 (2.290.04)]
Lever
Boost press.
0
150
90+20 (3.2+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
EF-3-32
Remarks
Basic
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.6 (0.535)
700
92.52 (3.260.07)
3.5
Rack
Approx. 9.7
(0.382)
275
171.8 (0.600.06)
10
Rack
R1 [13.6
(0.535)]
700
92.51 (3.260.04)
Lever
1,400
[99.51.6
(3.500.06)]
Lever
R2 [R1 0.2
(0.008)]
420
[801.6 (2.820.06)]
Lever
R2 1.8
(0.071)
420
[461 (1.620.04)]
Lever
Boost press.
0
150
105+20 (3.7+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
Remarks
Basic
Pump
speed
rpm
Injection qty
milliliter (Imp fl oz)/
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.6 (0.535)
700
92.52 (3.260.07)
3.5
Rack
Approx. 9.7
(0.382)
275
171.8 (0.600.06)
10
Rack
R1 [13.6
(0.535)]
700
92.51 (3.260.04)
Lever
1,400
[99.51.6
(3.500.06)]
Lever
R2 [R1 0.2
(0.008)]
420
[801.6 (2.820.06)]
Lever
R2 1.15
(0.0453)
420
[56.51 (1.990.04)]
Lever
Boost press.
0
150
105+20 (3.7+0.7)
Lever
Boost press.
0
Rack limit
Adjusting
point
EF-3-33
Remarks
Basic
2.
3.
4.
EF-3-34
GOVERNOR ADJUSTMENT
This section is divided into 3 parts according to the governor type.
Each part describes the general adjustment procedure first and
then each governors performance chart.
RAD type
Preparations
1. Mount the injection pump assembly securely on a pump test
stand. Then, attach the test nozzle and nozzle holder
assembly, test lines and measuring device to measure control rack travel, to the injection pump.
2. Remove the damper spring, cover, torque control spring
using a socket wrench (157914-0500) and Idling spring.
Loosen adjusting screw.
3.
4.
5.
EF-3-35
After fixing load control lever in the idling position, temporarily set speed adjusting screw so that governor begins to
move the control rack in the fuel-decrease direction at
pump speed of 500 to 600 rpm.
2.
2.
EF-3-36
4.
Readjust the full-load stopper bolt to the full-load fuel injection quantity position according to the service data.
Idling
1.
2.
3.
4.
EF-3-37
7.
z
Damper spring
1.
2.
ZEF109A
3.
Screw in damper spring until control rack position corresponds with Rf minus 0.1 mm (0.004 in) and lock the spring
at this point.
EF-3-38
Stopper bolt
If idling performance is included in service data, as represented by
dotted line, adjust stopper bolt setting.
1. After setting damper spring when pump speed is decreased
to 0 rpm, control rack position moves to Re.
2.
3.
Stopping lever
1.
2.
3.
4.
EF-3-39
Smoke limiter
1.
2.
3.
4.
5.
6.
7.
EF-3-40
EF-3-41
RLD type
Preparation
Follow the instructions below to prepare for adjustment.
1. Secure the fuel injection pump on the pump test stand and
fill both the governor chamber and cam chamber with lubricating oil (injection pump oil 131453-0120 is recommended).
2.
Mount the control rack travel measuring device (1057826280) on the end of the control rack.
Setting the control racks 0 position.
1) Screw in the governor shaft fully, and hold the control
lever at the idling position.
EF-3-42
Cautions on adjustment
[Governor performance chart]
EF-3-43
2.
3.
Idling adjustment
1.
With the pump speed maintained at 80 to 100 rpm, temporarily set the control lever so that the control rack position is
Rs mm (in).
2.
EF-3-44
Thickness
mm (in)
029310-9240
029310-9250
029310-9260
029310-9270
0.10 (0.0039)
0.20 (0.0079)
0.25 (0.0098)
1.00 (0.0394)
Remarks
ZEF119A
4.
5.
EF-3-45
2.
3.
Adjust the full-load setting bolt so that the control rack position is Rf mm (in) when the pump speed is Nf rpm.
NOTE
z When the full-load setting bolt is turned clockwise, the
control rack position value decreases.
EF-3-46
5.
3.
4.
5.
EF-3-48
Pushrod table
Part No.
Length
mm (in)
159274-0120
159274-0220
159274-0320
159274-0420
159274-0520
159274-0620
159274-0720
159274-0820
159274-0920
159274-1120
159274-1220
159274-1320
159274-1420
159274-1520
125.0 (4.92)
127.5 (5.02)
128.0 (5.04)
127.0 (5.00)
126.0 (4.96)
129.0 (5.08)
128.5 (5.06)
125.5 (4.94)
126.5 (4.98)
119.5 (4.70)
120.0 (4.72)
120.5 (4.74)
121.0 (4.76)
121.5 (4.78)
Part No.
Length
mm (in)
159274-1620
159274-1720
159274-1820
159274-1920
159274-4220
159274-4320
159274-4420
159274-4520
159274-4620
159274-4720
159274-4820
159274-4920
159274-5020
122.0 (4.80)
122.5 (4.82)
123.0 (4.84)
123.5 (4.86)
129.5 (5.10)
130.0 (5.12)
130.5 (5.14)
131.0 (5.16)
131.5 (5.18)
132.0 (5.20)
132.5 (5.22)
133.0 (5.24)
133.5 (5.26)
3.
4.
EF-3-49
Remarks
5.
EF-3-50
The above confirmation ensures that the sensor lever and torque
cam are positioned as shown in the figure when the control rack
moves beyond Rs mm (in).
NOTE
With the pump speed maintained above N liter (that is, Nb)
rpm, fix the control lever at the idling position.
2. Ensure the control rack does not move beyond Rf5 mm (in)
when the control lever is shifted toward the maximumspeed position.
3. Keep the control lever at the maximum-speed position and
gradually increase the pump speed.
4. Confirm that the control rack begins moving from Rf5 mm
(in) in the fuel decrease direction when the pump speed
exceeds Nj rpm.
The above confirmation ensures that the sensor lever and torque
cam are as shown in the figure when the control lever is shifted
toward the maximum-speed position during engine operation.
EF-3-51
2.
3.
4.
Attach both the bolt and nut to the end of the control rack.
Adjust the bolt so that the distance between the end face of
the pump housing and the bolt top is liter, that is, the rack
cap depth. Tighten the nut to lock the bolt.
5.
EF-3-52
Sealing
All adjusting stoppers (bolts, nuts) that directly affect engine performance are sealed after adjustment. Do not readjust any stopper
without using the pump test stand or the engine test bench, as this
will adversely effect the engine, which will then be unable to operate at peak performance. In addition, the engine may overrun or
overheat, causing damage.
1 On full-load stopper
z
Sealing cap part No.: 154062-1900
Unit: mm (in)
Stopper bolt protrusion
L1 = 21 - 24 (0.83 - 0.94)
2 On maximum-speed stopper
z
Sealing cap part No.: 154062-1700
Unit: mm (in)
Stopper bolt protrusion
L2 = 29 - 36 (1.14 - 1.42)
EF-3-53
EF-3-54
EF-3-55
EF-3-56
EF-3-57
EF-3-58
EF-3-59
EF-3-60
EF-3-61
EF-3-62
EF-3-63
EF-3-64
EF-3-65
EF-3-66
EF-3-67
EF-3-68
RFD type
Preparations
1. Remove damper spring, cover, torque control springs and
idling spring, and loosen adjusting screws.
2. Mount injection pump assembly securely on a pump test
stand. Then, attach the test nozzle and nozzle holder
assembly, test lines and measuring device to measure control rod travel, to injection pump.
3.
4.
5.
After fixing load control lever in the idling position, temporarily set speed control lever so that governor begins to
move the control rack to the fuel decrease direction at pump
speed of 500 to 600 rpm.
EF-3-69
3.
EF-3-70
EF-3-71
Idling
1.
2.
3.
4.
Damper spring
1.
2.
EF-3-72
Screw in damper spring until control rack position corresponds with Rf minus 0.1 mm (0.004 in) and lock the
spring at this point.
Stopper bolt
1.
2.
After loosening the stopper bolt, move the load control lever
until control rack position is Rg and set stopper bolt at this
point.
EEF3-222
EF-3-73
NOTE
z
4.
Stopper bolt
When used as variable speed governor.
1. After making adjustments as described in the figure, fix load
control lever at full-load position.
2. Then, run the injection pump at speed Ny rpm which is
slightly higher than the idling speed.
3. Return stopper bolt to the low-speed position side and lock
it with nut, at control rack position Rd mm (in).
EF-3-74
Smoke limiter
1.
2.
3.
EF-3-75
EF-3-76
EF-3-77
TESTING TIMER
In general, measurement of the timer advance angle is performed
on the pump tester after completing an adjustment of the injection
timing, injection quantity and governor.
(1,140)
1,500
Advance angle ()
Start
Finish 4.00.5
Below 850
800
1,500
Advance angle ()
Start
Below 0.5
Finish 4.00.5
Below 1,250
1,200
1,500
Advance angle ()
Start
Below 0.5
Finish 1.00.5
Below 1,050
1,000
1,500
Advance angle ()
Start
Below 0.5
Finish 2.00.5
1,400
Advance angle ()
Finish 2.00.3
Below 1,170
1,120
1,400
Advance angle ()
Start
Below 0.5
Finish 2.00.5
Below 1,170
1,120
1,400
Advance angle ()
Start
Below 0.5
Finish 3.00.5
EF-3-78
4.
5.
6.
7.
Be sure not to apply any large shock or vibration to the timing checker.
Do not use the reflection plate excessively. Carefully store
the remaining plate to avoid discoloration.
Never use the equipment in any location where inflammable
gases or any other explosive atmosphere may exist
because very high pulse voltages are generated in the
equipment.
This equipment has a built-in DC high-tension circuit. Do
not use the equipment at any location where it may get wet;
otherwise, equipment may be damaged and electric shock
to the human body may result.
The sensor generates an intense flash of light. Do not look
straight at the light source of this equipment; otherwise,
eyesight may be harmed.
The light source unit is separate from the power supply unit
of this equipment. Before disconnecting or connecting the
lamp cable, be sure to turn OFF the power switch to avoid
electrical shock.
This equipment uses high tension current. Be sure to connect the ground terminal of the equipment to the ground by
using a proper ground cable.
Installation
1.
Attach the timer to the coupling shaft unit and fix it firmly.
Fix the timer to the test stand flywheel firmly. At this time,
make sure that there is no eccentricity in the center of the
rotating portion.
EF-3-79
3.
4.
5.
EF-3-80
- MEMO -
For information on disassembly, inspection, reassembly, adjusting and testing of the injection pump,
refer to the service manual published by Zexel Co.
CONSTRUCTION
INJECTION PUMP ASSEMBLY
Type I (for HONG KONG)
EF-4-1
EF-4-2
1. Sleeve
2. Oil seal
3. Bolt
4. Cover
5. Pointer
6. Socket head bolt
7. Shim
8. O-ring
9. Bearing
10. Camshaft
11. Woodruff key
12. Bushing
13. Socket head bolt
14. Connector
15. Bushing
16. Bearing
17. Washer
18. Control rod
19. Plug
20. Gasket
21. Stud
22. Nut
23. Washer
24. Delivery valve holder
25. O-ring
26. Spring
27. Valve assembly
28. O-ring
29. O-ring
30. Stopper
31. Plunger assembly
32. Control sleeve
33. Spring seat
34. Plunger spring
35. Spring seat
36. Shim
37. Guide
38. Snap ring
39. Bushing
40. Plug
41. Pin
42. Roller
43. Screw
44. Gasket
45. Center bearing
46. Stud
47. Gasket
48. Nut
49. Overflow valve
50. Control rack
51. Pin
52. Bushing
53. Bushing
54. Gasket
55. Plug
56. Plug
57. Bearing
58. Ring
59. Shim
60. Eye bolt
61. Eye bolt
NOTE
z
1. Sleeve
2. Oil seal
3. Bolt
4. Cover
5. Pointer
6. Socket head bolt
7. Shim
8. O-ring
9. Bearing
10. Camshaft
11. Woodruff key
12. Bushing
13. Socket head bolt
14. Connector
15. Bushing
16. Bearing
17. Washer
18. Control rod
19. Plug
20. Gasket
21. Stud
22. Nut
23. Washer
24. Delivery valve holder
25. O-ring
26. Spring
27. Valve assembly
28. O-ring
29. O-ring
30. Stopper
31. Plunger assembly
32. Control sleeve
33. Spring seat
34. Plunger spring
35. Spring seat
36. Shim
37. Guide
38. Snap ring
39. Bushing
40. Plug
41. Pin
42. Roller
43. Screw
44. Gasket
45. Center bearing
46. Stud
47. Gasket
48. Nut
49. Overflow valve
50. Control rack
51. Pin
52. Bushing
53. Bushing
54. Gasket
55. Plug
56. Plug
57. Bearing
58. Ring
59. Shim
60. Eye bolt
61. Eye bolt
NOTE
z
GOVERNOR
EF-4-5
1. Nut
2. Lever
3. Spring
4. Shim
5. O-ring
6. Nut
7. Spring washer
8. Lever
9. Washer
10. Oil seal
11. Bolt
12. Gasket
13. Governor housing
14. Nut
15. Bolt
16. Cover cap
17. Shaft
18. Oil seal
19. Washer
20. Shim
21. Snap ring
22. Lever
23. Snap ring
24. Bolt
25. Lever
26. Plug
27. Nut
28. Shaft
29. Spring
30. Woodruff key
31. Bolt
32. Flyweight assembly
33. Lever
34. Shaft
35. Spring seat
36. Governor spring
37. Governor spring
38. Spring seat
39. Plate
40. Bolt
41. Spring
42. Socket head bolt
43. Link
44. Spring washer
45. Nut
46. Sleeve
47. Shim
48. Shifter
49. Rack sensor assembly
50. Snap ring
51. Washer
52. Shaft
53. Spring
54. Washer
55. Lever
56. Lever
57. Snap ring
58. Lock screw
59. Adjusting nut
60. Guide lever
61. Spring
62. Snap ring
63. Tension lever assembly
64. Plug
65. Snap ring
66. Shaft
67. Snap ring
68. Pin
69. Rod
70. Spring
71. Spring
72. Spring
73. Nut
74. Shifter
75. Screw
76. Snap ring
77. Snap ring
78. Cam plate
79. Snap ring
80. Snap ring
81. Plug
82. Gasket
83. Gasket
84. Bolt
85. Lever
86. Nut
87. Lever
88. Oil seal
89. Snap ring
90. Shim
91. Nut
92. Bolt
93. Cover cap
94. Bolt
95. Nut
96. Screw
97. Plug
98. Bracket
99. Bolt
100. Nut
101. Plug
102. Plug
103. Governor cover
104. Bolt
105. Spring
106. Washer
107. Spring assembly
108. Screw
109. Plug
110. Tube
111. Spring
112. Nut
113. Spring washer
114. Disk
115. Plate
116. Bushing
117. Nut
118. Spring
119. Diaphragm
120. Gasket
121. Screw
122. Cover
123. Gasket
124. Eye bolt
125. Bolt
126. Spring washer
127. Bolt
128. Nut
129. Gasket
130. Cap nut
131. Push rod
132. Bolt
133. Guide plate
134. Bolt
135. Lever assembly
NOTE
z
EF-4-6
COUPLING
Type I (for HONG KONG) and Type II (for NORWAY)
1. Bolt
2. Plate
3. Bolt
4. Nut
5. Lock washer
6. Coupling
7. Nut
8. Washer
9. Coupling
10. Bolt
11. Bolt
12. Plate
13. Bolt
14. Cross coupling
15. Sensor
16. Nut
17. Washer
18. Plate
19. Bolt
20. Washer
15 - 20. Type II only
NOTE
z
EF-4-7
ACTUATOR HOUSING
15. Bolt
16. Seal ring
17. Eye bolt
18. Bolt
19. Gasket
20. Seal ring
21. Housing
NOTE
z
EF-4-8
FEED PUMP
EF-4-9
1. Plug
2. Gasket
3. Check valve spring
4. Check valve
5. Priming pump
6. Gasket
NOTE
z
EF-4-10
REMOVAL
1.
Apply chocks to the front and rear wheels and tilt open the
cab.
2. Turn the key switch OFF and disconnect the ground cable
from the battery.
3. Remove the left side cover.
4. Disconnect the fuel line.
z
Disconnect the fuel tube.
z
Remove the fuel filter assembly and bracket as a unit.
z
Disconnect the injection nozzle tube.
NOTE
z Use a container or a clean cloth to catch and wipe oil as
required.
5.
EF-4-11
7.
Disconnect the inlet and outlet oil tubes from the injection
pump.
8.
9.
EF-4-12
Place the fuel feed pump in a vise, remove the plug, gasket
and pull out the piston spring and piston.
3.
INSPECTION
Wash all disassembled parts in cleaning solvent. Carefully check
for scratches, cracks or damage. Replace faulty parts as necessary.
Service limit
0.1 (0.004)
Service limit
0.15 (0.0059)
Gauze filter
Check the gauze filter for clogging.
EF-4-13
REASSEMBLY
Before assembling the feed pump, replace old gaskets and O-rings
with new ones.
1. Insert the piston, piston spring and gasket, and tighten the
plug.
2. Install the discharge side check valve, check valve spring
and gasket, and tighten adapter and priming pump.
3. Install the push rod in the housing.
NOTE
Capacity test
1.
2.
Pump speed
Supply rate
100 rpm
500 rpm
1,000 rpm
1,500 rpm
EF-4-14
INSTALLATION
1.
Install the injection pump assembly. (Refer to the DR section for procedures.)
2.
Connect the inlet and outlet oil tubes to the injection pump.
3.
EF-4-15
5.
6.
Test condition
Pump rotation
Nozzle
Nozzle holder
105780-2190
kPa {kgf/cm2, psi}
mm (in)
Test oil
C (F)
40 - 45 (104 - 113)
11
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.8
(0.543)
1,400
1121 (3.940.04)
Lever
12.1
(0.476)
900
1052 (3.700.07)
Lever
9.85
(0.3878)
350
332 (1.160.07)
Lever
Boost press.
0
Approx.
11.45
(0.4508)
100
89 (3.1)
Lever
Boost press.
0
EF-4-16
Remarks
Basic
Adjusting
point
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
R1 [13.8
(0.543)]
1,400
1121 (3.940.04)
Lever
R1 -1.7
(0.067)
900
1052 (3.700.07)
Lever
R2 -0.6
(0.024)
350
252 (0.880.07)
Lever
Boost press.
0
Approx.
R1 -2.0
(0.079)
100
90 (3.17)
Lever
Boost press.
0
Remarks
Basic
Adjusting
point
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.8
(0.543)
1,400
1121 (3.940.04)
Lever
12.1
(0.476)
900
1052 (3.700.07)
Lever
9.85
(0.3878)
350
332 (1.160.07)
Lever
Boost press.
0
Approx.
11.45
(0.4508)
100
89 (3.1)
Lever
Boost press.
0
EF-4-17
Remarks
Basic
EF-4-18
EF-4-19
EF-4-20
Injection timing
Pre-stroke: No. 1 Plunger 5.60.03 mm (0.22050.0012 in)
NOTE
1. Adjust using the shim (1).
2. Adjust with the rack in the full-load position.
z
14,
12,
16,
13,
15,
6015
12015
18015
24015
30015
Tappet clearance:
Manually rotate the camshaft 2 to 3 times and confirm that it
rotates smoothly.
Pre-stroke sensor
Output Voltage
V
Remarks
2.50.05
(0.09840.0020)
2.830.01
5.60.03
(0.22050.0012)
V1=1.20.2
Confirmation
Above 3.05
EF-4-21
Pre-stroke sensor
Output Voltage
V
Remarks
2.50.01
(0.09840.0004)
2.830.01
5.60.01
(0.22050.0004)
V1=1.20.2
Confirmation
Above 3.05
NOTE
At adjustment
Item
Pre-stroke
Adjustment point
Adjustment point Z
Adjusting
point
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.8
(0.543)
1,400
1122 (3.940.07)
Rack
Basic
Approx.
8.0
(0.315)
465
10.61.8
(0.370.06)
10
Rack
EF-4-22
Remarks
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.8
(0.543)
1,400
1121 (3.940.04)
Lever
12.1
(0.476)
900
1052 (3.700.07)
Lever
9.85
(0.3878)
350
[6.92 (0.240.07)]
Lever
Boost press.
0
Approx.
11.45
(0.4508)
100
[80 (2.8)]
Lever
Boost press.
0
Remarks
Basic
Adjusting
point
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
R1 [13.8
(0.543)]
1,400
1121 (3.940.04)
Lever
R1 -1.7
(0.067)
900
1052 (3.700.07)
Lever
R2 -0.6
(0.024)
350
252 (0.880.07)
Lever
Boost press.
0
Approx.
R1 -2.0
(0.079)
100
90 (3.17)
Lever
Boost press.
0
Remarks
Basic
Adjusting
point
Rack
position
mm (in)
Pump
speed
rpm
Injection qty
m liter (lmp fl oz)
1,000 strokes
Max. var.
bet. cyl.
(%)
Fixed
13.8
(0.543)
1,400
1121 (3.940.04)
Lever
12.1
(0.476)
900
1052 (3.700.07)
Lever
9.85
(0.3878)
350
332 (1.160.07)
Lever
Boost press.
0
Approx.
11.45
(0.4508)
100
89 (3.1)
Lever
Boost press.
0
EF-4-23
Remarks
Basic
RACK SENSOR
1.
Adjust the rack sensor after determining VR from the control unit
part no.
VR
2V
3V
407910-3032
407910-6010
407910-7210
2.
3.
Adjust the bobbin (1) so that the rack sensors output voltage is VR0.01.
After adjustment, mark the area where the joint (2) and the
nut (3) contact and the area where the joint (2) and the
pump housing contact with red paint.
EF-4-24
Speed sensor
ZEXEL No. 107069-1220 and 107692-0920
Install the speed sensor so that the gap between the sensor and
the coupling (flywheel) projection is 0.8 to 1.0 mm (0.031 to 0.039
in), and then secure it using the lock nut (i.e. the position when the
speed sensor is returned 1 revolution from the point where it contacts the coupling (flywheel) projection).
z
EF-4-25
CONVENTIONAL TYPE
REMOVAL
1.
2.
3.
EF-5-1
CONVENTIONAL TYPE
DISASSEMBLY
5. Push rod
6. Inlet connector
7. Gasket
+ 8. Retaining nut
9. Nozzle
10. Pin
11. Nozzle holder
Marks + and , indicate that the key points of operation are explained in the text.
EF-5-2
INSPECTION
Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Remove carbon from around nozzle jets using a wire
brush.
z
1.
Remove carbon from around nozzle jets using the pin vice
(99727 Z5005).
Unit: mm (in)
Z, D3
D2, A5, A6
C1, F4
Injection nozzle
hole diameter
Wire diameter
0.29 (0.0114)
0.26 (0.0102)
0.30 (0.0118)
0.29 (0.0114)
0.245 (0.0096)
0.23 (0.0091)
NOTE
2.
Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3.
4.
Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation.
Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.
5.
EF-5-3
CONVENTIONAL TYPE
REASSEMBLY
To reassemble, reverse the order of the above removal procedures. Observe the following:
NOTE
ADJUSTMENT
1.
2.
Loosen the adjusting screw and install the nozzle on a nozzle tester (105785-0960). Operate the hand lever forcefully
two or three times to remove foreign matter.
Adjust fuel valve opening pressure using the adjusting
screw.
Unit: kPa {kgf/cm2, psi}
Maintenance
standard
Service limit
Z, D2, A5,
A6, C1, F4
20,104 - 20,595
{205 - 210, 2,915 - 2,986}
D3, F4
22,066 - 22,556
{225 - 230, 3,200 - 3,271}
Item
Valve opening
pressure
(Regulated
pressure)
WARNING
WARNING
z
3.
4.
4.
2.
5.
3.
6.
EF-5-4
CONVENTIONAL TYPE
INSTALLATION
1.
2.
3.
4.
EF-5-5
CONVENTIONAL TYPE
= TWO-SPRING TYPE =
CONSTRUCTION
REMOVAL
1.
2.
3.
EF-5-6
TWO-SPRING TYPE
TWO-SPRING TYPE
DISASSEMBLY
8. Setscrew
9. Spacer
10. Shim (for valve opening pressure
adjustment)
11. No. 1 spring
12. No. 1 push rod
EF-5-7
INSPECTION
Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Remove carbon from around injection hole using wire
brush.
z
1.
Injection nozzle
hole diameter
Wire diameter
0.30 (0.0118)
0.29 (0.0114)
NOTE
2.
Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3.
4.
Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation.
Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.
5.
EF-5-8
TWO-SPRING TYPE
REASSEMBLY
To reassemble, reverse the sequence of disassembly, paying
attention to the following points.
NOTE
Tightening torque
Cap nut
Retaining nut
Nut
Set screw
Inlet connector
ADJUSTMENT
OVERHAULING TYPE
Adjusting nozzle opening pressure
1.
3.
EF-5-9
TWO-SPRING TYPE
Service limit
17,162 - 17,947
{175 - 183, 2,489 - 2,602}
5.
Pre-lift adjustment
1.
2.
EF-5-10
TWO-SPRING TYPE
7.
Maintenance standard
Service limit
Remarks
24,321 - 24,910
{248 - 254, 3,527 - 3,612}
NOTE
z
EF-5-11
TWO-SPRING TYPE
3.
EF-5-12
TWO-SPRING TYPE
Insert pre-lift adjusting shim selected in step 6 (under Prelift adjustment) between spacer and No. 2 push rod, and
assemble spacer and rod onto nozzle holder, and fit No. 2
spring; then tighten with set screw assembly.
: 49 - 59 Nm {5.0 - 6.0 kgfm, 36 - 43 ftlbf}
NOTE
z At this stage, No. 1 and No. 2 push rods are separated by
space equivalent to pre-lift.
3.
4.
5.
Checking pre-lift
1.
2.
3.
TWO-SPRING TYPE
Valve opening
pressure
(Regulated
pressure)
Maintenance standard
Service limit
23,046 - 23,537
{235 - 240, 3,342 - 3,413}
Remarks
Nozzle cover
method
NOTE
z
Nozzle cover method means that the special tools retaining nut and the plug at the tip are attached.
3.
3.
Injection opening
pressure
(1st stage)
Maintenance standard
Service limit
NOTE
z
EF-5-14
TWO-SPRING TYPE
Check spray pattern, injection holes for clogging, and for oil
tightness. If nozzle body seat face and nozzle needle are
scratched or worn by chips or carbon in fuel, repair by lapping with compound, provided damage is very small.
If replacement is needed, be sure to replace nozzle needle
and body as a matched set.
1.
4.
Too thin
2.
Asymmetrical
5.
Stepped
3.
Branching
6.
SIMPLIFIED INSPECTION
Checking injection beginning pressure and spray pattern
1.
Injection opening
pressure (1st stage)
Maintenance standard
Service limit
NOTE
z
2.
3.
1.
4.
Too thin
2.
Asymmetrical
5.
Stepped
3.
Branching
6.
EF-5-15
TWO-SPRING TYPE
Remove retaining nut, and install retaining nut (1578922020) for adjustment.
: 59 - 78 Nm {6.0 - 8.0 kgfm, 43 - 58 ftlbf}
NOTE
z Be sure to tighten retaining nut after making sure that
dowel pin is fitted completely into nozzle.
2.
3.
4.
Valve opening
pressure
(Regulated
pressure)
5.
Maintenance standard
Service limit
23,046 - 23,537
{235 - 240, 3,342 - 3,413}
Remarks
Nozzle cover
method
Finish inspection
Check injection beginning pressure, spray condition and oil tightness according to steps 1 and 2 (under Checking injection beginning pressure and spray pattern).
INSTALLATION
1.
2.
3.
4.
TWO-SPRING TYPE
FUEL FILTER
FUEL FILTER
CONSTRUCTION
Cartridge type
EF-6-1
FUEL FILTER
<Type II>
EF-6-2
FUEL FILTER
Fuel strainer
Cartridge type
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.
Cartridge assembly
2.
Cover
EF-6-3
FUEL FILTER
Drain plug
6.
Seat spring
2.
Packing
7.
Retainer
3.
Center bolt
8.
Element
4.
Packing
9.
Packing
5.
Filter case
10.
Filter cover
Plug
7.
Set spring
2.
Packing
8.
Retainer
3.
Drain cock
9.
Element
4.
Center bolt
10.
Packing
5.
Packing
11.
Filter cover
6.
Filter case
EF-6-4
FUEL FILTER
<Type II>
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.
Drain plug
7.
Seat
2.
Packing
8.
Element
3.
Center bolt
9.
Packing
4.
Packing
10.
Filter cover
5.
Filter case
11.
Filter plug
6.
Spring
12.
O-ring
Fuel strainer
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.
Drain plug
6.
Set spring
2.
Center bolt
7.
Baffle
3.
Packing
8.
Screen
4.
Strainer case
9.
Packing
5.
Spring retainer
10.
Strainer cover
EF-6-5
ADJUSTMENT
ENGINE CONTROL WIRE
Turn the engine control knob fully counterclockwise and connect
the engine control wire to lever.
Securely fit the clips (2 places on the wire end) in the bracket.
Dimension L: 78.0 - 80.0 mm (3.071 - 3.150 in)
EF-7-1
ACCELERATOR WIRE
1.
2.
3.
Dimension L mm (in)
118.0 (4.646)
128.0 (5.039)
EF-7-2
Connect the clevis of the cable tip to the stop lever of the
injection pump. Pull the stop lever to the stop position and
temporarily install the wire adjusting nut on the support.
3.
EF-7-3
ADJUSTMENT
ENGINE CONTROL WIRE
Turn the engine control knob fully counterclockwise and connect
the engine control wire to lever.
Securely fit the clips (2 places on the wire end) in the bracket.
L length: 78.0 - 81.0 mm (3.071 - 3.189 in)
EF-7-4
ACCELERATOR WIRE
1.
2.
3.
EF-7-5
3.
Turn the key switch ON. Current flows so that the solenoid
retracts.
NOTE
z Ensure that solenoid retracts completely.
4.
5.
Turn the swivel one more turn in the direction of the arrow,
and move the stop lever approximately 3.0 mm (0.118 in)
towards the stop side.
After stop lever adjustment, tighten the lock nut and solenoid mounting bolts.
EF-7-6
- MEMO -
MD-TICS SYSTEM
MD-TICS SYSTEM
CONTENTS
SYSTEM OVERVIEW ................................................................................................. EF-8-2
SYSTEM DIAGRAM ............................................................................................................................. EF-8-2
LOCATION OF EQUIPMENT .............................................................................................................. EF-8-4
FUNCTION OF EQUIPMENT ............................................................................................................. EF-8-5
EF-8-7
EF-8-8
EF-8-9
EF-8-13
EF-8-14
EF-8-14
EF-8-14
EF-8-17
EF-8-18
EF-8-21
EF-8-29
EF-8-33
EF-8-36
EF-8-43
EF-8-49
EF-8-54
EF-8-58
EF-8-62
EF-8-64
EF-8-65
EF-8-66
EF-8-67
EF-8-70
NOTE
z
There are two types of MD-TICS SYSTEM; one is destined for HONG KONG and the other for
NORWAY. On the following pages, Type I refers to HONG KONG specifications and Type II
refers to NORWAY specifications.
EF-8-1
MD-TICS SYSTEM
SYSTEM OVERVIEW
The MD-TICS system is a system that optimizes the fuel injection rate and fuel injection timing by using electronic control.
MD - TICS
Code
The MD-TICS system consists of the control unit, the pre-stroke actuator that is actuated by the signal from the
control unit, the sensors (engine speed sensor, rack sensor, engine coolant temperature sensor, and prestroke sensor) that read the operating condition of the engine and give signals to the control unit, the switches
and lights, and the electrical wiring.
This is an electronic control system in which the action of these units is used to compare the ideal values programmed beforehand into the microcomputer (control unit) with the actual values. In this way, the injection timing and fuel feed rate are controlled, the exhaust gas is cleaned, and the output is improved.
SYSTEM DIAGRAM
<Type I>
EF-8-2
MD-TICS SYSTEM
<Type II>
EF-8-3
MD-TICS SYSTEM
LOCATION OF EQUIPMENT
EF-8-4
MD-TICS SYSTEM
FUNCTION OF EQUIPMENT
Control Unit
Main function
z
Fuel injection rate control
z
Fuel injection timing control
Supplementary function
z
Self-diagnosis function
z
Back up function
Pre-stroke Actuator/Sensor
The pre-stroke actuator is installed at the front of the injection
pump. It consists of the pre-stroke sensor and pre-stroke servo that
is actuated by signals from the control unit.
The pre-stroke sensor is inside the pre-stroke actuator. It compares
the target position instructed from the pre-stroke control unit with
the actual position to detect if the position is correct, and feeds this
information back to the control unit.
<Type II>
The engine speed sensor is installed to the injection pump and
detects the engine speed with a magnetic pick-up.
It detects the potential difference generated when the protrusions
(12 places at equal distances) on the coupling (flywheel) of the
injection pump pass the tip of the engine speed sensor and sends
this to the control unit.
EF-8-5
MD-TICS SYSTEM
Rack Sensor
The rack sensor is a non-contact displacement meter that acts to
send the movement of the control rack of the injection pump to the
control unit.
The rack sensor sends out an alternating wave current (sine wave)
from the OSC terminal (oscillation terminal) of the control unit. It
detects the position of the rack from the MDL (middle) signal generated by the change in the impedance (self-induction) between the
two coils, and sends this to the control unit.
Diagnostic Switch
The diagnostic switch is the switch used to carry out trouble-shooting of the electronic control system.
The diagnostic switch consists of one pair of male and female terminals. These are normally connected; they are disconnected only
when carrying out trouble-shooting.
The diagnostic switch is installed behind the electrical unit board
and labeled with a DIAGNOSIS tag.
EF-8-6
MD-TICS SYSTEM
EF-8-7
MD-TICS SYSTEM
<Pre-stroke>
The amount of cam lift when the injection pump cam rotates and
moves from the plunger lift starting point a to the fuel feed starting
point A is called the pre-stroke.
EF-8-8
MD-TICS SYSTEM
1.
2.
3.
4.
EF-8-9
MD-TICS SYSTEM
(4) The pre-stroke sensor that always feeds back the movement of
the rotary solenoid to the control unit
When the control sleeve goes up, the pre-stroke becomes larger,
and when it goes down, the pre-stroke becomes smaller.
EF-8-10
MD-TICS SYSTEM
<Pre-stroke Actuator>
The pre-stroke actuator has a shape that forms three sides of a square, and consists of an iron core with a coil
wound around it. A rotor is placed between the jaws of the actuator, and a magnetic force proportional to the
control signal (current) from the control unit is generated by the rotary solenoid. The action of this magnetic
force then causes the rotor to rotate. The control sleeve is interconnected, so it moves up or down.
EF-8-11
MD-TICS SYSTEM
<Power Circuit>
The power source for the pre-stroke actuator has a separate circuit. If there is any abnormality in the pre-stroke
servo system, this circuit functions to stop the control, and at the same time it opens the pre-stroke cut relay to
cut the power for the pre-stroke actuator.
At the same time, the boost compensator cut 3-way magnetic valve is switched OFF, and the maximum injection amount is limited to prevent any secondary damage being caused when the control of the injection pump
is stopped.
EF-8-12
MD-TICS SYSTEM
<Pre-stroke Sensor>
The pre-stroke sensor compares the target position sent from the
control unit and detects if the pre-stroke actuator is actually in the
correct position.
Like the rack sensor, it is a non-contact displacement meter, and
sends out an alternating wave current (sine wave) from the OSC
terminal (oscillation terminal) of the control unit. It detects the position of the pre-stroke actuator (control sleeve) from the MDL (middle) signal generated by the change in the impedance (selfinduction) between the two coils, and sends this to the control unit.
The pre-stroke sensor harness is equipped with a shielding wire to
prevent noise.
The shielding wire acts to prevent the influence of any outside interference, thereby protecting the signal detected by the sensor; it
also acts to set the measurement standard. If there is improper
connection of the shielding wire (particularly at the connector), or
there is improper grounding of the control unit case, this may cause
disconnections or resistance (increased or reduced) which will
cause abnormalities in the pre-stroke control. To prevent this,
please be sure to carry out the grounding connection of the control
unit and the pre-stroke sensor wiring harness properly.
EF-8-13
MD-TICS SYSTEM
Trouble diagnosis
Trouble diagnosis can be carried out by releasing the diagnostic
switch. The results of the diagnosis are displayed by the diagnosis
light (Engine Control warning light and Overheat warning light)
(flashing light: Diagnosis Display Code). [Dealer mode]
When the Overheat warning light flashes, the buzzer also sounds at
the same time.
EF-8-14
MD-TICS SYSTEM
Engine Control warning light: displays present trouble
NOTE (*)
z To carry out analysis of past troubles, the system is
equipped with a diagnostic memory function. This function stores in the memory any failure signals for abnormality that occurred during travel. It acts to replay these
signals when carrying out analysis of the trouble.
The signals stored in the memory are retained even when
the ignition key switch is turned OFF.
z Normally, the Overheat warning light lights up when the
engine overheats or when the coolant level becomes too
low. However, when the diagnostic switch is released, it
displays the result of the diagnosis of past troubles in
the MD-TICS system.
The overheat warning function is not incorporated in the
control unit.
EF-8-15
MD-TICS SYSTEM
EF-8-16
MD-TICS SYSTEM
This is called the User mode. The user mode is displayed when the diagnostics switch is ON (connected).
Remarks
Engine stopped
Engine running
Light ON
Light OFF
Light ON
Light ON
Abnormality in MD-TICS
Light OFF
Light OFF
EF-8-17
MD-TICS SYSTEM
The reason for using these three positions of the ignition key switch is to allow diagnosis to be
carries out under all three conditions so that all troubles can be located.
Refer to Diagnosis Display Code and Trouble Location table.
3)
Normal
Abnormal
MD-TICS
NOTE (*)
z The diagnostic memory of the control unit has a memory that stores the past trouble conditions, and displays them. When the diagnostic switch is released, it does not show the engine
overheating condition; instead of this, it displays the results of diagnosis of past troubles.
z If the trouble that occurred in the past is the same as the trouble that is occurring at the
present, only the present condition (Engine Control warning light) is displayed.
EF-8-18
MD-TICS SYSTEM
OFF ON
ON
(after cranking, stop engine)
ON
(engine running)
Diagnosis light
(Engine control warning light
Overheat warning light)
01
OFF
(1)
ON
(2)
13
(3)
15
User mode
[MD-TICS normal or
abnormal]
Diagnosis
display code
Normal
OFF
Location of trouble
(trouble-shooting item number)
Lighting pattern
(4)
16
21
(5)
23
(6)
12
(7)
22
(8)
24
(6)
Abnormal
ON
Note (*)
O: Displayed
X: Not displayed
EF-8-19
MD-TICS SYSTEM
EF-8-20
MD-TICS SYSTEM
[3] TROUBLE-SHOOTING
If the trouble diagnosis makes the condition of the trouble clear, go on to trouble-shooting.
The explanation below gives the procedure for trouble-shooting for each trouble location (this forms a pair with
the diagnosis display code).
2) Do not insert the test lead of the tester directly into the
connector terminal. If it is pushed in by force, the terminal inside the connector will be expanded and this will
cause improper contact.
EF-8-21
MD-TICS SYSTEM
[Preparation]
Parts name and parts number
Use
Circuit tester
(Commercially available; use
tester with digital display)
EF-8-22
Shape
MD-TICS SYSTEM
<Abbreviation>
C.U.
U
CF
M
C
: Control Unit
: Unit Harness
: Cab Front Harness
: Main Harness
: Chassis Harness
EF-8-23
MD-TICS SYSTEM
<Connector symbol>
EF-8-24
MD-TICS SYSTEM
<How to match connectors>
Color code:
Unicolor
Alphabetical symbol
Color
White
Black
Red
Yellow
Green
Blue
Pink
BR
Brown
LG
Light green
OR
Orange
PU
Purple
GR
Gray
SB
Sky Blue
When the wire color is striped, the base color is given first, followed by the
stripe color as shown below:
Example: L/W = Blue with White Stripe
EF-8-25
MD-TICS SYSTEM
EF-8-26
MD-TICS SYSTEM
D. Front of engine
Location for inspection
1. Engine coolant temperature sensor harness connector C27 (2 pin)
NOTE
z
EF-8-27
MD-TICS SYSTEM
2.
3.
4.
[Service data]
Item
Terminals to measure
Maintenance standard
20 - 28
92.5 - 101.5
92.5 - 101.5
186
5-7
5-7
10 - 14
Resistance
2.5 - 2.9
20 - 28
Pre-stroke actuator
Engine speed
sensor
Type I
Type II
mm (in)
mm (in)
2.1 - 2.5
Refer to EF-8-51.
[Engine coolant temperature
and resistance of engine
coolant temperature sensor]
867 - 1,073
0.8 - 1.0 (0.031 - 0.039)
3
V
EF-8-28
MTM 1.77
MD-TICS SYSTEM
CHECK
NG
FUSE
1
OK
CHECK
LIGHT
NG
2
OK
CHECK
Check continuity between terminal (4) - light - fuse
OK
4
NG
CHECK
Check continuity between terminal (12) and body ground
NG
3
OK
Replace fuse
Replace C.U.
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-29
MD-TICS SYSTEM
Turn the ignition key switch OFF, then remove control unit
harness connector U-12.
Turn the ignition switch ON, then use the lead wire to
ground terminal (4) of connector U-12, and check if the light
lights up.
Judgement
z
If it lights up lamp is normal go to CHECK (3).
z
If it does not light up go to CHECK (4).
EF-8-30
MD-TICS SYSTEM
1.
Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness
connector U-12.
2. Judgement
z
Continuity check again from CHECK (2).
z
No continuity light bulb blown or disconnection in harness replace light, or repair or replace
harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
EF-8-31
MD-TICS SYSTEM
1.
Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness
connector U-12.
2. Judgement
z
Continuity check again from CHECK (2).
z
No continuity lamp bulb blown or disconnection in harness replace lamp, or repair or replace
harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
EF-8-32
MD-TICS SYSTEM
(2) Checking Control Unit Power Supply System (lights do not go out)
Lights stay
lighted up
CHECK
FUSE
NG
1
OK
NG
Replace fuse.
Locate cause of
blown fuse
CHECK
Check power circuit (+end)
4
OK
CHECK
Does light go
out?
2
NO
YES
CHECK
Check power circuit
NG
Check continuity
of unit harness
2
NG
3
OK
Repair or replace
harness for diagnostic light system
CHECK
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-33
OK
MD-TICS SYSTEM
Check that the fuse for the control unit power is not blown.
When doing this, measure the voltage at the fuse also.
Voltage values
Unit: V
2.
Place of measurement
Standard value
20 - 28
Judgement
Fuse is blown replace fuse (voltage is normal)
z
z
z
3.
z
z
Measurement location
Standard value
20 - 28
Judgement
Voltage normal replace control unit
Voltage abnormal go to CHECK (4).
EF-8-34
MD-TICS SYSTEM
3.
Measurement location
Standard value
20 - 28
Judgement
Voltage normal go to CHECK (5)
z
Voltage abnormal harness abnormal repair or
replace
z
EF-8-35
MD-TICS SYSTEM
CHECK
Check harness of C.U. portion
NG
1
OK
NG
CHECK
CHECK
Check resistance of rack sensor
3
OK
NG
2
OK
or
NG
CHECK
Check each harness
4
OK
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-36
MD-TICS SYSTEM
Connector U-13
4.
Standard value
(22) - (21)
92.5 - 101.5
(21) - (27)
92.5 - 101.5
(22) - (27)
186
Min. M
Judgement
Resistance value normal rack sensor harness normal go to CHECK (2).
z
Resistance value abnormal check resistance of rack
sensor body go to CHECK (3).
z
3.
Measurement location
Standard
reference value
MTM 1.77
(630 - 670 rpm)
Judgement
Output voltage normal rack sensor position normal
carry out CHECK (1) again or replace C.U.
z
Output voltage abnormal replace injection pump
assembly
z
EF-8-37
MD-TICS SYSTEM
Connector C-24
3.
Standard value
(3) - (2)
92.5 - 101.5
(2) - (1)
92.5 - 101.5
(3) - (1)
186
Min. M
Judgement
Resistance value is as specified go to CHECK (4).
z
Disconnection, short circuit, or resistance value is not
as specified rack sensor abnormal replace injection pump
z
EF-8-38
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-24
C-3
U-4
U-13
Check 1
(1)
(6)
(6)
(27)
Check 2
(2)
(5)
(5)
(21)
Check 3
(3)
(4)
(4)
(22)
Check 4
Shield
(7)
(7)
(27)
EF-8-39
MD-TICS SYSTEM
3.
Judgement
If the harness is abnormal (disconnection, short circuit,
etc.) repair or replace the harness
z
If the harness is not abnormal improper output voltage of rack sensor or abnormality in control unit
contact ZEXEL sales for repair
NOTE
z If there is no abnormality in the harness or resistance
value of the rack sensor, the rack sensor output voltage
may be defective or the may be an abnormality in the
control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine,
so it is difficult to check.
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no
abnormality.
z
EF-8-40
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-24
C-82
U-18
U-13
Check 1
(1)
(6)
(6)
(27)
Check 2
(2)
(5)
(5)
(21)
Check 3
(3)
(4)
(4)
(22)
Check 4
Shield
(7)
(7)
(27)
EF-8-41
MD-TICS SYSTEM
3.
Judgement
If the harness is abnormal (disconnection, short circuit,
etc.) repair or replace the harness
z
If the harness is not abnormal improper output voltage of rack sensor or abnormality in control unit
contact ZEXEL sales for repair
NOTE
z If there is no abnormality in the harness or resistance
value of the rack sensor, the rack sensor output voltage
may be defective or the may be an abnormality in the
control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine,
so it is difficult to check.
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no
abnormality.
z
EF-8-42
MD-TICS SYSTEM
CHECK
Check harness of C.U.
portion
NG
1
OK
NG
CHECK
Check resistance of engine
speed sensor body
2
CHECK
Check engine speed sensor
gap
OK
NG
4
OK
or
NG
CHECK
Check each harness
3
OK
Replace C.U.
Adjust gap
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
Reference
If the Diagnosis Display Code is 1-5, it can be taken that there is a disconnection, and if it is 1-6, the problem is something other than disconnection (short circuit, improper adjustment of gap, etc.).
EF-8-43
MD-TICS SYSTEM
Turn the ignition key switch OFF and remove connector U12.
Measure the resistance between terminal (9) and terminal
(18) of unit harness connector U-12.
3.
Check the insulation between terminal (9) of connector U12 and the body.
4. Check the insulation between terminal (18) of connector U12 and the body.
Resistance of engine speed sensor
Unit: k
Measurement location
(9) - (18)
Connector U-12
(9) - Body
(18) - Body
5.
Standard value
2.1 - 2.5
Judgement
Resistance value is as specified sensor normal
go to CHECK (4).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified go to CHECK
(2).
z
Standard value
867 - 1,073
(3) - Body
(2) - Body
(1) - Body
EF-8-44
MD-TICS SYSTEM
3.
Judgement
Resistance value is as specified sensor normal
go to CHECK (3).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified replace sensor
go to CHECK (4).
z
Standard value
2.1 - 2.5
(3) - Body
(2) - Body
(1) - Body
3.
Judgement
Resistance value is as specified sensor normal
go to CHECK (3).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified replace sensor
go to CHECK (4).
z
EF-8-45
MD-TICS SYSTEM
1.
Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit.
Harness
Chassis harness
Connector No.
Terminal
2.
Unit harness
C-22
C-3
U-4
U-12
Check 1
(2)
(2)
(2)
(18)
Check 2
(3)
(1)
(1)
(9)
Check 3
(1)
(3)
(3)
(18)
Judgement
z
If the harness is abnormal (disconnection, short circuit, etc.) repair or replace the harness
z
If the harness is not abnormal abnormality in control unit replace control unit
EF-8-46
MD-TICS SYSTEM
1.
Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit.
Harness
Chassis harness
Connector No.
Terminal
Unit harness
C-22
C-82
U-18
U-12
Check 1
(2)
(2)
(2)
(18)
Check 2
(3)
(1)
(1)
(9)
Check 3
(1)
(3)
(3)
(18)
Judgement
z
If the harness is abnormal (disconnection, short circuit, etc.) repair or replace the harness
z
If the harness is not abnormal abnormality in control unit replace control unit
EF-8-47
MD-TICS SYSTEM
Check the gap between the engine speed sensor and the
drive gear (Air compressor).
Standard value for engine speed sensor gap
Unit: mm (in)
0.7 - 1.3 (0.028 - 0.051)
2.
Judgement
Gap normal check again from CHECK (1), or
replace C.U.
z
Gap defective adjust as follows
1) Align the centers of the engine speed sensor and the
protrusions on the drive gear (Air compressor).
2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut.
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no
abnormality.
z
Check the gap between the engine speed sensor and the
protrusions on the coupling (flywheel) of the injection pump.
Standard value for engine speed sensor gap
Unit: mm (in)
0.8 - 1.0 (0.031 - 0.039)
2.
Judgement
z
Gap normal check again from CHECK (1), or
replace C.U.
z
Gap defective adjust as follows
1) Align the centers of the engine speed sensor and the
protrusions on the coupling (flywheel) of the injection
pump.
2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut.
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no
abnormality.
EF-8-48
MD-TICS SYSTEM
CHECK
Check harness at C.U. portion
NG
1
OK
CHECK
NG
or
NG
Replace C.U.
CHECK
Check each harness
3
OK
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-49
MD-TICS SYSTEM
4.
Check for insulation and short circuit between the body and
terminal (14) of connector U-12 and terminal (19) of connector U-13.
Resistance of engine coolant temperature sensor
Sensor resistance (x102)
454
270
55
Sensor
error
40
(40)
39
(38)
1 (30)
3.2
1.8
0.9
111
(232)
130
(266)
Sensor
error
24
20 (68)
5.
12
Judgement
z
Resistance corresponds to engine coolant temperature
sensor normal
z
Disconnection, short circuit, or defective insulation, or
resistance does not correspond to engine coolant temperature go to CHECK (2).
EF-8-50
MD-TICS SYSTEM
2.
Judgement
Resistance corresponds to engine coolant temperature
engine coolant temperature sensor normal go to
CHECK (3).
z
Disconnection, short circuit, or defective insulation, or
resistance does not correspond to engine coolant temperature engine coolant temperature sensor abnormal replace engine coolant temperature sensor
z
EF-8-51
MD-TICS SYSTEM
1.
Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and
U-13 and harness connector C-27 of the engine coolant temperature sensor.
Harness
Chassis harness
Connector No.
Terminal
Unit harness
C-27
C-4
U-5
Check 1
(1)
(5)
(5)
Check 2
(2)
(4)
(4)
2.
U-13
U-12
(14)
(19)
Judgement
If harness is abnormal (disconnection, short circuit) repair or replace harness
z
If there is no abnormality in the harness carry out CHECK (1) again if it is normal, the control unit is abnormal replace unit
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z
EF-8-52
MD-TICS SYSTEM
1.
Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and
U-13 and harness connector C-27 of the engine coolant temperature sensor.
Harness
Chassis harness
Connector No.
Terminal
Unit harness
C-27
C-81
U-17
Check 1
(1)
(5)
(5)
Check 2
(2)
(4)
(4)
2.
U-13
U-12
(14)
(19)
Judgement
If harness is abnormal (disconnection, short circuit) repair or replace harness
z
If there is no abnormality in the harness carry out
CHECK (1) again if it is normal, the control unit is abnormal replace unit
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z
EF-8-53
MD-TICS SYSTEM
CHECK
Check wiring harness at C.U. portion
NG
1
OK
CHECK
NG
Check pre-stroke
sensor
2
OK
NG
Check each
harness
3
OK
or
CHECK
Replace C.U.
Repair or replace
harness
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-54
MD-TICS SYSTEM
3.
Standard value
(23) - (24)
5-7
(23) - (29)
5-7
(24) - (29)
10 - 14
Judgement
z
Resistance is as specified pre-stroke sensor normal
check pre-stroke actuator (refer to (7) Check prestroke servo system)
z
Resistance value is not as specified disconnection,
short circuit, or pre-stroke sensor abnormal go to
CHECK (2).
3.
Standard value
(2) - (5)
5-7
(2) - (4)
5-7
(5) - (4)
10 - 14
Judgement
z
Resistance is as specified pre-stroke sensor normal
check harness go to CHECK (3).
z
Resistance value is not as specified pre-stroke sensor abnormal replace pre-stroke sensor (injection
pump assembly)
EF-8-55
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-24
C-82
U-4
U-13
Check 1
(1)
(12)
(12)
(30)
Check 2
(2)
(11)
(11)
(23)
Check 3
(3)
(10)
(10)
(29)
Check 4
(4)
(9)
(9)
(29)
Check 5
(5)
(8)
(8)
(24)
3.
Judgement
Continuity is as specified control unit abnormal replace control unit
z
Continuity is not as specified harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z
EF-8-56
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-85
C-82
U-18
U-13
Check 1
(1)
(12)
(12)
(30)
Check 2
(2)
(11)
(11)
(23)
Check 3
(3)
(10)
(10)
(29)
Check 4
(4)
(9)
(9)
(29)
Check 5
(5)
(8)
(8)
(24)
3.
Judgement
Continuity is as specified control unit abnormal replace control unit
z
Continuity is not as specified harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z
EF-8-57
MD-TICS SYSTEM
CHECK
Check wiring harness at C.U. portion
NG
1
OK
NG
CHECK
Check resistance
of pre-stroke
actuator
2
OK
or
CHECK
NG
Replace C.U.
Check each
harness
3
OK
Repair or replace
harness
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-58
MD-TICS SYSTEM
Turn the ignition key switch OFF, then remove control unit
harness connector U-12.
2. Measure the resistance between terminals (1) and (10) of
harness connector U-12.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector U-12
3.
(1) - (10)
Standard value
2.5 - 2.9
Judgement
Resistance is as specified check pre-stroke sensor
z
Resistance value is not as specified pre-stroke actuator or harness abnormal go to CHECK (2).
z
Turn the ignition key switch OFF, then remove the harness
connector of the pre-stroke actuator.
2. Measure the resistance between terminals (7) and (6) of
connector C-85 at the pre-stroke actuator end.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector U-85
3.
(7) - (6)
Standard value
2.5 - 2.9
Judgement
Resistance is as specified pre-stroke actuator normal check harness go to CHECK (3).
z
Resistance value is not as specified replace injection pump
z
EF-8-59
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-85
C-4
U-5
U-12
Check 1
(6)
(7)
(7)
(10)
Check 2
(7)
(6)
(6)
(1)
3.
Judgement
Continuity is normal check for CHECK (1) again replace control unit or replace injection
pump
z
Continuity is not normal harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z
EF-8-60
MD-TICS SYSTEM
1.
2.
Chassis harness
Connector No.
Terminal
Unit harness
C-85
C-81
U-17
U-12
Check 1
(6)
(7)
(7)
(10)
Check 2
(7)
(6)
(6)
(1)
3.
Judgement
Continuity is normal check for CHECK (1) again replace control unit or replace injection
pump
z
Continuity is not normal harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z
EF-8-61
MD-TICS SYSTEM
NG
CHECK
FUSE
1
or
OK
CHECK
Check continuity between fuse
and connector
NG
2
OK
or
Replace fuse
Replace C.U.
Carry out troubleshooting using the diagnostic light, and check that there is no abnormality
EF-8-62
MD-TICS SYSTEM
Check that the power fuse for the pre-stroke actuator is not
blown.
2. Measure the voltage at the fuse portion.
Value for power source voltage
Unit: V
3.
Measurement location
Standard value
20 - 28
Judgement
Fuse is blown (voltage is normal) after finding
cause, replace fuse
z
Fuse is normal go to CHECK (2).
z
Voltage is not as specified disconnection in harness
between battery and fuse, battery abnormal repair
harness or check battery
z
2.
Measurement location
Standard value
20 - 28
Judgement
Voltage is as specified control unit abnormal
replace control unit
z
Voltage is not as specified abnormality in power harness between power harness connectors, or pre-stroke
cut relay abnormal repair or replace harness, or
replace pre-stroke cut relay
z
EF-8-63
MD-TICS SYSTEM
EF-8-64
MD-TICS SYSTEM
APPENDIX
Table 1 Failure Judgement Conditions For MD-TICS System
Trouble system
Judgement
time (sec)
Immediate
Immediate
Reset condition
20
EF-8-65
2.4
MD-TICS SYSTEM
Table 2 BACK-UP Operations For MD-TICS System
Back-up operation
Trouble system
Pre-stroke control
Max. injection
limit by boost
compensator cut
(Yes: O, No: X)
Expected result
No abnormality is felt
1-5 or 1-6
2-1
2-3
1-2
Same as above
Same as above
2-2
Same as above
Same as above
Pre-stroke learning
function system
2-4
Engine performance
changes slightly but no
abnormality is felt
Stays lighted
up
1-3
EF-8-66
MD-TICS SYSTEM
EF-8-67
MD-TICS SYSTEM
EF-8-68
MD-TICS SYSTEM
- MEMO -
EF-8-69
MD-TICS SYSTEM
EF-8-70
MD-TICS SYSTEM
EF-8-71
MD-TICS SYSTEM
EF-8-72
MD-TICS SYSTEM
EF-8-73
- MEMO -
CONTENTS
SERVICE DATA ...................................... IE-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
INTAKE AND EXHAUST SYSTEM ..................
IE-1-1
IE-1-3
IE-1-4
IE-1-6
TOOLS .................................................... IE-2-1
AIR CLEANER ........................................ IE-3-1
CONSTRUCTION............................................. IE-3-1
REPLACING AIR CLEANER ELEMENT .......... IE-3-3
TURBOCHARGER.................................. IE-4-1
IE-4-1
IE-4-1
IE-4-2
IE-4-6
IE-4-9
IE-4-13
IE-4-14
IE-4-15
IE-4-16
IE-4-20
IE-4-22
IE-5-1
IE-5-2
IE-5-2
IE-5-3
IE-5-4
IE-6-1
IE-6-1
IE-6-1
IE-6-2
IE-6-4
IE-6-4
IE-6-5
= CYLINDER TYPE =
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
INSTALLATION ................................................
IE-6-6
IE-6-8
IE-6-9
IE-6-14
IE-6-15
IE-6-16
IE
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Engine model
Max. gross output
FE6A
kW {PS/rpm}
FE6B
118 {160}/3,000
119 {162}/3,000
132 {180}/3,000
Type
135 {183}/3,000
151 {205}/2,800
Engine model
Max. gross output
FE6T
kW {PS/rpm}
162 {220}/2,800
Engine model
Max. gross output
FE6TA
kW {PS}/rpm
173 {235}/2,800
157 {213}/2,800
Type
T04B
T04E
138,000
125,000
TURBOCHARGER
Models T04B and T04E
Model
Direction of rotation
Air volume
Compression ratio
21 (46)
20 (44)
3.2
3.0
IE-1-1
SERVICE DATA
RHC62E
RHC6V
140,000
Counterclockwise as viewed from the exhaust turbine side
kg (lb)/min
18.8 (41.5)
19.4 (42.8)
Compression ratio
3.2
EXHAUST BRAKE
Engine model
Max. gross output
FE6A
kW {PS}/rpm
FE6B
118 {160}/3,000
119 {162}/3,000
132 {180}/3,000
Type
Chamber type
Cylinder type
Operating method
Vacuum type
Air type
286-04505
*286-04446 (286-04442)
Model
Engine model
Max. gross output
FE6T
kW {PS}/rpm
135 {183}/3,000
151 {05}/2,800
Type
Cylinder type
Operating method
Air type
*286-04446 (286-04442)
*286-04453 (286-04441)
286-06109
Model
*286-04446
(286-04442)
Engine model
Max. gross output
286-06109
FE6TA
kW {PS}/rpm
157 {213}/2,800
Type
173 {235}/2,800
Cylinder type
Operating method
Air type
*286-04446 (286-04442)
*286-04453 (286-04441)
Model
NOTE
z
162 {220}/2,800
IE-1-2
SERVICE DATA
SERVICE DATA
TURBOCHARGER
Models T04B and T04E
Unit: mm (in)
Maintenance standard
Service limit
Item
0.011 (0.0004)
Journal part
10.16 (0.4000)
17.34 (0.6827)
12.71 (0.5004)
11.66 (0.4591)
Bearing part
15.81 (0.6224)
18.06 (0.7110)
4.36 (0.1717)
Runout of shaft
Outside diameter of shaft
Remarks
Thrust bushing,
Oil thrower,
Thrust bearing
Maintenance standard
Service limit
10.39 (0.4091)
1.33 (0.0524)
Runout
0.011 (0.0004)
4.08 (0.1606)
1.25 (0.0492)
Seal ring
groove width
Small diameter
1.46 (0.0575)
3.98 (0.1567)
Inside diameter
10.44 (0.4110)
Outside diameter
14.98 (0.5898)
Inside diameter
15.10 (0.5945)
17.03 (0.6705)
Small diameter
12.45 (0.4902)
Large diameter
14.05 (0.5531)
0.10 (0.0039)
0.17 (0.0067)
Floating bearing
Center housing
Seal plate
Seal ring
insertion hole
Large diameter
IE-1-3
Remarks
SERVICE DATA
EXHAUST BRAKE
Chamber type
Unit: mm (in)
Item
Clearance between
valve and body
Maintenance standard
Service limit
Remarks
0.80 - 1.05
(0.0315 - 0.0413)
1.6 - 2.1
(0.063 - 0.083)
Cylinder type
<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>
Unit: mm (in)
Item
Maintenance
standard
Service limit
Spindle O.D.
286-04446 (286-04442)
286-04453 (286-04441)
16.50 (0.6496)
16.43
(0.6468)
Clearance between
spindle and bushing
286-04446 (286-04442)
286-04453 (286-04441)
0.3 - 0.4
(0.012 - 0.016)
Clearance between
bushing and body
286-04446 (286-04442)
286-04453 (286-04441)
0.015 - 0.090
(0.0006 - 0.0035)
0.80 - 1.05
(0.0315 - 0.0413)
1.6 - 2.1
(0.063 - 0.083)
Free length
151.5 (5.965)
Tension
N {kgf, lbf}
134.4 - 161.2
{13.70 - 16.44,
30.2 - 36.3}
Clearance between
valve and body
286-04446
(286-04442)
286-04453
(286-04441)
286-04446
(286-04442)
286-04453
(286-04441)
286-06109
Remarks
When compressed to
107.8 mm (4.244 in)
TIGHTENING TORQUE
TURBOCHARGER
Models T04B and T04E
Unit: Nm{kgfcm, inlbf}
Item
Compressor wheel lock nut
Back plate and center housing mounting bolt
Tightening torque
2.1 - 2.3 {21 - 23, 18 - 20} Tighten (110)
8.4 - 10.2 {86 - 104, 75 - 90}
IE-1-4
Remarks
SERVICE DATA
Tightening torque
Remarks
EXHAUST BRAKE
Chamber type
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Cylinder type
<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
286-04446 (286-04442)
286-04453 (286-04441)
286-04446 (286-04442)
286-04453 (286-04441)
286-04446 (286-04442)
286-04453 (286-04441)
286-04446 (286-04442)
286-04453 (286-04441)
286-04446 (286-04442)
286-04453 (286-04441)
286-06109
286-04446 (286-04442)
286-04453 (286-04441)
286-06109
286-04446 (286-04442)
286-04453 (286-04441)
286-06109
IE-1-5
SERVICE DATA
IE-1-6
SERVICE DATA
FE6TA
IE-1-7
TOOLS
TOOLS
TURBOCHARGER
Models T04B and T04E
Tool name and number
Description
Pick
99767 96003
IE-2-1
Shape
TOOLS
Description
T-handle
99773 96000
Torque wrench
99537 96001
Holding fixture
99768 Z5500
Torque wrench
99537 Z5500
Used to tighten and remove the turbine housing and center housing.
Torque 16.7 Nm {170 kgfcm, 148 inlbf}
IE-2-2
Shape
TOOLS
Description
Torque wrench
99537 Z5501
Used to tighten and remove the turbine housing and center housing.
Torque 16.7 Nm {170 kgfcm, 148 inlbf}
Torque wrench
99537 Z5502
Shape
Description
Bar
Measuring needle
IE-2-3
Shape
TOOLS
Tool name
Description
Plier
Plier
Torx driver
Torque wrench
Box spanner
Measuring needle
IE-2-4
Shape
AIR CLEANER
AIR CLEANER
CONSTRUCTION
Type I
Type II
IE-3-1
AIR CLEANER
IE-3-2
AIR CLEANER
IE-3-3
6. Evacuator valve
7. Body assembly
AIR CLEANER
6. Evacuator valve
7. Body assembly
5. Wing nut
6. Packing
7. Outer element
8. Wing nut
IE-3-4
9. Packing
10. Inner element
11. Evacuator valve
12. Body assembly
TURBOCHARGER
TURBOCHARGER
= MODELS T04B AND T04E =
CONSTRUCTION
REMOVAL
Key point of removal
WARNING
WARNING
z
IE-4-1
T04B, T04E
TURBOCHARGER
T04B, T04E
DISASSEMBLY
+
+
,
+
+
,+
+
1. Retaining ring
2. Actuator
3. Lock plate
4. Clamp
5. Turbine housing
6. Lock plate
7. Clamp
8. Compressor housing
9. Rotating assembly
Marks + and , indicate that the key points of operation are explained in the text.
IE-4-2
TURBOCHARGER
Set the dial gauge to the end play measuring tool (99766
96000). Replace the dial gauge adapter with the end play
adapter (99765 96001).
Set the end play measuring tool so that the end of the
adapter is contacting the compressor wheel end of the
shaft.
Measure the play in the axial direction.
Unit: mm (in)
Maintenance standard
Service limit
Set the dial gauge to the radial play measuring tool (99764
96000) and replace the dial gauge adapter with the radial
play adapter (99765 96000).
Tighten the measuring tool with hex socket head bolt
(14220 Z9001). Make sure the measuring element contacts
the center of the shaft.
Measure the play in the radial direction.
Unit: mm (in)
Maintenance standard
Service limit
IE-4-3
T04B, T04E
TURBOCHARGER
8 Compressor housing
Remove the compressor housing being careful not to damage the
compressor wheel.
NOTE
z
9 Rotating assembly
Place holding fixture (99768 Z5500) in a vise, and set the turbine
wheel on it with the compressor wheel on it with the turbine wheel
side facing downward.
IE-4-4
T04B, T04E
TURBOCHARGER
11 Compressor wheel
Remove the compressor wheel.
z
Using a T-handle (99773 96000), remove the lock nut, and
then remove the compressor wheel by hand.
NOTE
Since bending of the shaft is also related to the life of the
turbocharger, be careful not to bend it.
z Support the turbine wheel by hand while loosening the
lock nuts.
z
13 Piston ring
Remove the piston ring.
NOTE
z
16 Back plate
Unbend the lock plate and remove the back plate.
NOTE
z
Using retaining ring pliers (99546 Z5500), remove the compressor wheel side retaining ring and journal bearing.
IE-4-5
T04B, T04E
TURBOCHARGER
2.
3.
T04B, T04E
Using retaining ring pliers (99546 Z5500), remove the turbine side retaining ring and journal bearing.
Remove the two retaining rings located in the rear of the
center housing.
EIE3048A
INSPECTION
INSPECTION BEFORE CLEANING
Turbocharger failure may sometimes be due to faulty engine parts.
It is, therefore advisable to closely inspect parts for accumulation of
carbon, presence of dirt or dust, obstruction of oil passages, etc.
prior to cleaning, so that the cause of problems may be located
easily.
CLEANING
After soaking all the parts in clean detergent for about 20 to 30 minutes, remove dirt and grime with a rough brush and then blow dry
with compressed air.
NOTE
z
Inspection point
z
z
z
z
z
z
z
z
z
z
Oil leakage
z
z
z
z
z
z
z
z
z
Clogging
z
z
z
z
IE-4-6
TURBOCHARGER
T04B, T04E
INSPECTION
Inspect parts visually, replacing as necessary.
Inspection position
Inspection item
Compressor housing
Clamp
Turbine housing
z
z
z
z
Compressor wheel
z
z
z
z
Turbine wheel
z
z
z
z
z
z
Back plate
z
z
z
Thrust collar
z
z
Thrust bearing
z
z
Center housing
z
z
Heat shroud
z
z
Corrosion.
Scratches caused by interference with housing.
Blade breakage and deformity.
Clogging in shaft holes.
Scratches from interference with turbine housing.
Blade breakage, deformity and cracks.
Shaft bent.
Discolored journals and blades.
Worn and scratched journals.
Worn and damaged piston rings.
Worn bore.
Wear and damage on contact surface of thrust collar.
Scratches on rear face of compressor wheel.
Wear and scratches on contact surface.
Worn and damaged piston ring groove.
Thermal discoloration.
Wear and scratches on contact surface.
Wear and scratches on journal bores and inner surfaces
of piston rings.
Obstruction in oil hole
Scratches caused by contact.
Thermal discoloration and corrosion.
Runout of shaft
NOTE
z
Since the turbine side is heavy and the front end of the
shaft will lift when the shaft is supported by V-block, use
a magnet V-block or place another V-block to keep the
journal part in place.
Unit: mm (in)
Maintenance standard
Service limit
0.011 (0.0004)
IE-4-7
TURBOCHARGER
Service limit
12.71 (0.5004)
Maintenance standard
Service limit
Journal part
10.16 (0.4000)
17.34 (0.6827)
Service limit
11.66 (0.4591)
Maintenance standard
Service limit
15.81 (0.6224)
18.06 (0.7110)
Service limit
4.36 (0.1717)
IE-4-8
T04B, T04E
TURBOCHARGER
REASSEMBLY
PREPARATIONS BEFORE REASSEMBLY
Repair light damage by polishing. Aluminum parts must be polished
with a polishing cloth, using silicon carbide. Moreover, steel parts
must be polished with a polishing cloth, using polishing powder.
16 Back plate
1. Install the back plate.
z
Install the piston ring to the thrust collar.
z
Coat the thrust bearing with engine oil and then install the
thrust bearing and thrust collar.
2.
Fit the thrust collar into the groove pin of the center housing, and fit the seal ring to the peripheral groove of the center housing.
NOTE
z When installing the thrust collar, align the portions indicated by dotted lines in the figure at right.
IE-4-9
T04B, T04E
TURBOCHARGER
3.
Use bolt and lock plate to install the back plate to the center
housing and bend the lock plate.
: 8.4 - 10.2 Nm {86 - 104 kgfcm, 75 - 90 inlbf}
NOTE
z Ensure that the bosses are ready to be detached from the
flanged portions of the inlet and outlet.
13 Piston ring
Install the piston ring to the turbine wheel using the piston ring
guide (99763 Z5500).
12 Turbine wheel
Apply a coat of engine oil to the turbine wheel journal, and carefully
insert the turbine wheel into the bore in the center housing. Use
pick (99767 96003) to compress the piston ring and install it while
rotating the wheel shaft.
NOTE
z Be careful not to scratch or break the piston ring.
11 Compressor wheel
NOTE
z Before installing the compressor wheel, clean the parts
and check carefully the tightening surface for dust or foreign matter.
z When tightening the nut, be careful not to give the bending force to the shaft.
z Keep the rated tightening torque and tightening angle.
1.
2.
3.
IE-4-10
T04B, T04E
TURBOCHARGER
4.
5.
2.
3.
Maintenance standard
Service limit
Seat the dial gauge to the end play measuring tool (99766
96000). At this time, replace the dial gauge adapter with the
end play adapter (99765 96001).
IE-4-11
T04B, T04E
TURBOCHARGER
4.
Service limit
8 Compressor housing
1. Attach the compressor housing to the back plate by properly aligning their marks, then tighten the bolts with the
clamps and lock plates in place.
: 11.3 - 14.7 Nm {115 - 150 kgfcm, 100 - 130 inlbf}
2.
5 Turbine housing
1. Align the marks on the turbine housing and center housing,
attach the turbine housing to the rotating assembly, then
tighten bolts with a clamp and lock plate in place.
: 18.0 - 21.5 Nm {184 - 219 kgfcm, 160 - 190 inlbf}
NOTE
z Apply a gauge-preventive compound to bolts. Do not
confuse these bolts (designed especially for high temperature use) with other conventional bolts.
2.
IE-4-12
T04B, T04E
TURBOCHARGER
INSTALLATION
Key point of installation
1.
IE-4-13
T04B, T04E
TURBOCHARGER
IE-4-14
RHC62E, RHC6V
TURBOCHARGER
Model RHC6V
REMOVAL
Key point of removal
WARNING
WARNING
z
IE-4-15
RHC62E, RHC6V
TURBOCHARGER
RHC62E, RHC6V
DISASSEMBLY
Model RHC62E
9. Sealed wheel
,+ 10. Snap ring
11. Floating metal
,+ 12. Center housing
,+ 13. Torx screw
14. Seal plate
, 15. Oil thrower
16. Thrust bearing
Marks + and , indicate that the key points of operation are explained in the text.
IE-4-16
TURBOCHARGER
RHC62E, RHC6V
Model RHC6V
8.Turbine shaft
9. Sealed wheel
,+ 10. Snap ring
11. Floating metal
,+ 12. enter housing
,+ 13. Torx screw
14. Seal plate
Marks + and , indicate that the key points of operation are explained in the text.
IE-4-17
TURBOCHARGER
Turbocharger assembly
1. Cover the oil inlet and outlet using masking tape.
2. Check if the turbine vane is in contact with the compressor
impeller or if there is evidence of leaking oil.
3. Check the actuator for improper movement or wear.
4. Check that the impeller spins smoothly by hand.
5. Measure the turbine shaft axial play.
z
Fix the dial gauge to the turbocharger by the magnetic
base.
z
Move the tip of the turbine shaft by hand in the axial direction so that the dial gauge registers the maximum deflection.
Unit: mm (in)
6.
z
Maintenance standard
Service limit
0.10 (0.0039)
Service limit
0.17 (0.0067)
IE-4-18
RHC62E, RHC6V
TURBOCHARGER
IE-4-19
RHC62E, RHC6V
TURBOCHARGER
RHC62E, RHC6V
INSPECTION
Check all parts for scratches (frictional), scratches (on the joining
surfaces), cracks, corrosion, bends, wear, thermal deformation, pitting, discoloration, breakage, oil clogging, etc. Replace faulty parts
with new ones.
Cleaning procedure
Turbine shaft
Pour cleaning liquid (decarbonizing agent) into the cleaning basket. Immerse parts in the liquid, then heat them.
NOTE
z Protect the turbine shaft journal surface and seal ring groove from damage in advance.
NOTE
IE-4-20
TURBOCHARGER
Maintenance standard
Service limit
1.33 (0.0524)
10.39 (0.4091)
Runout
Unit: mm (in)
Maintenance standard
Service limit
0.011 (0.0004)
Service limit
4.08 (0.1606)
Maintenance standard
Service limit
1.25 (0.0492)
1.46 (0.0575)
Service limit
3.98 (0.1567)
IE-4-21
RHC62E, RHC6V
TURBOCHARGER
FLOATING BEARING
Inside diameter (C) and outside diameter (D)
Unit: mm (in)
Item
Maintenance standard
Service limit
10.44 (0.4110)
14.98 (0.5898)
CENTER HOUSING
Inside diameter (B) and seal ring insertion hole (F) (on
turbine side)
Unit: mm (in)
Maintenance standard
Service limit
Item
15.10 (0.5945)
17.03 (0.6705)
SEAL PLATE
Seal ring insertion hole (H1 and H2) (on impeller side)
Unit: mm (in)
Item
Maintenance standard
Service limit
12.45 (0.4902)
14.05 (0.5531)
REASSEMBLY
Key point of reassembly
NOTE
z
IE-4-22
RHC62E, RHC6V
TURBOCHARGER
13 (RHC62E) 13 (RHC6V) Torx screw
Use a Torx driver when installing the Torx T type screws which
secure the seal plate.
7 (RHC62E) 7 (RHC6V) Seal ring
Fit the seal ring to the groove on the turbine shaft, as shown in the
figure.
IE-4-23
RHC62E, RHC6V
TURBOCHARGER
INSTALLATION
Key point of installation
1.
IE-4-24
RHC62E, RHC6V
EXHAUST SYSTEM
EXHAUST SYSTEM
REMOVAL
Key point of removal
WARNING
WARNING
z
Tail pipe
1.
2.
Muffler
1.
2.
Remove the bolt from the exhaust shutter, and separate the
exhaust brake from the muffler.
Separate the hanger from the bracket which secures the
rear pipe of the muffler. Remove the muffler.
Exhaust pipe
1.
2.
3.
IE-5-1
EXHAUST SYSTEM
DISASSEMBLY
(Example)
1. Gasket
2. Exhaust tube assembly
3. Hanger
4. Rubber
8. Muffler
9. Hanger
10. Tail tube assembly
NOTE
z
INSPECTION
Carefully check all disassembled parts for scratches, cracks or
damage. Repair or replace faulty parts if necessary.
IE-5-2
EXHAUST SYSTEM
INSTALLATION
1.
2. Install the hanger and rubber pad on the tail pipe bracket.
NOTE
z Always install the hanger using the hole at the outer end
of the bracket.
z Make sure that the convex end of the rubber pad faces
down and that the bolt is inserted from the lower side.
z Make sure that the nut which secures the rubber pad
makes contact with the graded portion of the bolt when
tightened.
3.
4.
5.
Insert the rear pipe of the muffler into the clamp. Connect
the front pipe to the exhaust pipe by using the exhaust
brake assembly and gasket.
NOTE
z Install the muffler so that the bent part is 30 degrees
towards the vehicle from the bottom of the muffler.
6.
7.
Insert the tail pipe between the clamp (which was installed
temporarily in step 4 above) and the rear pipe of the muffler.
Secure the tail pipe hanger to the tail pipe clamp.
IE-5-3
EXHAUST SYSTEM
8. Adjust the position of the tail pipe and tighten the clamp.
NOTE
z Make sure that the tail pipe clamp is tightened at a point
approximately 5 mm (0.20 in) from the end of the tail pipe.
2.
Check that the exhaust pipe, muffler and tail pipe are sufficiently clear of adjacent parts for safety. Also check that
there is sufficient clearance between the exhaust pipes and
the seats and ropes.
Start the engine. Check the muffler for proper function and
connections for signs of air leakage.
IE-5-4
EXHAUST BRAKE
EXHAUST BRAKE
= CHAMBER TYPE =
CONSTRUCTION
REMOVAL
Position the vehicle on a flat surface and apply chocks to the front
and rear wheels.
WARNING
WARNING
z
IE-6-1
CHAMBER TYPE
EXHAUST BRAKE
CHAMBER TYPE
DISASSEMBLY
EXHAUST SHUTTER AND POWER CHAMBER ASSEMBLY
, 4. Clevis
5. Power chamber assembly
6. Bearing
7. Gasket
8. Insulator
9. Exhaust shutter assembly
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-2
EXHAUST BRAKE
CHAMBER TYPE
EXHAUST SHUTTER
4. Cover
5. Gasket
6. Body
7. Bracket assembly
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-3
EXHAUST BRAKE
INSPECTION
z
REASSEMBLY
EXHAUST SHUTTER
Key point of reassembly
3, 2 Seal ring
Position the spindle, valve and bushing in the body. Install the seal
rings on the spindle.
NOTE
z Make sure that the different seal rings are installed alternately.
Adjustment of clearance between the valve and body
Apply a vacuum pressure of 86.6 to 93.3 kPa {650 to 700 mmHg,
25.59 to 27.56 inHg} to the power chamber with the valve fully
closed. Check to ensure that the clearance between the body and
valve is in the specified range indicated in the table below. If it is
not, adjust the stopper bolt and tighten the lock nut.
: 5 - 7 Nm {0.5 - 0.7 kgfm, 3.6 - 5.1 ftlbf}
Unit: mm (in)
Item
Clearance
between valve
and body
Maintenance
standard
Service limit
0.80 - 1.05
(0.0315 - 0.0413)
1.6 - 2.1
(0.063 - 0.083)
IE-6-4
CHAMBER TYPE
EXHAUST BRAKE
: Clevis adjusting nut
10 - 16 Nm {1.0 - 1.6 kgfm, 7 - 12 ftlbf}
: Stopper bolt lock nut
5 - 7 Nm {0.5 - 0.7 kgfm, 3.6 - 5.1 ftlbf}
INSTALLATION
Key point of installation
1. Connect the vacuum hoses.
NOTE
z Be careful not to twist the hoses.
2.
Start the engine. When vacuum pressure reaches the specified value, turn the exhaust brake switch ON to ensure
that the exhaust brake operates properly. Also check to be
sure there is no air leakage.
IE-6-5
CHAMBER TYPE
EXHAUST BRAKE
= CYLINDER TYPE =
CONSTRUCTION
EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY
Models 286-04442 and 286-04441
IE-6-6
CYLINDER TYPE
EXHAUST BRAKE
Models 286-04446 and 286-04453
IE-6-7
CYLINDER TYPE
EXHAUST BRAKE
Model 286-06109
REMOVAL
Key point of removal
Position the vehicle on a flat surface and apply chocks to the front
and rear wheels.
WARNING
WARNING
z
IE-6-8
CYLINDER TYPE
EXHAUST BRAKE
CYLINDER TYPE
DISASSEMBLY
EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY
Models 286-04442 and 286-04441
4. Shield plate
5. Air cylinder assembly
6. Insulator
7. Exhaust shutter assembly
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-9
EXHAUST BRAKE
CYLINDER TYPE
4. Shield plate
5. Air cylinder assembly
6. Insulator
7. Exhaust shutter assembly
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-10
EXHAUST BRAKE
CYLINDER TYPE
EXHAUST SHUTTER
Models 286-04442, 286-04441, 286-04446 and 286-04453
4. Plate
, 5. Seal ring
, 6. Seal ring
7. Exhaust shutter
Marks + and , indicate that the key points of operation are explained in the text.
CAUTION
z
Do not disassemble the exhaust shutter in model 286-06109. Never loosen the stopper bolt.
IE-6-11
EXHAUST BRAKE
CYLINDER TYPE
6. Packing
7. Plate
8. Wear ring
9. Protector
+ 10. Spring
11. Shaft
12. Guide
13. Cover
14. Dust seal
15. Cylinder
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-12
EXHAUST BRAKE
CYLINDER TYPE
7. Plate
8. Wear ring
9. Protector
+ 10. Spring
11. Shaft
12. Guide
13. Washer
14. Cover
15. Dust seal
16. Retaining ring
17. Filter
18. Cylinder
Marks + and , indicate that the key points of operation are explained in the text.
IE-6-13
EXHAUST BRAKE
INSPECTION
z
Spindle O.D.
Unit: mm (in)
Maintenance standard
Service limit
16.50 (0.6496)
16.43 (0.6468)
Service limit
Service limit
Spring
Unit: mm (in)
Item
Maintenance
standard
Service limit
Free length
151.5 (5.965)
134.4 - 161.2
{13.70 - 16.44,
30.2 - 36.3}
Tension
N {kgf, lbf}
Remarks
IE-6-14
CYLINDER TYPE
EXHAUST BRAKE
REASSEMBLY
EXHAUST SHUTTER
Key point of reassembly
6, 5 Seal ring
Position the spindle, valve and bushing in the body and attach the
seal rings on the spindle.
NOTE
z Alternately install different types of seal rings.
Adjustment of clearance between the valve and body
Move the lever toward the full-open side. When the lever contacts
the stopper bolt, adjust the stopper bolt so that clearances A and B
are equal. Move the lever toward the full-close side. When the lever
contacts the stopper bolt, adjust the stopper bolt so that the clearance between the valve and body is within specifications. After
adjusting the clearance, tighten the stopper bolt with the lock nut.
: 10 - 16 Nm {1.0 - 1.6 kgfm, 7 - 12 ftlbf}
Unit: mm (in)
Item
Maintenance
standard
0.80 - 1.05
One side
Clearance
(0.0315 - 0.0413)
between valve
1.6 - 2.1
and body
Both total
(0.063 - 0.083)
Service limit
Remarks
(*)
(*) When an air pressure of 637 kPa {6.5 kgf/cm2, 92 psi} is applied to the
air cylinder and the valve is fully closed
IE-6-15
CYLINDER TYPE
EXHAUST BRAKE
INSTALLATION
Key point of installation
Install the connector so that its hose mounting hole faces upward.
NOTE
z
Wind two turns of sealing on the threads of the connector in the opposite direction of the threads.
IE-6-16
CYLINDER TYPE
- MEMO -
- MEMO -
ELECTRICAL SYSTEM
CONTENTS
SERVICE DATA ...................................... EE-1-1
SPECIFICATIONS............................................ EE-1-1
SERVICE DATA ............................................... EE-1-1
TIGHTENING TORQUE ................................... EE-1-2
STARTING MOTOR ................................ EE-2-1
CONSTRUCTION............................................. EE-2-1
DISASSEMBLY ................................................ EE-2-3
INSPECTION.................................................... EE-2-4
ADJUSTMENT ................................................. EE-2-7
EE-3-1
EE-3-5
EE-3-7
EE-3-8
AIR HEATER ........................................... EE-4-1
CONSTRUCTION ............................................. EE-4-1
INSPECTION .................................................... EE-4-1
EE
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model
Type
Shift
Output
V-kW
24-4.5
ALTERNATOR
0202 152
Model
0201 152
0202 152 0310 0202 152 0311 0202 152 0220 0202 152 0221 0201 152 0420 0201 152 0421 0201 222 0273
With vacuum pump
Output
0201 222
V-A
24-50
Type of
regulator
24-80
IC transistor (Built-in)
Vacuum pump
model
AIR HEATER
Type
Ribbon
Rated current
V-A
Rated time
Second
22-85
Less than 50
SERVICE DATA
STARTING MOTOR
Models 0350 502 0310 and 0350 502 0321
Unit: mm (in)
Item
Service limit
36.0 (1.417)
34.0 (1.339)
Runout
Less than
0.09 (0.0035)
More than
0.10 (0.0039)
0.5 - 0.8
(0.020 - 0.031)
0.2 (0.008)
18.0 (0.709)
13.0 (0.512)
Magnetic
Brush
switch
Undercut depth
Brush height
Gear shaft
Commutator
Maintenance standard
Outside diameter
Shaft runout
N {kgf, lbf}
0.70 - 0.86
0.85 - 1.05
Less than
0.09 (0.0035)
More than
0.10 (0.0039)
0.1 - 0.5
(0.004 - 0.020)
Thrust gap
Insulation resistance M
0.5
Brush holder
Insulation resistance M
0.5
EE-1-1
Remarks
SERVICE DATA
Unit: mm (in)
Performance
Adjustment
check
Bracket
Item
Maintenance standard
Service limit
15.0 (0.591)
15.2 (0.598)
28.0 (1.102)
28.1 (1.106)
35.0 (1.378)
35.1 (1.382)
0.5 - 3.0
(0.020 - 0.118)
Less than 16
Number of rotations
rpm
Remarks
ALTERNATOR
Performance check
Item
Resistance
Service limit
0.18 - 0.22
0201 222
0.14 - 0.18
5.6 - 6.8
5.0 - 7.0
28 - 29
Less than 50
Less than 80
0202 152
0201 152
0201 222
Resistance
No-load speed
Maintenance standard
0202 152
0201 152
0202 152
rpm 0201 152
0201 222
Regulating voltage
V
0202 152
A 0201 152
0201 222
Output current
Remarks
Between two phases at
20C (68F)
At 20C (68F)
TIGHTENING TORQUE
STARTING MOTOR
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
C terminal
B terminal
M terminal
Through bolt
EE-1-2
SERVICE DATA
ALTERNATOR
Unit: Nm {kgfm, ftlbf}
Item
Pulley mounting nut
Tightening torque
0202 152
0201 152
0201 222
EE-1-3
STARTING MOTOR
STARTING MOTOR
CONSTRUCTION
EE-2-1
0350 502
No
EE-2-2
O.K.
N.G.
(Turns
Does starting motor slowly)
turn normally?
Yes
Yes
No
O.K.
O.K.
Repair or replace
starting motor.
Replace engine
oil.
*A
Yes
N.G.
No
Yes
No
No
N.G.
No
No
netic switch.
battery terminals.
*A
: Check item
Yes
O.K.
Yes
Yes
O.K.
N.G.
STARTING MOTOR
0350 502
TROUBLESHOOTING
STARTING MOTOR
0350 502
DISASSEMBLY
9. Packing
10. Retaining ring
11. Hook
+ 12. Pinion stopper
13. Holder
14. Shaft
15. Lever assembly
Marks + and , indicate that the key points of operation are explained in the text.
EE-2-3
STARTING MOTOR
12 Pinion stopper
Move the pinion stopper toward the pinion. Using a screwdriver, pry
off the pinion stopper clip. Then, extract the pinion assembly and
center plate.
INSPECTION
z
COMMUTATOR
Outside diameter
Unit: mm (in)
Maintenance standard
Service limit
36.0 (1.417)
34.0 (1.339)
NOTE
z
Runout
Unit: mm (in)
Maintenance standard
Service limit
EE-2-4
0350 502
STARTING MOTOR
Undercut depth
Unit: mm (in)
Maintenance standard
Service limit
0.2 (0.008)
BRUSH
Brush height
Unit: mm (in)
Maintenance standard
Service limit
18.0 (0.709)
13.0 (0.512)
Service limit
Remarks
When spring is set
MAGNETIC SWITCH
Continuity test (Pull coil resistance)
Perform the continuity test between the M and C terminals.
Unit:
Maintenance standard
Service limit
0.70 - 0.86
Service limit
0.85 - 1.05
EE-2-5
0350 502
STARTING MOTOR
GEAR SHAFT
Shaft runout
Unit: mm (in)
Maintenance standard
Service limit
Thrust gap
Unit: mm (in)
Maintenance standard
Service limit
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
Insulation resistance
Unit: M
Maintenance standard
Service limit
0.5
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
EE-2-6
0350 502
STARTING MOTOR
Insulation resistance
Unit: M
Maintenance standard
Service limit
0.5
BRUSH HOLDER
Insulation resistance
Unit: M
Maintenance standard
Service limit
0.5
BRACKET
Front bearing (metal) inside diameter
Unit: mm (in)
Maintenance standard
Service limit
15.0 (0.591)
15.2 (0.598)
Service limit
28.0 (1.102)
28.1 (1.106)
Service limit
35.0 (1.378)
35.1 (1.382)
ADJUSTMENT
Measure dimension L moved towards the thrust direction of the pinion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal
through the magnetic switch. Ground the M terminal midway and then connect it to the battery negative terminal.
EE-2-7
0350 502
STARTING MOTOR
2.
Dimension L
3.
Maintenance standard
Service limit
PERFORMANCE CHECK
1.
Current
Maintenance standard
Service limit
2.
Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.
3.
Service limit
Less than 16
EE-2-8
0350 502
- MEMO -
ALTERNATOR
ALTERNATOR
CONSTRUCTION
Models 0202 152 0310 and 0202 152 0311
EE-3-1
ALTERNATOR
Models 0202 152 0220 and 0202 152 0221
EE-3-2
EE-3-3
Normal alternator
Yes
Yes
*B
Yes
*A
Yes
No
No
No
No
No
Normal
Yes
Faulty alternator
Normal
Normal
To *A
Yes
No
Normal
Faulty alternator
To *B
Abnormal
To *A
Normal
Abnormal
Abnormal
To *A
Abnormal
Abnormal
No
Abnormal
ALTERNATOR
0202 152, 0201 152, 0201 222
TROUBLESHOOTING
Normal alternator
No
Yes
Faulty alternator (Regulator)
: Check item
ALTERNATOR
EE-3-4
ALTERNATOR
DISASSEMBLY
Models 0202 152 and 0201 152
1. Nut
2. Lock washer
3. Washer
+ 4. Pulley assembly
5. Spacer
+ 6. Front cover
7. Oil seal
8. Washer
9. Ball bearing
10. Washer
11. Oil seal
12. Cover
13. Rotor assembly
14. Stator assembly
15. Field coil assembly
16. Housing
Marks + and , indicate that the key points of operation are explained in the text.
NOTE
z
EE-3-5
ALTERNATOR
1. Nut
2. Lock washer
3. Washer
+ 4. Pulley assembly
+ 5. Front cover
6. Bearing felt
7. Retainer
8. Ball bearing
9. Retainer
10. Cover
11. Rotor assembly
12. Stator assembly
13. Field coil assembly
14. Housing
Marks + and , indicate that the key points of operation are explained in the text.
NOTE
z
EE-3-6
ALTERNATOR
} Front cover
Be careful not to damage the stator coil with the screwdriver tip.
} Pulley assembly
INSPECTION
z
STATOR COIL
Continuity test of the stator coil
Unit:
Maintenance
standard
Service
limit
0202 152
0201 152
0.18 - 0.22
0201 222
0.14 - 0.18
Item
Resistance
Remarks
Between two
phases at
20C (68F)
EE-3-7
ALTERNATOR
FIELD COIL
Continuity test of the field coil
Unit:
Maintenance
standard
Service
limit
0202 152
0201 152
5.6 - 6.8
0201 222
5.0 - 7.0
Item
Resistance
Remarks
At 20C (68F)
PERFORMANCE CHECK
NOTE
EE-3-8
ALTERNATOR
Unit: rpm
Maintenance
standard
Service
limit
0202 152
0201 152
0201 222
Item
No-load
speed
Remarks
At 20C (68F)
Service limit
28.0 - 29.0
Service
limit
0202 152
0201 152
Less than 50
0201 222
Less than 80
Item
Remarks
At 20C (68F)
EE-3-9
AIR HEATER
AIR HEATER
CONSTRUCTION
INSPECTION
z
1.
2.
EE-4-1
- MEMO -
AUXILIARY EQUIPMENT
CONTENTS
SERVICE DATA ...................................... EA-1-1
SPECIFICATIONS............................................ EA-1-1
SERVICE DATA ............................................... EA-1-2
TIGHTENING TORQUE ................................... EA-1-4
TOOLS .................................................... EA-2-1
AIR COMPRESSOR......................................... EA-2-1
AIR COMPRESSOR ............................... EA-3-1
= MODEL F8040 =
CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................
EA-3-1
EA-3-1
EA-3-2
EA-3-3
EA-3-5
= MODEL 408738 =
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
EA-3-7
EA-3-9
EA-3-10
EA-3-13
EA-3-14
EA-4-1
EA-4-1
EA-4-2
EA-4-2
EA-4-3
EA-5-1
EA-5-1
EA-5-1
EA-5-2
EA-5-2
EA
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
AIR COMPRESSOR
<SANWA make>
Model
F8040
mm (in)
80 x 40 - 1 (3.15 x 1.57 - 1)
Theoretical discharge
Operating speed (max. service revolutions)
Working pressure (max. service pressure)
201 (12.27)
rpm
1,600
<ZEXEL make>
408738
Model
5600
cm3(cu in)/rev
5601
5610
5611
5741
5780
85 x 40 - 1
(3.35 x 1.57 - 1)
85 x 60 - 1
(3.35 x 2.36 - 1)
227 (13.85)
340 (20.75)
1,600
VACUUM PUMP
Model
Type
Vane
Theoretical discharge
rpm
Vacuum
performance
Alternator model
30 (1.83)
120 (7.32)
7,800
EA-1-1
SERVICE DATA
SERVICE DATA
AIR COMPRESSOR
Model F8040
Unit: mm (in)
Maintenance
standard
Service
limit
800 rpm
290 sec.
3,200 rpm
85 sec.
Piston top
0.25 - 0.35
(0.0098 - 0.0138)
0.38
(0.0150)
Piston skirt
0.10 - 0.20
(0.0039 - 0.0079)
0.25
(0.0098)
Compression ring
0.30 - 0.50
(0.0118 - 0.0197)
1.0
(0.039)
Oil ring
0.30 - 0.50
(0.0118 - 0.0197)
1.0
(0.039)
Compression ring
0.01 - 0.05
(0.0004 - 0.0020)
0.08
(0.0031)
Oil ring
0.01 - 0.05
(0.0004 - 0.0020)
0.08
(0.0031)
0.01L - 0.02T
(0.0004L - 0.0008T)
0.08
(0.0031)
L: Loose
T: Tight
0.015 - 0.045
(0.0006 - 0.0018)
0.07
(0.0028)
0.015 - 0.085
(0.0006 - 0.0033)
0.1
(0.004)
0 - 0.22
(0 - 0.0087)
Item
Charging performance
Piston-to-cylinder
clearance
Piston ring-to-ring
groove clearance
Engine
speed
Cylinder head
Valve lift
Remarks
Tank capacity: 30 liter (6-5/8 Imp gal)
Tank pressure:
0 - 785 kPa {0 - 8 kgf/cm2,
0 - 114 psi}
Replace ring.
Replace.
4.41
{0.45, 0.99}
3.53
Measured length 7.0 mm (0.276 in)
{0.36, 0.79}
4.51
{0.46, 1.01}
3.63
Measured length 9.5 mm (0.374 in)
{0.37, 0.82}
Delivery valve
3.0 (0.118)
Unloader valve
1.0 (0.039)
Suction valve
2.6 (0.102)
EA-1-2
SERVICE DATA
Model 408738
Unit: mm (in)
Maintenance
standard
Service
limit
500 rpm
448 sec.
3,200 rpm
66 sec.
500 rpm
264 sec.
3,200 rpm
46 sec.
Piston skirt
0.07 - 0.12
(0.0028 - 0.0047)
0.25
(0.0098)
Compression ring
0.15 - 0.30
(0.0059 - 0.0118)
0.6
(0.024)
Oil ring
0.15 - 0.35
(0.0059 - 0.0138)
0.7
(0.028)
Compression ring
0.02 - 0.05
(0.0008 - 0.0020)
0.08
(0.0031)
Oil ring
0.03 - 0.07
(0.0012 - 0.0028)
0.10
(0.0039)
0.006 - 0.026
(0.0002 - 0.0010)
0.08
(0.0031)
Clearance between connecting rod smallend piston pin hole and piston pin
0.006 - 0.026
(0.0002 - 0.0010)
0.08
(0.0031)
Clearance between connecting rod bigend crank pin hole and crank pin
0.034 - 0.075
(0.0013 - 0.0030)
0.1
(0.004)
0 - 0.50
(0 - 0.0197)
1.0
(0.039)
Replace.
Suction valve
spring
1.0
{0.1, 0.2}
Item
Charging
performance
5600
5601
5610
5611
Engine
speed
5741
5780
Engine
speed
Piston-to-cylinder
clearance
Piston ring-to-ring
groove clearance
Cylinder head
Tension
Valve lift
Tank capacity:
30 liter (6-5/8 Imp gal)
Tank pressure:
0 - 785 kPa {0 - 8 kgf/cm2,
0 - 114 psi}
Replace piston or cylinder.
Replace ring.
When compressed to
8.2 mm (0.323 in)
6.08
When compressed to
{0.62, 1.37} 12.5 mm (0.492 in)
Suction valve
2.0 (0.079)
Delivery valve
1.5 (0.059)
EA-1-3
Remarks
SERVICE DATA
VACUUM PUMP
Unit: mm (in)
Item
Vane height
Maintenance standard
Service limit
13.5 (0.531)
13.0 (0.512)
21.5 (0.846)
21.0 (0.827)
Remarks
TIGHTENING TORQUE
AIR COMPRESSOR
Model F8040
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Model 408738
Unit: Nm {kgfm, ftlbf}
Item
Tightening torque
Cylinder bolt
EA-1-4
TOOLS
TOOLS
AIR COMPRESSOR
Model F8040
Tool name and number
Description
Shape
Model 408738
Tool name and number
Description
EA-2-1
Shape
AIR COMPRESSOR
AIR COMPRESSOR
= MODEL F8040 =
CONSTRUCTION
REMOVAL
1.
2.
3.
EA-3-1
F8040
AIR COMPRESSOR
F8040
DISASSEMBLY
Marks + and , indicate that the key points of operation are explained in the text.
EA-3-2
AIR COMPRESSOR
Service limit
0 - 0.22 (0 - 0.0087)
INSPECTION
z
Piston-to-cylinder clearance
Unit: mm (in)
Item
Maintenance standard
Service limit
Piston top
0.38 (0.0150)
Piston skirt
0.25 (0.0098)
Maintenance standard
Service limit
Compression ring
0.30 - 0.50
(0.0118 - 0.0197)
1.0 (0.039)
Oil ring
0.30 - 0.50
(0.0118 - 0.0197)
1.0 (0.039)
EA-3-3
F8040
AIR COMPRESSOR
Maintenance standard
Service limit
Compression ring
0.01 - 0.05
(0.0004 - 0.0020)
0.08 (0.0031)
Oil ring
0.01 - 0.05
(0.0004 - 0.0020)
0.08 (0.0031)
Service limit
0.01L - 0.02T
(0.0004L - 0.0008T)
0.08 (0.0031)
Remarks
L: Loose
T: Tight
Service limit
0.07 (0.0028)
Service limit
0.1 (0.004)
NOTE
z
Maintenance
standard
Service limit
Remarks
Suction valve
Measured length
7.0 mm (0.276 in)
Delivery valve
Measured length
9.5 mm (0.374 in)
EA-3-4
F8040
AIR COMPRESSOR
REASSEMBLY
38 Suction valve assembly, 32 Unloader valve assembly,
24 Delivery valve assembly
1. Install the suction valve assembly (using special tool 99744
97000), unloader valve assembly, and delivery valve
assembly to the cylinder head through the packing or Oring.
Unit: Nm {kgfm, ftlbf}
Item
Suction valve holder
Unloader valve connector
Delivery valve holder
Tightening torque
98 - 118 {10.0 - 12.0, 72 - 87}
29 - 34 {3.0 - 3.5, 22 - 25}
98 - 118 {10.0 - 12.0, 72 - 87}
NOTE
z
2.
Maintenance standard
Service limit
3.0 (0.118)
1.0 (0.039)
2.6 (0.102)
EA-3-5
F8040
AIR COMPRESSOR
12 Oil ring, 11 Compression ring
Install the piston rings in the ring grooves, and attach the connecting rod to the piston.
NOTE
z
Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturers
mark faces up.
3 Cylinder
Using the piston inserting kit (99750 Z5500), install the cylinder with
the O-ring in place.
: 25 - 29 Nm {2.5 - 3.0 kgfm, 18 - 22 ftlbf}
Piston insert kit (99750 Z5500)
(1) Piston inserting tool (99754 96002)
(2) Crankshaft holder (99756 Z5500)
(3) Bolt (81-11025-1A)
(4) Bolt (81-10825-1A)
EA-3-6
F8040
AIR COMPRESSOR
= MODEL 408738 =
CONSTRUCTION
Model 5600, 5601, 5610 and 5611
EA-3-7
408738
AIR COMPRESSOR
Model 408738-5741
EA-3-8
408738
AIR COMPRESSOR
Model 408738-5780
REMOVAL
1.
2.
3.
EA-3-9
408738
AIR COMPRESSOR
408738
DISASSEMBLY
Model 5600, 5601, 5610 and 5611
8. Piston
9. Connecting rod
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring
, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve
Marks + and , indicate that the key points of operation are explained in the text.
EA-3-10
AIR COMPRESSOR
408738
Model 5741
8. Piston
9. Connecting rod
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring
, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve
Marks + and , indicate that the key points of operation are explained in the text.
EA-3-11
AIR COMPRESSOR
408738
Model 5780
8. Piston
9. Connecting rod assembly
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring
, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve
Marks + and , indicate that the key points of operation are explained in the text.
EA-3-12
AIR COMPRESSOR
Service limit
0 - 0.50 (0 - 0.0197)
1.0 (0.039)
INSPECTION
z
Piston-to-cylinder clearance
Unit: mm (in)
Item
Piston skirt
Maintenance standard
Service limit
0.25 (0.0098)
Maintenance standard
Service limit
Compression ring
0.6 (0.024)
Oil ring
0.7 (0.028)
Maintenance standard
Service limit
Compression ring
0.08 (0.0031)
Oil ring
0.10 (0.0039)
EA-3-13
408738
AIR COMPRESSOR
Service limit
0.08 (0.0031)
Service limit
0.08 (0.0031)
Service limit
0.1 (0.004)
Maintenance
standard
Service limit
Remarks
Suction valve
spring
1.18
{0.12, 0.26}
1.0
{0.1, 0.2}
When compressed to
8.2 mm (0.323 in)
Delivery valve
spring
7.65
{0.78, 1.72}
6.08
{0.62, 1.37}
When compressed to
12.5 mm (0.492 in)
REASSEMBLY
Key point of reassembly
14 Sleeve
Press-fit the ball bearing onto the crankshaft, and using the oil seal
replacer (99753 Z5501), install the sleeve.
11 Oil seal
Using the oil seal replacer (99753 Z5501), install the oil seal.
EA-3-14
408738
AIR COMPRESSOR
10 Piston rings
Install the piston rings in the ring grooves, and attach the connecting rod to the piston.
NOTE
z Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturers
mark faces up.
3 Cylinder
Using the piston inserting kit (99750 Z5501), install the cylinder with
the O-ring in place.
: 26 - 32 Nm {2.7 - 3.3 kgfm, 20 - 24 ftlbf}
Piston insert kit (99750 Z5501)
(1) Piston inserting tool (99754 96001)
(2) Crankshaft holder (99756 Z5500)
(3) Bolt (81-11025-1A)
(4) Bolt (81-10825-1A)
Maintenance standard
Service limit
Suction valve
2.0 (0.079)
Delivery valve
1.5 (0.059)
Make sure that the end play of the crankshaft is within the
maintenance standard.
Unit: mm (in)
Maintenance standard
Service limit
0 - 0.50 (0 - 0.0197)
1.0 (0.039)
EA-3-15
408738
VACUUM PUMP
VACUUM PUMP
CONSTRUCTION
Model 1290 009 00 (VD-30)
EA-4-1
VACUUM PUMP
DISASSEMBLY
6. Connector
7. Packing
8. Retaining ring
9. Oil seal
Marks + and , indicate that the key points of operation are explained in the text.
INSPECTION
z
VANE
Unit: mm (in)
Item
Height
Maintenance standard
Service limit
1290 009 00
13.5 (0.531)
13.0 (0.512)
1290 011 00
21.5 (0.846)
21.0 (0.827)
CENTER PLATE
Check for damage at the sliding surface with the rotor and replace
when worn or damaged.
HOUSING
Inspect the sliding surface with the rotor for damage and replace
when worn or damaged, especially when the inside diameter is
worn or damaged.
EA-4-2
VACUUM PUMP
OTHERS
z
z
REASSEMBLY
Key point of reassembly
13 Vane
Assemble the four vanes with the end having the round chamfer at
the outside.
3.
EA-4-3
PUMP SUPPORT
PUMP SUPPORT
CONSTRUCTION
REMOVAL
Remove the injection pump support.
NOTE
z
EA-5-1
PUMP SUPPORT
INSTALLATION
Install the injection pump support using an O-ring (if removed after
measuring front gear train backlash).
1.
EA-5-2
7. Drive shaft
8. Oil seal
9. Bearing holder
PUMP SUPPORT
2.
Align the scribe mark on the injection pump drive gear tooth
with the pointer at the check window on the upper side of
the timing gear case. Then, install the injection pump support.
EA-5-3
- MEMO -