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Hitachi S12A2 Excavator Engine Workshop Manual (KM-927E-04) – PDF Download
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- Hitachi S12A2 Excavator Engine Workshop Manual
- Part No:KM-927E-04
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Description
Hitachi S12A2 Excavator Engine Workshop Manual (KM-927E-04)
File Details:
Hitachi S12A2 Excavator Engine Workshop Manual (KM-927E-04)
- Manual Language:English
- Pages: 352
- Size: 12.9 MB
- Downloadable:Yes
- Format:PDF
HITACHI S12A2 EXCAVATOR ENGINE WORKSHOP MANUAL (KM-927E-04) – PDF DOWNLOAD:
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Description:
Hitachi S12A2 Excavator Engine Workshop Manual (KM-927E-04)
- This service manual describes the specifications of the Mitsubishi Diesel Engine and the maintenance and adjustment procedures.
- To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
- Read this manual carefully and understand the work procedures fully before disassembling, inspecting, repairing or reassembling the engine.
- The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual.
Table of Contents:
Hitachi S12A2 Excavator Engine Workshop Manual (KM-927E-04)
COVER............................................................................................................................................................................................................. 1
INTRODUCTION...................................................................................................................................................................................................... 3
How to Use This Manual........................................................................................................................................................................................ 5
Methods of Indication..................................................................................................................................................................................... 5
Terms Used in This Manual................................................................................................................................................................................. 6
Abbreviations, Standards, Etc............................................................................................................................................................................. 6
Units of Measurement...................................................................................................................................................................................... 6
Safety Cautions............................................................................................................................................................................................... 7
Warning Fire and Explosion................................................................................................................................................................................ 7
Keep flames away...................................................................................................................................................................................... 7
Keep engine and surrounding area clean................................................................................................................................................................ 7
Never open crankcase until engine cools............................................................................................................................................................... 7
Check for fuel, oil and exhaust gas leaks............................................................................................................................................................. 7
Use flameproof light.................................................................................................................................................................................. 7
Do not short electrical wires......................................................................................................................................................................... 7
Keep fire extinguishers and first-aid kit nearby...................................................................................................................................................... 7
Warning Stay Clear of All Rotating and Moving Parts....................................................................................................................................................... 8
Install protective covers on rotating parts........................................................................................................................................................... 8
Check surrounding area for safety..................................................................................................................................................................... 8
Stay clear of all rotating and moving parts while engine is operating................................................................................................................................. 8
Lockout and Tagout.................................................................................................................................................................................... 8
Always stop engine before inspection and maintenance.................................................................................................................................................. 8
Always return turning tools to original position...................................................................................................................................................... 8
Warning Be Careful of Burns............................................................................................................................................................................... 9
Do not touch engine during operation or immediately after operation................................................................................................................................... 9
Open radiator filler cap carefully.................................................................................................................................................................... 9
Add coolant only after coolant temperature drops...................................................................................................................................................... 9
Do not dismount heat protection covers................................................................................................................................................................ 9
Warning Be Careful of Exhaust Fume Poisoning.............................................................................................................................................................. 9
Perform engine operation in a well-ventilated site.................................................................................................................................................... 9
Warning Protect Ears from Noises.......................................................................................................................................................................... 9
Wear earplugs......................................................................................................................................................................................... 9
Warning Be Careful of Falling Down........................................................................................................................................................................ 10
Lifting engine carefully.............................................................................................................................................................................. 10
Do not climb onto engine.............................................................................................................................................................................. 10
Always prepare steady platform........................................................................................................................................................................ 10
Caution Be Careful of Handling Fuel, Engine Oil and LLC................................................................................................................................................... 10
Use only specified fuel, engine oil and coolant (LLC)................................................................................................................................................. 10
Handle LLC carefully.................................................................................................................................................................................. 10
Properly dispose of drained oil and LLC............................................................................................................................................................... 10
Caution Service Battery................................................................................................................................................................................... 11
Handle battery carefully.............................................................................................................................................................................. 11
Caution When Abnormality Occurs........................................................................................................................................................................... 11
If engine overheats, conduct cooling operation before stopping engine................................................................................................................................. 11
If engine stops due to abnormality, exercise caution when restarting.................................................................................................................................. 11
If engine oil pressure drops, stop engine immediately................................................................................................................................................. 11
If fan belt is broken off, stop engine immediately.................................................................................................................................................... 11
Caution Other Cautions.................................................................................................................................................................................... 12
Never modify engine................................................................................................................................................................................... 12
Never break seals..................................................................................................................................................................................... 12
Everyday checkup and periodic inspection and maintenance.............................................................................................................................................. 12
Perform engine break-in............................................................................................................................................................................... 12
Warm up engine before use............................................................................................................................................................................. 12
Never operate engine under overload condition......................................................................................................................................................... 12
Conduct cooling operation before stopping engine...................................................................................................................................................... 12
Do not splash water on engine......................................................................................................................................................................... 12
Conduct proper maintenance of air cleaner/ pre-cleaner................................................................................................................................................ 13
Observe safety rules at workplace..................................................................................................................................................................... 13
Wear proper work clothes and protective gear.......................................................................................................................................................... 13
Use appropriate tools for maintenance work............................................................................................................................................................ 13
Do not use starter continuously....................................................................................................................................................................... 13
Keep battery switch ON when engine is in operation.................................................................................................................................................... 13
Cautions concerning transportation.................................................................................................................................................................... 13
Do not operate engine continuously under low load..................................................................................................................................................... 13
Ventilate the engine room sufficiently................................................................................................................................................................ 13
Do not touch high-pressure injection fuel............................................................................................................................................................. 13
Caution About Warning Labels.............................................................................................................................................................................. 14
Always keep warning labels clean and legible.......................................................................................................................................................... 14
GENERAL CONTENTS.................................................................................................................................................................................................. 15
GENERAL........................................................................................................................................................................................................... 17
1. Outline.................................................................................................................................................................................................... 18
1.1 External view......................................................................................................................................................................................... 18
1.2 Inlet and outlet systems.............................................................................................................................................................................. 20
1.3 Outline of fuel system................................................................................................................................................................................ 22
1.4 Outline of lubrication system......................................................................................................................................................................... 22
1.5 Outline of cooling system............................................................................................................................................................................. 23
1.6 Outline of inlet and exhaust system................................................................................................................................................................... 23
1.7 Engine serial number location......................................................................................................................................................................... 24
1.8 Engine model code identification...................................................................................................................................................................... 24
2. Main specification......................................................................................................................................................................................... 25
3. Tips on Disassembly and Reassembly......................................................................................................................................................................... 28
3.1 Disassembly........................................................................................................................................................................................... 28
3.2 Reassembly............................................................................................................................................................................................ 28
MAINTENANCE STANDARDS............................................................................................................................................................................................. 29
1. Maintenance Standards Table................................................................................................................................................................................ 30
1.1 General............................................................................................................................................................................................... 30
1.2 Engine main part...................................................................................................................................................................................... 30
1.3 Inlet and exhaust systems............................................................................................................................................................................. 35
1.4 Fuel system........................................................................................................................................................................................... 35
1.5 Lubrication system.................................................................................................................................................................................... 36
1.6 Cooling system........................................................................................................................................................................................ 37
1.7 Electrical system..................................................................................................................................................................................... 39
2. Tightening torque table.................................................................................................................................................................................... 40
2.1 Important bolts and nuts.............................................................................................................................................................................. 40
2.1.1 Engine main parts............................................................................................................................................................................... 40
2.1.2 Inlet and exhaust systems....................................................................................................................................................................... 41
2.1.3 Fuel system..................................................................................................................................................................................... 41
2.1.4 Lubrication system.............................................................................................................................................................................. 41
2.1.5 Cooling system.................................................................................................................................................................................. 42
2.1.6 Electrical system............................................................................................................................................................................... 42
2.2 Standard Bolts and Nuts Tightening Torque............................................................................................................................................................. 43
2.3 Standard Eyebolt Tightening Torque.................................................................................................................................................................... 44
2.4 Standard Union Nut Tightening Torque.................................................................................................................................................................. 44
2.5 High-Pressure Fuel Injection Pipe Tightening Torque................................................................................................................................................... 44
3. Sealants and Lubricants Table.............................................................................................................................................................................. 45
3.1 Engine main parts..................................................................................................................................................................................... 45
3.2 Cooling System........................................................................................................................................................................................ 45
3.3 Inlet System.......................................................................................................................................................................................... 45
3.4 Others................................................................................................................................................................................................ 45
BASIC AND SPECIAL TOOLS........................................................................................................................................................................................... 47
1. Special tools.............................................................................................................................................................................................. 48
OVERHAUL INSTRUCTIONS............................................................................................................................................................................................. 59
1. Determination of Overhaul Timing........................................................................................................................................................................... 60
2. Testing Compression Pressure............................................................................................................................................................................... 61
DISASSMBLY OF ENGINE MAIN PARTS................................................................................................................................................................................... 63
1. Disassembly of cylinder heads and valve mechanisms......................................................................................................................................................... 64
1.1 Removal of fuel injection pipes....................................................................................................................................................................... 65
1.2 Removal of nozzle assemblies.......................................................................................................................................................................... 65
1.3 Removal of rocker shaft assemblies.................................................................................................................................................................... 65
1.4 Removal of rocker assemblies.......................................................................................................................................................................... 66
1.5 Removal of valve bridge............................................................................................................................................................................... 66
1.6 Removal of cylinder head bolt......................................................................................................................................................................... 66
1.7 Removal of cylinder head assemblies................................................................................................................................................................... 66
1.8 Removal of valves and valve springs................................................................................................................................................................... 67
1.9 Removal of studs and connectors....................................................................................................................................................................... 67
2. Disassembly of flywheel, timing gear and camshaft.......................................................................................................................................................... 68
2.1 Removal of flywheel................................................................................................................................................................................... 69
2.2 Removal of timing gear case........................................................................................................................................................................... 69
2.3 Measurement of timing gear backlash and end play...................................................................................................................................................... 69
2.4 Removal of idler gears................................................................................................................................................................................ 70
2.5 Removal of fuel injection pump gear................................................................................................................................................................... 70
2.6 Removal of accessory drives........................................................................................................................................................................... 70
2.7 Removal of camshaft gears............................................................................................................................................................................. 70
2.8 Removal of camshafts.................................................................................................................................................................................. 71
2.9 Removal of Idler shafts............................................................................................................................................................................... 71
3. Disassembly of damper side................................................................................................................................................................................. 72
3.1 Removal of fan pulley................................................................................................................................................................................. 73
3.2 Removal of damper..................................................................................................................................................................................... 73
3.3 Removal of water pump pulley.......................................................................................................................................................................... 74
3.4 Removal of front cover................................................................................................................................................................................ 74
4. Disassembly of cylinder liners, pistons and connecting rods................................................................................................................................................ 75
4.1 Removal of connecting rod caps........................................................................................................................................................................ 76
4.2 Removal of carbon deposits from cylinder liner upper areas............................................................................................................................................ 77
4.3 Removal of pistons engine right bank cylinder......................................................................................................................................................... 77
4.4 Removal of pistons for left bank cylinders............................................................................................................................................................ 80
4.5 Removal of piston rings............................................................................................................................................................................... 80
4.6 Removal of piston pins and piston..................................................................................................................................................................... 80
5. Disassembly of crankcase, crankshaft, and main bearings.................................................................................................................................................... 81
5.1 Reversal of crankcase................................................................................................................................................................................. 82
5.2 Removal of pistons right bank cylinder................................................................................................................................................................ 82
5.3 Removal of main bearing caps.......................................................................................................................................................................... 83
5.4 Removal of crankshafts................................................................................................................................................................................ 84
5.5 Removal of piston cooling nozzles..................................................................................................................................................................... 84
INSPECTION AND REPAIR OF ENGINE MAIN PARTS........................................................................................................................................................................ 85
1. Cylinder head and valve mechanism.......................................................................................................................................................................... 87
1.1 Measurement of rocker inside diameter and rocker shaft diameter....................................................................................................................................... 87
1.2 Replacement of rocker bushings........................................................................................................................................................................ 87
1.3 Inspection and replacement of nozzle ground stud and eridge guides.................................................................................................................................... 87
1.4 Measurement of valve stem diameter and valve guide inside diameter.................................................................................................................................... 88
1.5 Replacement of valve guides and stem seals............................................................................................................................................................ 88
1.6 Inspection of valve face.............................................................................................................................................................................. 89
1.7 Correction of valve face.............................................................................................................................................................................. 89
1.8 Correction of valve seats............................................................................................................................................................................. 90
1.9 Replacement of valve seats............................................................................................................................................................................ 90
1.10 Lapping of valves against valve seats................................................................................................................................................................ 92
1.11 Measurement of valve spring perpendicularity and free length......................................................................................................................................... 92
1.12 Inspection of clearance between valve bridge with valve cotter and valve rotator..................................................................................................................... 93
1.13 Inspection of tappets................................................................................................................................................................................ 93
1.14 Measurement of push rod bend......................................................................................................................................................................... 93
1.15 Measurement of cylinder head bottom face for distortion.............................................................................................................................................. 94
1.16 Inspection of water director......................................................................................................................................................................... 94
2. Flywheel, Damper Timing Gears and Camshafts................................................................................................................................................................ 95
2.1 Measurement of axial and redial runouts of flywheel................................................................................................................................................... 95
2.2 Inspection of damper.................................................................................................................................................................................. 95
2.3 Measurement of timing gear backlash................................................................................................................................................................... 96
2.4 Measurement of idler bushing inside diameter and idler shaft diameter................................................................................................................................. 96
2.5 Measurement of idler gear end play.................................................................................................................................................................... 97
2.6 Replacement of idler bushings......................................................................................................................................................................... 97
2.7 Measurement of camshaft cam height.................................................................................................................................................................... 97
2.8 Measurement of camshaft deflection.................................................................................................................................................................... 98
2.9 Measurement of camshaft journal diameter.............................................................................................................................................................. 98
2.10 Checking camshaft bushing............................................................................................................................................................................ 98
2.11 Replacement of camshaft bushings..................................................................................................................................................................... 99
2.12 Measurement of camshaft end play..................................................................................................................................................................... 99
3. Cylinder Liners, Pistons and Connecting Rods...............................................................................................................................................................100
3.1 Measurement of cylinder liner bore diameter...........................................................................................................................................................100
3.2 Measurement of cylinder liner collar protrusion.......................................................................................................................................................100
3.2.1 When cylinder liner is not to be replaced.......................................................................................................................................................101
3.2.2 When cylinder liner is to be replaced...........................................................................................................................................................101
3.2.3 Measurement of step height of cylinder liner....................................................................................................................................................102
3.2.4 Insertion of cylinder liner shim................................................................................................................................................................102
3.3 Replacement of cylinder liners........................................................................................................................................................................103
3.4 Inspection of piston exterior.........................................................................................................................................................................103
3.5 Measurement of piston outside diameter................................................................................................................................................................104
3.6 Inspection of piston ring groove......................................................................................................................................................................104
3.7 Measurement of piston pin bore diameter...............................................................................................................................................................105
3.8 Measurement of piston protrusion......................................................................................................................................................................105
3.9 Replacement standard of piston ring...................................................................................................................................................................105
3.10 Measurement of piston pin diameter...................................................................................................................................................................106
3.11 Measurement of connecting rod bushing inside diameter................................................................................................................................................106
3.12 Changing connecting rod bushing......................................................................................................................................................................107
3.12.1 Connecting rod bushing installation procedure..................................................................................................................................................107
3.12.2 Removal of connecting rod bushing..............................................................................................................................................................108
3.12.3 Press fitting of connecting rod bushing........................................................................................................................................................108
3.13 Inspection of connecting rod bend and twist..........................................................................................................................................................109
3.14 Inspection of connecting rod bearings................................................................................................................................................................110
3.15 Measurement of connecting rod end play...............................................................................................................................................................110
3.16 Weight difference of connecting rods in one engine...................................................................................................................................................110
3.17 Measurement of connecting rod big-end bore diameter and circularity..................................................................................................................................111
3.18 Inspection of connecting rod big-end bore serration..................................................................................................................................................111
3.19 Measurement of connecting rod bearing thickness......................................................................................................................................................111
4. Crankcase, Crankshaft, and Main Bearings...................................................................................................................................................................112
4.1 Measurement of crankshaft crankpin and journal diameters..............................................................................................................................................112
4.2 Grinding of crankshaft................................................................................................................................................................................112
4.3 Crankshaft end play...................................................................................................................................................................................113
4.4 Measurement of crankshaft deflection..................................................................................................................................................................114
4.5 Replacement of front side oil seal sleeve and oil seal................................................................................................................................................114
4.5.1 Replacemen of oil seal sleeve...................................................................................................................................................................115
4.5.2 Installation of oil seal........................................................................................................................................................................115
4.6 Replacement of rear side oil seal slinger.............................................................................................................................................................116
4.6.1 Removal of oil seal slinger.....................................................................................................................................................................116
4.6.2 Installation of oil seal slinger................................................................................................................................................................116
4.7 Replacement of Rear Side Oil Seal.....................................................................................................................................................................117
4.8 Replacement of crankshaft gear........................................................................................................................................................................117
4.8.1 Replacement of Crankshaft Gear..................................................................................................................................................................117
4.8.2 Installation of crankshaft gear.................................................................................................................................................................117
4.9 Inspection of main bearing surface....................................................................................................................................................................118
4.10 Measurement of main bearing thickness................................................................................................................................................................118
4.11 Replacement of main bearings.........................................................................................................................................................................118
4.12 Measurement of crankcase gasket surface distortion...................................................................................................................................................118
4.13 Measurement of main bearingb bore diameter...........................................................................................................................................................119
REASSEBLY OF ENGINE MAIN PARTS....................................................................................................................................................................................121
1. Reassembly of Crankcase, Crankshaft and Main Bearing.......................................................................................................................................................122
1.1 Installation of main bearing upper....................................................................................................................................................................122
1.2 Installation of crankshafts...........................................................................................................................................................................123
1.3 Installation of thrust plate upper....................................................................................................................................................................124
1.4 Installation of main bearing lower and thrust plate lower.............................................................................................................................................124
1.5 Installation of main bearing caps.....................................................................................................................................................................124
1.6 Installation of main bearing cap bolts................................................................................................................................................................125
1.7 Measurement of crankshaft end play....................................................................................................................................................................125
1.8 Reversal of crankcase.................................................................................................................................................................................126
2. Reassembly of Cylinder Liner, Piston and Connecting Rod....................................................................................................................................................127
2.1 Reassembly of pistons and connecting rods.............................................................................................................................................................127
2.2 Reassembly of piston..................................................................................................................................................................................127
2.3 Preparation for installation of pistons...............................................................................................................................................................128
2.4 Installation of connecting rod bearing upper halves...................................................................................................................................................129
2.5 Installation of piston................................................................................................................................................................................129
2.6 Installation of connecting rod cap....................................................................................................................................................................131
2.7 Measurement of piston protrusion......................................................................................................................................................................132
3. Assembly of Flywheel, Timing Gears and Camshafts...........................................................................................................................................................133
3.1 Installation of front cover...........................................................................................................................................................................133
3.2 Installation of pulley and damper.....................................................................................................................................................................133
3.3 Installation of rear plate............................................................................................................................................................................134
3.4 Turning the engine....................................................................................................................................................................................134
3.5 Installation of idler shaft...........................................................................................................................................................................134
3.6 Installation of camshafts.............................................................................................................................................................................135
3.7 Installation of camshaft gears........................................................................................................................................................................135
3.8 Installation of accessory drives......................................................................................................................................................................136
3.9 Installation of fuel injection pump gears.............................................................................................................................................................136
3.10 Installation of idler gears..........................................................................................................................................................................136
3.11 Measurement of timing gear backlash..................................................................................................................................................................137
3.12 Measurement of idler gear end play...................................................................................................................................................................137
3.13 Measurement of camshaft end play.....................................................................................................................................................................137
3.14 Installation of timing gear case.....................................................................................................................................................................138
3.15 Installation of flywheel.............................................................................................................................................................................138
3.16 Measurement of flywheel perpendicularity runout and periphery runout.................................................................................................................................139
3.17 Installation of pickup...............................................................................................................................................................................139
3.18 Installation of oil pump and oil strainer............................................................................................................................................................139
3.19 Installation of oil pan..............................................................................................................................................................................139
4. Reassembly of Cylinder Heads and Valve Mechanisms..........................................................................................................................................................141
4.1 Reassembly of cylinder head assemblies................................................................................................................................................................141
4.2 Application of liquid gasket..........................................................................................................................................................................142
4.3 Installation of cylinder head gasket..................................................................................................................................................................142
4.4 Installation of cylinder head assemblies..............................................................................................................................................................143
4.5 Installation of bridge and bridge caps................................................................................................................................................................143
4.6 Installation of tappets and pushrods..................................................................................................................................................................143
4.7 Reassembly of rocker shaft assemblies.................................................................................................................................................................144
4.8 Installation of rocker shaft assemblies...............................................................................................................................................................144
4.9 Installation of cylinder headbolts....................................................................................................................................................................145
4.9.1 2-step tightening method........................................................................................................................................................................145
4.9.2 Angle tightening method.........................................................................................................................................................................145
4.10 Inspection of Valve Timing...........................................................................................................................................................................145
4.11 Installation of fuel injection nozzle assemblies.....................................................................................................................................................146
4.12 Installation of fuel pipes...........................................................................................................................................................................147
4.13 Adjustment of valve clearances.......................................................................................................................................................................147
FUEL SYSTEM.......................................................................................................................................................................................................149
1. Removing fuel system.......................................................................................................................................................................................150
1.1 Removing and inspecting fuel injection pipes and fuel leak-off pipes..................................................................................................................................150
1.2 Removing and inspecting fuel filter and fuel pipes....................................................................................................................................................151
1.3 Removing fuel control links...........................................................................................................................................................................152
1.4 Removing actuator.....................................................................................................................................................................................153
1.5 Removing stop solenoid................................................................................................................................................................................153
1.6 Removing fuel Injection Nozzles.......................................................................................................................................................................154
1.7 Removing fuel injection pumps.........................................................................................................................................................................154
2. Disassembling, inspecting and reassembling fuel system.....................................................................................................................................................155
2.1 Disassembling and inspecting fuel filter..............................................................................................................................................................155
2.2 Reassembling fuel filter..............................................................................................................................................................................155
2.3 Disassembling and inspecting fuel control links.......................................................................................................................................................156
2.4 Reassembling fuel control links.......................................................................................................................................................................157
2.5 Inspecting actuator control link......................................................................................................................................................................157
2.6 Disassembling and inspecting stop solenoid control link...............................................................................................................................................158
2.7 Reassembling stop solenoid control link...............................................................................................................................................................158
2.8 Disassembling and inspecting accessory drive..........................................................................................................................................................159
2.9 Inspecting accessory drives...........................................................................................................................................................................159
2.9.1 Outside and inside diameters of bearing-fitted sections.........................................................................................................................................159
2.10 Reassembling accessory drive.........................................................................................................................................................................160
2.11 Disassembling and inspecting fuel injection nozzles..................................................................................................................................................161
2.12 Adjusting and inspecting of fuel injection nozzles...................................................................................................................................................162
2.12.1 Injection starting pressure....................................................................................................................................................................162
2.12.2 Spray pattern..................................................................................................................................................................................162
2.12.3 Cleaning and replacement of faulty nozzles.....................................................................................................................................................163
2.13 Reassembling fuel injection nozzle...................................................................................................................................................................164
2.14 Disassembling fuel injection pump....................................................................................................................................................................165
2.14.1 Preparation for disassembly....................................................................................................................................................................165
2.14.2 Disassembling type PE-P fuel injection pump....................................................................................................................................................167
2.14.3 Disassembling Type KD fuel feed pump...........................................................................................................................................................176
2.15 Inspecting fuel injection pump.......................................................................................................................................................................179
2.15.1 Inspecting Type PE-P fuel injection pump.......................................................................................................................................................179
2.15.2 Inspecting Type KD fuel feed pump..............................................................................................................................................................183
2.16 Reassembling fuel injection pump.....................................................................................................................................................................184
2.16.1 Reassembling Type PE-P fuel injection pump.....................................................................................................................................................184
2.16.2 Fuel injection pump tightening torque..........................................................................................................................................................191
2.16.3 Fuel feed pump tightening torque...............................................................................................................................................................192
2.17 Adjusting fuel injection pump........................................................................................................................................................................193
2.17.1 Preparation for adjusting......................................................................................................................................................................193
2.18 Type PE-P fuel injection pump........................................................................................................................................................................194
2.18.1 Adjusting injection timing.....................................................................................................................................................................194
2.18.2 Adjusting injection volume.....................................................................................................................................................................198
2.18.3 Stamped line...................................................................................................................................................................................199
2.18.4 Adjusting of Type KD fuel feed pump............................................................................................................................................................200
2.19 Disassembling and inspecting water separator.........................................................................................................................................................202
2.20 Reassembling of water separator......................................................................................................................................................................202
3. Installing the fuel system.................................................................................................................................................................................203
3.1 Procedures after installation.........................................................................................................................................................................203
3.2 Installing fuel injection pumps.......................................................................................................................................................................203
3.2.1 Installing fuel injection pump (right side).....................................................................................................................................................204
3.2.2 Installing fuel injection pump (left side)......................................................................................................................................................205
3.2.3 Installing tamper nut...........................................................................................................................................................................205
3.3 Fuel Injection Nozzles................................................................................................................................................................................205
3.4 Installing stop solenoid..............................................................................................................................................................................206
3.5 Installing actuator...................................................................................................................................................................................206
3.6 Installing fuel control links.........................................................................................................................................................................207
3.6.1 Installing fuel control link....................................................................................................................................................................208
3.6.2 Adjustment and check of the stop solenoid.......................................................................................................................................................209
3.6.3 Adjustment of exhaust temperatures of right and left banks......................................................................................................................................210
3.7 Installing fuel filters and fuel pipes................................................................................................................................................................211
3.8 Installing fuel injection pipes and fuel leak-off pipes...............................................................................................................................................212
LUBRICATION SYSTEM................................................................................................................................................................................................213
1. Removing lubrication system................................................................................................................................................................................214
1.1 Removing oil pipe, oil cooler and oil filter for fuel injection pumps.................................................................................................................................214
1.2 Removing fan drive and oil pipe for accessory drives..................................................................................................................................................215
1.3 Removing breather and oil filler......................................................................................................................................................................216
1.4 Removing oil pan, oil strainer and oil pump...........................................................................................................................................................217
2. Disassembling, inspecting and reassembling lubrication system..............................................................................................................................................218
2.1 Disassembling and inspecting oil strainer.............................................................................................................................................................218
2.2 Disassembling and inspecting oil pump and safety valve................................................................................................................................................218
2.3 Inspecting oil pump and safety valve..................................................................................................................................................................219
2.3.1 Measurement of backlash between drive and driven gears..........................................................................................................................................219
2.3.2 Measurement of clearance between gear and case..................................................................................................................................................219
2.3.3 Measurement of side clearance between gears and case............................................................................................................................................219
2.3.4 Measurement of drive and driven gear shaft diameters and bushing inside diameter................................................................................................................219
2.3.5 Replacing oil pump bushings.....................................................................................................................................................................220
2.3.6 Inspecting of safety valve......................................................................................................................................................................220
2.4 Reassembling oil pump and safety valve................................................................................................................................................................221
2.5 Disassembling and inspecting oil cooler ,oill filter, alarm and relief valve..........................................................................................................................222
2.6 Inspecting oil cooler, oil filter, alarm and relief valve.............................................................................................................................................223
2.6.1 Inspection of oil cooler........................................................................................................................................................................223
2.6.2 Inspecting bypass valve.........................................................................................................................................................................223
2.6.3 Inspection of oil filter........................................................................................................................................................................223
2.6.4 Inspection of oil filter alarm..................................................................................................................................................................223
2.6.5 Measuring relief valve pressure.................................................................................................................................................................224
2.7 Removing oil cooler, oil filter, alarm and relief valve...............................................................................................................................................225
2.8 Disassembling and inspecting bypass oil filters.......................................................................................................................................................226
2.9 Reassembling bypass oil filters.......................................................................................................................................................................226
3. Installing lubrication system..............................................................................................................................................................................227
3.1 Installing oil pan, oil strainer and oil pump.........................................................................................................................................................227
3.1.1 Installing oil pump and strainer................................................................................................................................................................227
3.1.2 Installing oil pan..............................................................................................................................................................................228
3.2 Installing breather and oil filler....................................................................................................................................................................228
3.3 Installing fan drive and oil pipe for accessory drives................................................................................................................................................229
3.4 Installing oil pipe, oil cooler and oil filter for fuel injection pumps...............................................................................................................................230
COOLING SYSTEM....................................................................................................................................................................................................231
1. Removing cooling system....................................................................................................................................................................................232
1.1 Removing fan belt, water pump belt and alternator belt................................................................................................................................................232
1.1.1 Removing the fan belt...........................................................................................................................................................................232
1.1.2 Removing the water pump belt....................................................................................................................................................................232
1.1.3 Removing the alternator belt....................................................................................................................................................................232
1.2 Removing the fan drive and auto tensioner.............................................................................................................................................................233
1.2.1 Removing the Fan Pulley.........................................................................................................................................................................233
1.3 Removing thermostat and water pipe....................................................................................................................................................................234
1.4 Removing water pump and water pipes...................................................................................................................................................................235
1.4.1 Removing the oil drain pipes....................................................................................................................................................................235
2. Disassembling, inspection, and reassembling of cooling system..............................................................................................................................................236
2.1 Disassembling and inspecting fan drive................................................................................................................................................................236
2.1.1 Inspection of fan drive.........................................................................................................................................................................236
2.1.2 Reassembling fan drive..........................................................................................................................................................................237
2.2 Disassembling and inspecting auto tensioner for fan belt..............................................................................................................................................238
2.2.1 Inspecting auto tensioner for fan belt..........................................................................................................................................................238
2.2.2 Reassembling auto tensioner for fan belt........................................................................................................................................................239
2.2.3 Filling Tension Pulley for Fan Belts with Grease................................................................................................................................................240
2.3 Disassembling and inspecting auto tensioner for water pump belt.......................................................................................................................................241
2.3.1 Inspecting auto tensioner for water pump belt...................................................................................................................................................241
2.3.2 Reassembling auto tensioner for water pump belt.................................................................................................................................................242
2.3.3 Filling tension pulley for water pump belts with grease.........................................................................................................................................243
2.4 Disassembling thermostat..............................................................................................................................................................................244
2.4.1 Inspection of water thermostat..................................................................................................................................................................244
2.5 Disassembling and inspecting water pump...............................................................................................................................................................245
2.5.1 Inspecting pump mounted on engine...............................................................................................................................................................245
2.5.2 Removing water pump pulley......................................................................................................................................................................246
2.5.3 Removing the impeller...........................................................................................................................................................................246
2.5.4 Removing water pump shaft.......................................................................................................................................................................246
2.5.5 Inspection of water pump........................................................................................................................................................................247
2.5.6 Reassembling water pump.........................................................................................................................................................................247
3. Installing cooling system..................................................................................................................................................................................249
3.1 Installing water pump and water pipes.................................................................................................................................................................249
3.1.1 Installing of oil drain pipes...................................................................................................................................................................249
3.2 Installing thermostat and water pipe..................................................................................................................................................................250
3.3 Installing fan drive and auto tensioner...............................................................................................................................................................251
3.4 Installing fan belt, water pump belt and alternator...................................................................................................................................................252
3.4.1 Installing fan belt.............................................................................................................................................................................252
3.4.2 Installing water pump belt......................................................................................................................................................................253
3.4.3 Installing alternator belt......................................................................................................................................................................254
INLET AND EXHAUST SYSTEMS.........................................................................................................................................................................................255
1. Removing inlet and exhaust systems.........................................................................................................................................................................256
1.1 Removing inlet manifold...............................................................................................................................................................................256
1.2 Removing turbocharger and exhaust manifolds...........................................................................................................................................................257
2. Disassembling and inspection inlet and exhaust systems.....................................................................................................................................................258
2.1 Disassembling and inspection exhaust pipe.............................................................................................................................................................258
2.2 Disassembling and inspection turbocharger.............................................................................................................................................................259
2.2.1 Removal of turbine housing......................................................................................................................................................................260
2.2.2 Removal of compressor cover.....................................................................................................................................................................260
2.2.3 Removing Compressor Wheel.......................................................................................................................................................................260
2.2.4 Removal of snap ring............................................................................................................................................................................261
2.2.5 Removal of insert and oil deflector.............................................................................................................................................................261
2.2.6 Removal of V-clamp..............................................................................................................................................................................261
2.2.7 Removal of shaft & turbine wheel................................................................................................................................................................262
2.2.8 Removal of snap ring and bearing................................................................................................................................................................262
2.2.9 Removing plate..................................................................................................................................................................................262
2.3 Cleaning..............................................................................................................................................................................................263
2.4 Inspecting turbocharger...............................................................................................................................................................................265
2.4.1 Bearing housing.................................................................................................................................................................................265
2.4.2 Bearing.........................................................................................................................................................................................265
2.4.3 Shaft and Turbine Wheel.........................................................................................................................................................................266
2.4.4 Insert Measuring piston ring end gap............................................................................................................................................................266
2.5 Reassembling Turbocharger.............................................................................................................................................................................267
2.5.1 Installing the shaft & turbine wheel and bearing................................................................................................................................................268
2.5.2 Installing the thrust bearing...................................................................................................................................................................269
2.5.3 Installing the O-ring...........................................................................................................................................................................269
2.5.4 Installing the oil deflector....................................................................................................................................................................269
2.5.5 Assembling the insert sub-assembly..............................................................................................................................................................270
2.5.6 Installing the snap ring........................................................................................................................................................................270
2.5.7 Measuring clearance between the turbine wheel and turbine housing...............................................................................................................................271
2.5.8 Installing the compressor wheel.................................................................................................................................................................271
2.5.9 Measuring play of the shaft & turbine wheel in the axial direction..............................................................................................................................271
2.5.10 Measuring clearance between the turbine backplate and the back side of the turbine wheel.......................................................................................................272
2.5.11 Installing the compressor cover................................................................................................................................................................272
2.5.12 Installing lock plate..........................................................................................................................................................................272
2.5.13 Installing the turbine housing.................................................................................................................................................................273
2.5.14 Installing the V-clamp.........................................................................................................................................................................273
2.5.15 Installing plate...............................................................................................................................................................................273
2.6 Inspection of air heater..............................................................................................................................................................................274
3. Removing inlet and exhaust systems.........................................................................................................................................................................275
3.1 Installing turbocharger and exhaust manifolds.........................................................................................................................................................275
3.2 Installing inlet manifolds............................................................................................................................................................................276
ELECTRICAL SYSTEM.................................................................................................................................................................................................277
1. Removal of Electrical System...............................................................................................................................................................................278
1.1 Removal of starter....................................................................................................................................................................................278
1.2 Inspection before removal of alternator...............................................................................................................................................................279
1.2.1 Inspecting alternator for function..............................................................................................................................................................279
1.2.2 Handling precautions............................................................................................................................................................................279
1.3 Removal of alternato..................................................................................................................................................................................280
2. Inspection and Reassembly of Electrical System.............................................................................................................................................................281
2.1 Disassembly and inspection of starter.................................................................................................................................................................281
2.1.1 Removal of magnetic switch......................................................................................................................................................................282
2.1.2 Removal of rear bracket.........................................................................................................................................................................282
2.1.3 Removal of armature and yoke assemblies.........................................................................................................................................................282
2.1.4 Removal of center bracket.......................................................................................................................................................................283
2.1.5 Removal of pinion set...........................................................................................................................................................................283
2.2 Inspection and correction of starter..................................................................................................................................................................284
2.2.1 Testing magnetic switch coil....................................................................................................................................................................284
2.2.2 Testing magnetic switch contact points..........................................................................................................................................................284
2.2.3 Measurement of armature shaft bent..............................................................................................................................................................285
2.2.4 Inspection of commutator deflection.............................................................................................................................................................285
2.2.5 Measurement of commutator undercut..............................................................................................................................................................285
2.2.6 Measurement of commutator outside diameter......................................................................................................................................................286
2.2.7 Testing armature coil...........................................................................................................................................................................286
2.2.8 Testing field coil for open-circuit.............................................................................................................................................................286
2.2.9 Inspection of overrunning clutch................................................................................................................................................................286
2.2.10 Checking brush for wear........................................................................................................................................................................287
2.2.11 Testing brush spring tension...................................................................................................................................................................287
2.3 Reassembly of starter.................................................................................................................................................................................287
2.3.1 Installation of pinion shaft....................................................................................................................................................................288
2.3.2 Installation of shift lever and pinion shaft....................................................................................................................................................288
2.3.3 Installation of armature, yoke, brush and brush holder..........................................................................................................................................288
2.3.4 Installation of rear bracket....................................................................................................................................................................289
2.3.5 Measurement of armature end play................................................................................................................................................................289
2.3.6 Applicating grease to pinion shaft internal gear................................................................................................................................................289
2.3.7 Measurement of pinion shaft end play............................................................................................................................................................290
2.3.8 Measurement of pinion gear retraction length....................................................................................................................................................290
2.3.9 Installation of magnetic switch.................................................................................................................................................................290
2.4 Disassembly and inspection of alternator..............................................................................................................................................................291
2.4.1 Separation of stator and front bracket..........................................................................................................................................................291
2.4.2 Removal of field coil...........................................................................................................................................................................292
2.4.3 Removal of stator...............................................................................................................................................................................292
2.4.4 Removal of pulley...............................................................................................................................................................................292
2.4.5 Removal of rotor................................................................................................................................................................................293
2.4.6 Removal of rear bearing.........................................................................................................................................................................293
2.4.7 Removal of front bearing........................................................................................................................................................................293
2.5 Inspection and correction of alternator...............................................................................................................................................................294
2.5.1 Inspection of field coil........................................................................................................................................................................294
2.5.2 Inspection of rectifier.........................................................................................................................................................................294
2.5.3 Diode trio......................................................................................................................................................................................295
2.5.4 Inspection of stator coil.......................................................................................................................................................................295
2.6 Reassembly of alternator..............................................................................................................................................................................296
2.6.1 Installation of cover...........................................................................................................................................................................297
2.6.2 Installation of rear bearing....................................................................................................................................................................297
2.7 Inspection of alternator after reassembly.............................................................................................................................................................298
2.7.1 Performance test................................................................................................................................................................................298
2.7.2 Inspection of regulator.........................................................................................................................................................................299
3. Reinstallation of Electrical System........................................................................................................................................................................300
3.1 Installation of stator................................................................................................................................................................................300
3.2 Installation of alternator............................................................................................................................................................................300
ADJUSTMENT, BREK-IN OPERATION AND PERFORORMANCE TESTS.............................................................................................................................................................301
1. Adjustment of engine.......................................................................................................................................................................................302
1.1 Inspection and Adjustment of Valve Clearances.........................................................................................................................................................302
1.1.1 Checking clearance between bridge and valve rotator.............................................................................................................................................302
1.1.2 Inspection of valve clearance...................................................................................................................................................................302
1.1.3 Adjustment of front and rear valve heights by valve bridge......................................................................................................................................303
1.1.4 Adjustment of valve clearances..................................................................................................................................................................303
1.2 Bleeding of Fuel System...............................................................................................................................................................................304
1.2.1 Bleeding from water separator...................................................................................................................................................................304
1.2.2 Bleeding from fuel filters......................................................................................................................................................................304
1.2.3 Bleeding from fuel injection pumps..............................................................................................................................................................305
1.2.4 Tightening priming pump cap.....................................................................................................................................................................305
1.3 Inspection and adjustment of fuel injection timing (right side).......................................................................................................................................306
1.3.1 Injection timing and its indication location....................................................................................................................................................306
1.3.2 Checking No. 1 cylinder top dead center in compression stroke...................................................................................................................................306
1.3.3 Inspection of fuel injection timing.............................................................................................................................................................307
1.3.4 Adjustment of fuel injection timing.............................................................................................................................................................307
2. Adjustment of actuator control linkage.....................................................................................................................................................................308
2.1 Normal operation......................................................................................................................................................................................308
2.1.1 No injection state..............................................................................................................................................................................308
2.1.2 Maximum injection state.........................................................................................................................................................................308
2.1.3 Operation of stop solenoid......................................................................................................................................................................308
2.2 Operation of linkage components.......................................................................................................................................................................309
2.2.1 Actuator........................................................................................................................................................................................309
2.2.2 Control shaft...................................................................................................................................................................................309
2.2.3 Stop solenoid...................................................................................................................................................................................309
2.3 "Out of phase" check..................................................................................................................................................................................310
2.3.1 Checking for "out of phase" state...............................................................................................................................................................310
2.3.2 Set the engine speed throttle (in cab) to min. speed ("0%" actuator position)...................................................................................................................310
2.3.3 Set the engine speed throttle (in cab) to max. speed ("100%" actuator position).................................................................................................................311
2.3.4 Move the engine speed throttle (in cab) between min. and max. speeds ("0%" to "100%" actuator position).........................................................................................311
2.4 Adjustment............................................................................................................................................................................................313
2.4.1 If the "out of phase" check (2.3.1 Checking for "out of phase" state) produces "out of phase" results, adjust by lengthening or shortening the adjusting links 1 and 2 shown in the drawing.....313
2.4.2 Verification of adjustment......................................................................................................................................................................314
3. Break-In Operation.........................................................................................................................................................................................315
3.1 Starting Up...........................................................................................................................................................................................315
3.2 Inspection during break-in operation..................................................................................................................................................................315
3.3 Break-In Duration.....................................................................................................................................................................................315
3.4 Inspection and Adjustment After Break-In Operation....................................................................................................................................................315
4. Performance Tests..........................................................................................................................................................................................316
4.1 Standard equipment....................................................................................................................................................................................316
4.2 Test methods..........................................................................................................................................................................................316
4.2.1 Fuel consumption test...........................................................................................................................................................................316
4.2.2 No-load maximum speed test......................................................................................................................................................................316
4.2.3 No-load minimum speed test......................................................................................................................................................................316
4.2.4 Others..........................................................................................................................................................................................316
4.2.5 Engine output correction calculation............................................................................................................................................................316
5. Inspection procedure of dismounted engine..................................................................................................................................................................318
5.1 Major Specifications..................................................................................................................................................................................318
5.2 Test/inspection Items.................................................................................................................................................................................318
5.3 Test methods and judgment criteria....................................................................................................................................................................319
OTHERS............................................................................................................................................................................................................321
1. Dissassembly and Reassembly of General parts...............................................................................................................................................................322
1.1 oil seals.............................................................................................................................................................................................322
1.1.1 Installation of oil seals to housings...........................................................................................................................................................322
1.1.2 Installation of oil seals to shafts.............................................................................................................................................................322
1.2 O-rings...............................................................................................................................................................................................322
1.3 Bearings..............................................................................................................................................................................................323
1.4 Lock Plates...........................................................................................................................................................................................323
1.5 Split Pins and Spring Pins............................................................................................................................................................................323
ADJUSTING PROCEDURE OF ELECTRONIC GOVERNOR CONTROLS...............................................................................................................................................................325
1. Introduction...............................................................................................................................................................................................326
1.1 Adjustment procedure..................................................................................................................................................................................326
1.2 Order of adjustment...................................................................................................................................................................................326
2. Preparation for adjustment.................................................................................................................................................................................327
2.1 Required equipment....................................................................................................................................................................................327
2.2 Controller installing location and part number. location..............................................................................................................................................328
3. Connection of Personal Computer and Actuator Controller....................................................................................................................................................329
4. Service program start-up...................................................................................................................................................................................330
4.1 Normal start-up procedures............................................................................................................................................................................330
4.2 Starting from DOS mode................................................................................................................................................................................333
4.3 Instructions for tunable operation of governor........................................................................................................................................................335
5. Controller setting item chart..............................................................................................................................................................................338
6. Checks before parts and/or controller setting change.......................................................................................................................................................340
6.1 Confirmation procedure for present values.............................................................................................................................................................340
6.1.1 Confirm the values in controller. (Refer to TUNABLE LIST.)......................................................................................................................................340
6.1.2 Input for releasing protection..................................................................................................................................................................340
6.1.3 Confirm the conditions of engine operation......................................................................................................................................................340
6.1.4 Record the length of each link..................................................................................................................................................................341
7. Parts change...............................................................................................................................................................................................341
8. Adjustment of control link and controller..................................................................................................................................................................341
8.1 Assembly of control link..............................................................................................................................................................................341
8.2 Disconnection of boost sensor.........................................................................................................................................................................341
8.3 Checking actuator for function........................................................................................................................................................................342
8.4 Adjustment of control link length.....................................................................................................................................................................342
8.5 Adjustment of actuator lever angle....................................................................................................................................................................342
8.6 Confirmation of direct control wirings................................................................................................................................................................343
8.7 Installation of boost sensor..........................................................................................................................................................................343
8.8 Confirmation of high-idle engine speed and actuator lever angle.......................................................................................................................................343
8.9 Confirmation of low-idle and auto-idle engine speed...................................................................................................................................................343
9. Resetting of protection....................................................................................................................................................................................344
10. Disconnection of PC and actuator controller...............................................................................................................................................................344
11. Confirmation of stop solenoid.............................................................................................................................................................................344
12. Confirmation of engine stop...............................................................................................................................................................................344
13. Personal Computer Set-up (How the check when computer program does not start).............................................................................................................................345
14. Malfunction display.......................................................................................................................................................................................346
15. Tunable Value List (for Reference)........................................................................................................................................................................347
SERVICE MANUAL REVISION REQUEST FORM..............................................................................................................................................................................351
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