OM H25 ENGINE FOR FORKLIFT TRUCKS XG 25 – XG 30 REPAIR MANUAL – PDF DOWNLOAD

SAFETY INSTRUCTIONS 7
ACCIDENT PREVENTION 7
SAFETY INSTRUCTIONS 7
ELECTRICAL SYSTEM 10
HYDRAULIC SYSTEM 10
LPG FUEL SYSTEM 10
DISASSEMBLY AND ASSEMBLY 11
LIFTING INSTRUCTIONS 11
SPECIFICATIONS 15
OVERALL SPECIFICATIONS 15
INSPECTION AND ADJUSTMENT INFORMATION 15
• TUNING THE ENGINE 18
ADJUSTING THE IGNITION TIMING BY 12° 18
ADJUSTING THE IDLE 19
ADJUSTING THE CO VALUE 19 8

OVERALL SPECIFICATIONS
Cylinder arrangement 4 in line
Capacity cm3 2,472
Bore x stroke mm 92 0 x 93 0
Valve arrangement in head
Starting sequence 1-3-4-2
Number of segments 3
Compression segments 2
Scraper ring 1
Compression ratio 8 7
Minimum rated engine speed 650 rpm
INSPECTION AND ADJUSTMENT INFORMATION
Distribution
Valve clearance (when cold)
Intake mm 0,38
Exhaust mm 0,38
Valve head diameter
Intake mm 35,0 ÷ 35,2
Exhaust mm 30,0 ÷ 30,2
Valve length
Intake mm 108,55 ÷ 108,85
Exhaust mm 108,05 ÷ 108,35
Valve rod diameter
Intake mm 6,97 ÷ 6,985
Exhaust mm 6,945 ÷ 6,960
Length of expanded valve spring
Intake and exhaust mm 44,9
Lenght of compressed valve spring (valve open)
Intake and exhaust mm/N 29,3/385,4 ÷ 434,5
mm/kg 29,3/39,3 ÷ 44,3
Installed height of valve spring (valve closed)
Intake and exhaust mm/N 37,7/177,5 ÷ 201,0
mm/kg 37,7/18,1 ÷ 20,5
Valve spring out of square
intake and exhaust mm 1,5
Valve seat – guide clearance
Intake and exhaust mm 0,015 ÷ 0,048
Exhaust mm 0,040 ÷ 0,073
60424161 – 16 – 12/2003
H25 Engine
Distribution
Valve seat width
Intake mm 1,3 ÷ 1,5
Exhaust mm 1,6 ÷1,8
Valve seat angle
Intake and exhaust 45° degrees
Outer valve face angle
Intake and exhaust 45°30’ degrees
Camshaft
Camshaft flexure limit mm 0,05
Camshaft axial clearance mm 0,05 ÷ 0,23
Inside diameter of standard camshaft bushing
#1 front mm 45,472 ÷ 45,485
#2, #3 middle and rear mm 43,948 ÷ 43,961
Clearance between camshaft pin and bushing
#1, #3 front and rear mm 0,025 ÷ 0,051
#2 middle mm 0,038 ÷ 0,062
Camshaft lift
Intake and exhaust mm 36,750 ÷ 36,800
Engine shaft – bearings
Bearing pin diameter mm 62,942 ÷ 62,955
Maximum taper and roundness error mm 0,01
Wear limit mm 0,03
Assembly clearance mm 0,020 ÷ 0,062
Wear limit mm 0,1
Normal diameter of connecting rod pin mm 49,961 ÷ 49,974
Maximum taper and roudness error mm 0,01
Wear limit mm 0,03
Engine shaft axial clearance mm 0,05 ÷ 0,18
Wear limit mm 0,2
Maximum flexure of engine shaft less than 0,02 mm
Eccentricity / orthogonality of flywheel
On coupling side of converter less than 0,1 mm
Connecting rod
Wheel base mm 143,97 ÷ 144,03
Clearance between connecting rod / engine shaft pins mm 0,17 ÷ 0,3
Wear limit mm 0,4
Clearance between pin / connecting ron bearings mm 0,01 ÷ 0,066
Wear limit mm 0,03
Maximum flexure of connecting rod (for each 100 mm) less than 0,025 mm
60424161 – 17 – 12/2003
H25 Engine
Pistons
Piston diameter
Standard mm 91,965 ÷ 92,015
Increment 0,50 mm 92,465 ÷ 92,515
Increment 1,0 mm 92,965 ÷ 93,015
Clearance between segment / cavity
First ring mm 0,040 ÷ 0,073
Second and third rings mm 0,030 ÷ 0,063
Opening between segment ends
1° ring mm 0,25 ÷ 0,35
2° ring mm 0,15 ÷ 0,25
3° scraper ring mm 0,3 ÷ 0,9
Diameter of pin mm 20,993 ÷ 20,998
Clearance between pin / piston assemby mm 0,025 ÷ 0,045
Base plate
Inside diameter of cylinder hole mm 92,00 ÷ 92,05
Wear limit mm 0,2
Maximum taper and roundness error of cylinder hole mm 0,02
Surface flatness error less than 0,05 mm
Cylinder head