Druaoraed Medio i Wertidede Aven Srdutriall Py Avon, MA. 02322. Soe. SPE-7700 Fp Same 559 - 1323 Disres: RB. Gove Tne. 26' Sw GY sr Mine, FL. 33130 Ros- &54~5420 TELE Sy Fars GRAVE MA TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanisms, service and maintenance of Universal Diesel Engines Models12,18 & 25,The basic block is manufactured by Kubota to Universal specs. It is divided into two parts, “Mechanisms” and “Disassembly and Servicing.” BH Mechanisms Information on construction and functions is included for each engine section. This part should be understood before proceeding to troubleshooting, disas- sembly or servicing Disassembly and Servicing Under the heading “General” come general precautions, troubleshooting, lists of servicing specifications and periodic inspection items. For each engine section, there are “Checking and Adjustment,”* “Disassembly and Assembly,’ and “Servicing” which cover procedures, precautions, factory specifications and allowable limits. A\ll information, illustrations and specifications contained in this manual are based on the latest production information available at the time of publication. ‘The right is reserved to make changes in all information at any time without notice,CONTENTS FEATURE ENGINE BODY ... 7 [1] Cylinder Block’. | 7 [2] Cylinder Head 7 {3] Crankshaft. foe cee 8 [4] Piston and Piston Ring... 8 8 9 9 [5] Connecting Rod . . ce [6] Camshaft and Fuel Camshaft. [7] Rocker Arm Assembly . [8] Inlet and Exhaust Valves, . 10 [9] Valve Timing. beeen 10 [10] Flywheel... 10, LUBRICATING SYSTEM [1] Oil Pump. . [2] Relief Valve. cee [3] Oil Filter Cartridge - cee [4] Oil Pressure Switen 22222 COOLING SYSTEM ......... (1], Water Pump. [2] Thermostat [3] Radiator... 6.2.2. ‘i [4] Radiator Cap Geouag a7 FUEL SYSTEM. cece ee eee eee TB (1) Fuel Filter... cones 19 [2] Fuel Feed Pump... 02... 2.22. 20 [3] Fuel Injection Pump et [4] Governor... 0.22.60. c cece 28 [5] Injection Nozzle 28 ELECTRICAL SYSTEM [1] Starting System... 5... [2] Charging SystemUni: mm fin)FEATURE orvaron Models 12,18 & 26 are vertical, water-cooled, 4-cycle diesel engines. ‘They Incorporate UNIVERSAL'S foremost tech nologies. With UNIVERSAL'S spherical combustion ‘chamber, well-known Bosch MD mini type injection pump and the well-balanced design, they give greater ower, low fuel consumption, little vibration and ‘viet operation.ENGINE BODY ‘orosrote [1] CYLINDER BLOCK ‘The engine has @ highly durable tunnel-type cylinder block in which the bearings, pistons, crankshaft and camshafts are installed ‘There are two types of cylinder block cylinder finers and the other has no liners. liners are pressure-fitted into the cylinder block. (One has dry-type The cylinder [2] CYLINDER HEAD (1) Intet and Outlet Port ‘The cylinder head has cross-flow type inlet/exhaust ports, which lower the heat conduction from the exhaust port 10 the inlet port, The low heat conduction keeps the inlet air ‘rom being heated and expanded by the exhaust gas. (1) Inlet Port (2) Outiet Port (2) Combustion System Exclusive spherical combustion system — “TVCS" (Three Vortex Combustion System) — whirls the air and mixes it with the fuel effectively to accelerate combustion and reduce ‘uel consumption. Sheathed type glow plugs are installed in the combustion ‘chamber 10 ensure easy engine starting even’ at ~15°C (SF) ‘The injection nozzles are of the throttle type. (1) Glow Plug (2) Injection Nozzle (3) Combustion Chamberower o16 one? [3] CRANKSHAFT. ‘The crankshaft with the connecting red converts the recioro- cating motion of the piston into rotating motion to driver the ofl pump and camshafts ‘The crankshaft has counterweights opposite the cranks to balance the weight of the offset cranks, The crankshaft has oil passages drilled so that oil can flow from the main bearings to the connecting rod bearings The front journal is supported by a sleeve type bearing, the intermediate journal by a split type, and the rear by a split ‘ype with a thrust bearing, [4] PISTON AND PISTON RINGS ‘The piston has a slightly oval shape when cold (in conside: ration of thermal expansion) and a flat head. ‘Three rings are installed in grooves in the piston, ‘The top compression ring (1) is a keystone type, which can stand against heavy loads, and the barrel face on the ring fits well to the cylinder wall ‘The second compression ring {2} is an undercut type, which effectively prevents the oil from being carried up, ‘The oil ring (3) has chamfered contact faces and an expander increase the pressure of the oil ring against the cylinder wal Several grooves are cut on the headland area to help heet Jissipate and to prevent scuffing, The piston pin is lightly offset from the centerline of the piston toward the major-thrust-face, so that it contacts the cylinder with minimized “piston slaps.” (1) Top Compression Ring (2), Second Compression Ring (3) Oil Bing [5] CONNECTING ROD ‘The connecting rod (2) connects the piston end the crank- shaft, and has bearings at both ends, A solid type small end bushing (1) is installed between the piston pin and the rod Split type connecting rod bearing (3) is installed between the erankpin and the rod (2) and between the erankpin and the rod cap (4). (1) Small End Bushing (2) Connecting Rod (3) Connecting Red Bearing (4) Rod Ceporeo onseres never [6] CAMSHAFT AND FUEL CAMSHAFT ‘The cams on the camshaft (1) cause the inlet and exhaust valves to open as the camshaft rotates, The journals and the bearings are force-tubricated, The cams on the fuel camshaft (2} cause the injection pump for the fuel pump to feed the fuel (On the fuel camshaft, the governor sleeve (3) is installed, (1) Camshatt (2) Fuel Comshatt (3) Governor Sleeve [7] ROCKER ARM ASSEMBLY ‘Tho rooker arm assembly includes the rocker arms (2) and ‘an adjusting screw (1], the end of which rests on the push rod, rocker arm brackets (4) and rocker arm shaft (3h. The rocker arms swing and transmits the reciprocating motion of the push rods to the inlet and exhaust valves to open and close them, Every bearing surface is lubricated through the drilled holes ‘of the bracket and the rocker arm shaft, (1) Adjusting Screw (2) Rocker Arm (3) Rocker Arm Shaft (4) Rocker Arm Bracketower onureies veces [8] INLET AND EXHAUST VALVES ‘The valve and its guide for the inlet are different from those for the exhaust. Other parts, such as the spring (6), spring retainer (5), collet (4), stem seal (2) and cap (1) are the same for both the inlet and exhaust. (1) Cop, (2), Stem Seal (3) Valve Guide (4) Collet (6) Spring Retainer (6) Spring (7) Inlet Valve (8) Exaust Valve [9] VALVE TIMING The timing for opening and closing the valve is extremely important to achieve effective air intake and sufficient gos exhaust. ‘The appropriate timing can be obtained by aligning the marks fon the erank gear and the cam gear when assembling. Tnlat valve open 1.0) 035 red, (20 Toetore TOG, Inlet va else (LC) 0.79 rad, 5° latter 80.6, Exhaust valve open (E10) | 0.87 red, (60" before 8.0.6. Exhaust valve close (E.6) | 0.26 rad. (1S")after T.0.6. [10] FLYWHEEL ‘The flywheel is installed on the rear end of the crankshaft and its inertia tends to keop it turning at a constant speed, while the crankshaft tries to speed up during the power stroke and slow down during other strokes. ‘The flywheel has gear teeth around its outer rim, which mesh With the drive pinion of the starter. ‘The flywheel also has marks on its outer rim. Each must be aligned with the mark on the rear end plate to get the top deed centers and the injection timingsLUBRICATING SYSTEM onset ‘The lubricating system consists of an oil strainer, an ail pump, 2 relief valve, an oil filter cartridge and an oil pressure switch, ‘The oil pump sucks the lubricating ol in the oil pan through the strainer and sends it to the oil filter cartridge, where the oll is Further filtered, The filtered oil is forced to the crankshaft, the connecting rods, the idle gear, the camshaft and the racker arm shaft ‘through the oil passage in the crankcase and the shafts to lublicate the bearings. ‘Some oil, splashed by the crankshaft or thrown off from the. bearings, lubricates other engine parts: the pistons, the cylinder walls, the piston pins, the tappets, the pushrod, the timing gears, and the inlet and exhaust valves, [A] Piston [8] Oi Pump [C] Rocker Arm and Rocker Arm Shaft [F] Oit Fitter Cartridge and Relief ValveEngine Oil Flow (1) OitPan (7) Main Oil Gallery (13) Small End (19) Drain (2) Oil Strainer (8) Main Bearing (14) Piston (20) Rocker Arm (3) Oil Pump (9) Big End (15) Fuel Camshatt (21) Oil Switch (4) Relief Valve (10) Timing Gear (16) Toppers (22), Rocker Arm Shaft (5) Oil Filter Cartridge (11) Splash (17) Camshaft Bearing (6) Idle Gear (12) Cylinder (18) Camshaft 12creo ome ower 13 (1) o1 PUMP ‘The oi pump is a gear pump, whose rotors have trochoid lobes. The inner rotor {3) has 4 lobes and the outer rotor (4) has 5 lobes, and they are eccentrically engaged with each ‘other. The inner rotor, which is driven by the crankshaft ‘through the gears, rotates the outer rotor in the same di- rection, varying the space between the lobes, While the rotors rotate from (A) to (B!, the space leading to the inlet port increases, which causes the vacuum to suck in the al from the inlet port. When the rotors rotate to (C}, the connection to the space switches from the inlet port to the outlet port. At (D}, the space decreases and the sucked oil is discharged from the outlet port. (1) Inlet Port (2) Outlet Port (3) Inner Rotor (4) Outer Rotor [2] RELIEF VALVE ‘The relief valve prevents damage to the lubricating system due to the high pressure of the oil. ‘The relief valve is 2 ball type direct acting one, and is best suited for low pressures. When the pressure of the oil, forced by the pump, exceeds the specified value, the oil pushes back the ball (3) and ‘escapes to the oil pan. (1) Spring (2) Ball (3) Valve Seattases tube fal anrRIes {8} orureae 14 [3] OIL FILTER CARTRIDGE After lubricating, the lubricating oil brings back various particles of grit and dirt to the oil pan, Those particles and the impurities in the lubricating ol can cause wear or seizure of the engine parts. It may also impair the physical and chemical properties of the oil itself The lubricating oil, which is force-fed by the pump, is filtered by the filter cartridge with the filter element (2). When the filter element accumulates on excessive amount of, dirt and the oil pressure in the inlet line builds up by 98 kPa. (1.0 kgf/em?, 14 psi) more than the outlet line, the bypass valve (1) opens to allow the cil to flow from the inlet into ‘the outlet line, bypassing the filter element. (1) Bypass Valve (2) Filter Element [4] OIL PRESSURE SWITCH ‘The oil pressure switch is mounted on the erankease and is led to the lubricating oil passage. When the oi prossure falls below the specified value, the all pressure warring lamp lights. [A] At the proper oil pressure [B] At lower oil pressure, 49 kPa (0.5 kf/em?, 7 psi) or less (1) Terminal (2) Insulator (3) Spring (4) Rubber Gasket (5) Contact Rivet (6) Contact (7) Oil Switch BodyCOOLING SYSTEM The cooling system consists of a radiator (1) (not included in abasic model), a centrifugal water pump (4), a suction fan (2) ‘and a thermostat (3). ‘The water is cooled through the radiator core, and the fan behind the radiator pulls the cooling air through the core to improve cooling ‘The water pump sucks the water from the radistor or from the eylinder block and forees it into the crankease, ‘The thermostat opens or closes according to the water ‘temperature, to allow the water to flow from the cylinder block to the radiator while open, or only to the water pump while closed. pie ‘Thermostat opening temporature | Approx. 82°C (160°) (1) Radiator (2) Cooling Fan (3) Thermostat (4) Water Pump (5) Cylinder Head (6) Cytinder Block robo [1] WATER PUMP The water pump is driven by the crankshaft and a V belt, The rotating impeller (4) in the water pump sucks the cooled water from the radiator and sends it into the water jacket in the crankcase, The mechanical seal (3) prevents the water from entering the bearing unit (1). (1) Bearing Unit (2) Water Pump Body (3) Mechanical Seal (4) Water Pump Impeller 6[2] THERMOSTAT The thermostat is of the wax pellet type. ‘The thermostat controls the flow of the cooling water to the radiator to keep the proper temperature, ‘The case, which serves 35 2 valve seat (1), has a spindle in- serted in the pellet (3) which is installed to the valve (2) ‘The spindle is covered with the synthetic rubber (6) in the pellet. The wax is charged between the pellet and the rubber, At low temperatures (lower than 82°C (180° F)) ‘The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe without running into the radiator, Only the air in the water jacket escapes to the radiator cone through the leak hole (8) on the thermostat. 1 Athigh temperature (higher than 82°C (180° F)) ‘As the water tomperature rises, the wax in the pellet (3) tums liquid and expands, repelling the spindle, which causes ‘he pellet to lower, ‘The valve (2) opens to send the cooling water to the radiator. (1) Seat (2) Valve (3) Petiet (4) Spindle (5) Synthetic Rubber (6) Wax (solid) (7) Spring (8) Leak Hote (9) Wax (liquid) 16enon [3] RADIATOR ‘The radiator core consists of water carrying tubes (1) and fing (2) at a right angle to the tubes. The fin is louverless, corrugated type which is light in weight, high in heat ex ‘change ratio and less apt to clog, ‘The water in the tubes is cooled by the air flowing through the tube walls and fins (A) Cooling Air (1) Tube (2) Fin (3) Louverless Corrugated Fin (4) Louvered Corrugated Fin coer oonipase [4] RADIATOR CAP ‘The pressure type radiator cap prevents differences in pressure between the inside and the outside of the radiator from deforming the radiator. When the water temperature rises and the pressure In the radiator increases above the specified pressure, the pressure valve (1) opens to reduce the internal pressure. When the ‘water temperature falls and a vacuum forms in the radiator, the vacuum valve (2) opens to introduce the coolant into the engine or radiator. (1) Pressure Valve orients (2) Vacuum Valve (3) Expansion Bottle 7FUEL SYSTEM roseeee ‘The fuel is fed from the fuel tank (1) (not included in the basic model) through the fuel filter (6} to the injection pump. (5) by the fuel feed pump (7) (in the basic model). The injection pump force-teeds the fuel through the injection pipes (3) to the injection nozzles (4), which inject the fuel into the cylinders for combustion. ‘The excessive fuel in the injection pump and the injection nozzle is collected in the fuel overflow pipes (2) and returns {to the fuel tank, @ Note: '® Component marked * is not included in the basic model © Component marked ** is included only in the basic model, 8 “a 2) 3) (a) (5) (6) eet) Fuel Tank. Fuel Overflow Pipe Injection Pipe Injection Nozzle Injection Pump Fuel Filter Fuel Feed Pump (Elec.)19 (1] FUEL FILTER ‘The fuel filter is installed in the fuel line from the fuel tank ‘to the injection pump (between the tank and the feed pump In the basie model) {As the fuel from the inlet (A) of the cock body move through the filter element, the dirt and Impurities in the fuel are filtered, allowing only clean fuel to enter the inside of the filter element. The cleaned fuel flows out from the outlet (8) of the cock body. Before starting or after disassembling and reassembling, loosen the air vent plug (3) to bleed the air in the fuel line[2] FUEL FEED PUMP ‘The filtered fuel is fed to the injection pump by the fuel fed pump. ‘The chamber (1) is enclosed with the inlet valve 2), the out: let valve (6) and the diaphragm (6), which is linked to the rocker arm with the pull rod (7). The rocker arm is swinged by the eccentric cam on the fuel camshaft (4) When the diaphgram is pulled down, vaccum in the chamber (1) causes the outlet vaive (5) to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber, ‘opening the inlet valve (2), When the diaphragm is pushed up by the cam, the pressure in the chamber causes the inlet valve to close and forces out the fuel, opening the outlet valve (A) Inlet Stroke (B) Discharge Stroke (a) from fuel filter (0) 10 injection pump (1) Chamber (2) Inlet Valve (3) Rocker Arm (4) Fuel Camshaft (5) Outlet Valve (6) Diaphragm (7) Pull Rod ELECTRIC FUEL PUMPnes [3] FUEL INJECTION PUMP The injection pump is a Bosch MD type mini-injection pump, Which gives high injection quality even at low engine speeds. The plunger is reciprocated by the cam on the camshaft with the tappet and forces the fuel into the injection nozzle. ‘The control rack (4) is pushed or pulled by the fork lever fof the governor and rotates the control sleeve (5) and the plunger, which has a left-hand lead control groove, to vary the amount of fuel forced into the injection nozzle. (1) Delivery Valve Holder (2). Delivery Valve Spring (3) Delivery Valve (4) Control Rack (5) Control Sleeve (6) Cylinder (7) Plunger (8) Plunger Spring (9) Tapper s 1) Pump Element ‘The pump element consists of the plunger (4) and cylinder (3), and their sliding surfaces are super precision-machined to ‘maintain fueltightness. ‘The plunger fits in the control sleeve which is engaged with the control rack. ‘The plunger has control goove of with a leftchand helix lead (1) Feed Hole 12) Control Groove (3) Cytinger (4) Plunger 218 ouirare ®@ onsen 2) Delivery Valve The delivery valve consists of the valve (1) and the Valve seat (2) The delivery valve prevents the fuel from flowing back into the delivery chamber through the injection pipe. It also prevents the fuel from dribbling at the injection nozzle, When the delivery stroke ends the relief plunger moves into ‘the bore of the valve seat and seals the delivery line from the delivery chamber, The relief plunger lowers further until the valve seats suck back the fuel to prevent dribbling at the injection nozzle (1) Valve (2) Valve Seat (3) Relief Plunger 3) Operation of Pump Element 1. Before delivery AAs the tappet lowers, the plunger (2) also lowers and fuel is drawn into the delivery chamber (1) through the feed hole (51 from the fuel chamber (4), 2. Beginning of delivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole, the pressure in the delivery ‘chamber rises to push thereat plunger (3) open, Fuel is then foree-fed into the injection pip. 3. Delivery While the plunger i rising, the delivery of fuel continues 4. End of delivery When the plunger rises further and the control groove (6) on its periphery meets the feed hole, the fuel returns to the fuel chamber from the delivery chamber through the control ‘groove and the feed hol. (1) Detivery Chamber (2) Plunger (3) Reliet Plunger (4) Fuel Chamber (8) Feed Hole (6) Control Groove1095 4) Plunger Position 1. No fuel delivery At the engine stop position of the control rack 13), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). And the delivery chamber (4) is led to the feed hole during the entice stroke of the plunger. ‘The pressure in the delivery chamber does not build up and 1g fuel can be forced to the injection nozzle. 2. Fuel delivery ‘The plunger is rotated (See figure) by the control rack. When the plunger is pushed up, the hole is closed. The pres- sure in the delivery chamber builds up and force-feeds the fuel to the injection nozzle until the control groove (8) meets the feed hole. ‘The amount of the fuel corresponds to the distance “A”. (1) Stor (2) Plunger (3) Control Rack (4) Delivery Chamber (8) Feed Hole (6) Control Groove [4] GOVERNOR The governor controls the amount of the fuel to be fed in the entire speed range to prevent the engine from changing its speed according to the load ‘The fork lever 1 (3) is held where two forces on it are balanced. One is the force that fork lever 2 pushes, which is caused by the tension of the governor spring (4) between the governor lever (1) and fork lever 2 (5). Another is the ‘component of the centrifugel force produced by the steel balls (6) which are rotated by the fuel camshaft (10) (1) Governor Lever (2) Start Spring (3) Fork Lever 1 (8) Governar Spring (5) Fork Lever 2 (6) Steet Ball (7) Governor Sleeve (8), Steet Bail (9) Governor Ball Case (10) Fuel Camshafteres nares i Atstart ‘The steel ball (4) has no centrifugal force. Fork lever 1 (2) is pulled by the start spring (1) and the ‘control rack (3} moves to the maximum injection position for easy starting (1) Staet Spring (2) Fork Lever 1 (3) Control Rack (4) Stee! Ball B Atidling When the speed control lever (2) is set at the idling position, ‘the governor spring (3) is pulled slightly ‘As the camshaft rotates, the steel balls (8) increase their ceentrifugal force and push the governor sleeve (7). Fork lever 1 (4) pushed by the governor sleeve, pushes the control rack {5} and the control rack compresses, the idling adjust spring (6). Tre control rack is kept at a position where the centrifugal force is balanced with the spring tension on the control rack, providing stable idling. (1) Start Spring (2) Speed Control Lever (3) Governor Spring (4) Fork Lever 1 (5) Control Rack (6) Idling Adjust Spring (7) Governor Sieeve (8) Steel Ballon anette b onreir seeps 25 At medium or high speed running When the speed contol lever {1) is wened further, the overnor spring (2) increases the tension and the control rack (3) ispulld to increase the engine speed The stee balls (4) increase their centrtugel force and the contro rk is pushed, decreasing the eingine speed, until the cantrifugl force andthe spring tension are balanced When the engine speed is dropped (AB) with the increase of the load (ab), the centrifugal force the steel ball dcroases and the control rack is pulled. The amount of the fuel to the injsction nozzle is increased to produce a higher engine torque raquiced for the load, (1) Speed Control Lever (2) Governor Spring (3) Control Rack (4) Stee! Ball (5) Engine Torque Curve (6) Large Load Torque Curve (2) Small Load Torque Curve (8) Torque (9) Engine Speed IB At maximum speed running with an overload When the engine is overloaded at the high speeds and the engine speed drops, the centrifugal force of the steel balls (6) deoreases and the governor spring (2) pulls fork lever 1 (1), and 2 (3). When fork lever 2 contacts the adjusting serew (5), the spring (4) which is built in fork lever 2 begins to push the fark lever 4 to pull the contral rack, ‘The fuel to the injection nozzle is increased to run the engine at high speed and torque. (1) Fork Lever 1 (2) Governor Spring (3) Fork Lover 2 (@) Spring (8) Adjusting Screw (6) Steel Balless nent 26 @ To stop the engine When the stop lever (11 is moved to the stop position, fork lever 1 (2) is pushed and the control rack (3) is moved to stop the fuel injection. (1) Stop Lever (2) Fork Lever 1 (3) Control Rack [5] Injection Nozzle ‘The nozzle is of the throttle type, The needle valve (10) is pushed against the nozzle body (9} by the nozzle spring (6) with the push rod (7), ‘The fuel forced from the injection pump pushes up the needle valve and is injected into the subcombustion chamber (4), The excessive fuel which is not injected returns through ‘the center chamber of the nozzle holder and the eye joint (2) to the fuel tank. The injection pressure can be adjusted with the adjusting washer (5), from 13,73 to 14.71 MPa (140 to 150 kaf/em?, 1991 to 2133 psi), (1). Fusl Overfiow Pipe (2) Eye Joint (3) Nozzle Holder Body (4) Sub-combustionChamber (8) Adjusting Washe (6) Nozzle Spring (7) Push Rod (8) Retaining Nut (9) Nozzle Body (10) Needle ValveELECTRICAL SYSTEM z ° ~é ® B ® The electrical system of the engine consists of a starting (1) Oil Pressure Switch system (including a starter, glow plugs and others), a charging (2) Glow Plug system (including an AC dynamo, a regulator and others), (3) AC Dynamo a battery and an oil switch. (4) Regulator +15) Batter NOTE: ® Starter © Components marked « are not included in the basic model, einioitar| +18) Key Switch 27® © b \ ont ones 28 [1] STARTING SYSTEM 1) Starter ‘The starter is of the electromagnetic drive type. Type of motor (DG, Series, Elactromagnetie drive ‘Supply Volt 7 Rated output 07 RW fe ‘ese than 30 seconde Direction of rotation | Clockwise viewed from pinion sie a Q) i) 4) 6) 6) a (8) @ a 2) 3) (a) 5) cc) a 8) (9) (19) a (2) (13) (14) Solenoid Switch Plunger Spring Shift Lever Brush Commutator Armature Field Coil Overrung Clutch |. Schematic Circuit Starting Switch Magnetic Switch Holding Coil Pullin Coil Plunger Rod Shift Lever Field Coil Commutator Brush Armature Spiral Spline Overrunning Clutch Pinionyet 2 1 When the starting switch is turned on The contacts of starting switch (1) elase and the holding coil (3) is connected ta the battery to pull the plunger (5) The pullin eoil (4) and the starting motor are also connected to the battery. The pinion (8) is pushed against the ring gear {9} with the foverrunning clutch (71 by the shift lever (6) and the magnetic switch (2) is closed a (2) (3) ‘4 (5) 18) a (8) @) Starting Switch Magnetic Swviten Holding Coil Pullin Coil Plunger Shift Lever Overrunning Clutch Pinion Ring Gear When the magnet switch is closed The current from the battery flows through the magnetic switch (2) the starting motor The pinion (7), which is pushed agoinst the ring gear (8) and rotated along the spline (51, meshes with the ring gear to zank the engine, ‘The engine starts and increases its speed. While the pinion spins faster than the armature, the over- running clutch (6) allows the pinion to spin independently from the armature. The pullin coil (3) is shore-cireuited through the magnet switch (2) and the starting switeh (1, a (2 (3) (ay (5) 6) a (3) Starting Switch Magnetic Switch Pull-in Coil Armature Spline (Overrunning Cluteh Pinion Ring Gearovers ours? 1 When the starting switch is released ‘The current from the battery flows to the holding coil (1) through the pullin coil (2) to diminish the magnetism between them, ‘The plunger (3) is pushed by the spring to pull in the pinion, (1) Holding Coil (2) Pullin Coil (3) Plunger 2) Glow Plug Each sub-combustion chamber has 8 glow plug for easy starting. The glow plug is of the quick heating type. (1) Insulating Powder (2) Metal Tube (3) Housing (4) Heat CoitWIRING DIAGRAM Glow Plugs. (iper eyL) ER | atzmnator ep Elected Fuel Pump Starter WIRE fio. COLOR WIRE SIZE * ' Block 10 2 Grey 10 3 Yellow-Red 18 4 Orange 0 5 Red 10 6 Purp 16 7 Us. Blue 6 8 Ton 16 9 Open 14 10 Gray 16 311) ALTERNATOR ALTERNATOR GROUP s | wow | 1 | s nO SGIB A218 7 | daar | 1 | testa cao semw 561800 8 | ao 1 | Mecnvesriere ty | ane | 2 | mater smsae a 200950 1 ‘Bracket - Art, Mounting Asemiy te | za | 1 | Bexreas cap sew 3131603304 angen uses 2) Regulator “The regulator i @transistorised regulator with SCR, When the battery voltage is low, SCRs turn on to charge the battery with the current from the generator. When the generated voltage excessively rises, they turn off to stop charging (1) To AC Terminal of Key Switch (Red) (2) To Dynamo (Light Blue} (3) To Dynamo (Light Blue) (4) To Body (Black) 32mura a nest 1 While the engine is stopped A small amount of current is applied to the base of transistor 72, and transistor T2 turns on, turning on transistor T3. Transistor T3 pulls up the gate voltage of the SCR’s SCR1 and SCR2. (1) Battery (2) Dynamo Stator Coll 1B When the engine starts ‘The dynamo generates AC in the stator coils, and the current ‘charges the battery through SCR1 and 04 (in figure) o SCR2 and D3 {-in figure) (1) Battery (2) Dynamo Stator Coit |W Overcharge prevention When the battery voltage rises and reaches @ certain voltage determined by zener diode 2D1, the current begins to flow ‘to the base of transistor TI through ZD1, Transistor T1 turns on and turns off transistor T2, Transistor T3 turns off and stops applying the triggering current to the SCR’s SCRI and SCR2. The SCRs turn off and stop charging. (1) Battery (2) Dynamo Stator CoilCONTENTS DISASSEMBLY AND SERVICING GENERAL . [1] Engine Identification... ... . [2] Cylinder Number. ............ . 36 [3] General Precautions. ........ 6.22.45 37 {4] Tightening Torques. +38 (5] Troubleshooting . .... 39 {6] Servicing Specifications. ...... a1 [7] Maintenance Check List... 245, [8] Checking and Maintenance . 46 [9] Special Tools. . 22.81 ENGINE BODY ... 58 CHECKING AND ADJUSTMENT ... 5B DISASSEMBLY AND ASSEMBLY. 59 [1] External Components 5 [2] Cylinder Head...... {3] Injection Pump and Levers - [4] Gear Case and Flywheel [5] Timing Gears and Camshafts. . [6] Crankshaft and Piston....... SERVICING......... cee 70 [1] Cylinder Head... - 70 [2] Valve and Rocker Arm . ae [3] Camshaft and Timing Gear 274 [4] Cylinder Block : 76 [5] Crankshaft. . an [6] Piston and Connecting Rod. 81 LUBRICATING SYSTEM. CHECKING. SERVICING COOLING SYSTEM . CHECKING. . . ‘i 4 DISASSEMBLY AND ASSEMBLY........ .86 FUEL SYSTEM. . CHECKING AND ADJUSTMENT . [1] Injection Pump... 5 [2] Injection Nozzle DISASSEMBLY AND ASSEMBLY. [1] Injection Nozzle ........ ce [2] Air Bleeding...a See ELECTRICAL SYSTEM [AP Starter. ..eeceeeeceeeees CHECKING. DISASSEMBLY AND ASSEMBLY : SERVICING Abaob tS [2] AC Dynamo an Regulator ee oo) CHECKING. . 5 or 99 13]:"Glow Plug... .[Link] 99 CONTENTS CHECKING... es 99 35GENERAL (J ENGINE IDENTIFICATION When contacting your local UNIVERSAL distributor, always specify the engine serial number [2] CYLINDER NUMBER ] The cylinder numbers of the diesel engines are designated as shown in the figure. The sequence of cylinder numbers is given as No, 1, starting from the gear case side. C L 36[3] GENERAL PRECAUTIONS (6 37 During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and huts should be replaced in their original position to prevent reassembly errors. When special tools are required, use Universal's genuine special tools. Special tools which are not frequently used should be made according to the drawings provided. Before disassembling or servicing live wires, make sure to always disconnect the grounding cable from the battery first. Remove oil and dirt from parts before measuring. Use only Universal genuine parts for parts replacement to maintain engine performance and to ensure safety. Gaskets and O-rings must be replaced during reassemb: ly. Apply grease to new O-rings or oil seals before assembl- ing. When reassembling external circlips or internal circips, pposition thom so that the sharp edge faces the direction from which force is applied. (1) Greese (2) Force (3) Place the Sharp Edge against the Direction of Force [A] External Circtip [B) internal Circlip[4] TIGHTENING TOI RQUES Screws, bolts and nuts must be tightened to the specified torque using @ torque wrench. Several serews, bolts and nuts such 36 those used on the eylinder head must be tightened in proper sequence and at the proper toraue. 1) Tightening torques for @ Note: special use screws, bolts and nuts © For "0" marked screws, bolts and nuts in the table, apply engine oil to their threads snd seats before tightening, oer Size X Pitch Teprering Tore Nem kate Feb © Head caver ap vate ext 3a58 0a 1005 23043 Head seas ae mute MO 1.25 373 10422 3.81043 Wswsi7 (2 Bearing ease Seve 7 MB x10) 118 12t018 3.710 108) © Bearing case screws 2 M7 x 1.25, 19.6 10235 20t024 14.510 17.4 © Flywheel serene MIO x 125 Bagr5a8 | 85t06.0 Beat 484 Connecting rx serene M6 x0.75 14.7 10 186 15%0 19 70810 137 (B-Rlocker orm bracket note Me x10 981 wo11.28 7.0070 1.15) 7230832 (© eo gear shaft serows MEx10) 981 1011.28 1.0070 1.15) 72510832 Glow piugs Mion 125) 19610245 201025 7450 181 ‘rain plus Mia 1.28. 32410373) 3.31038 23310275 Nozsle hls 20 «1.5 49,0 v0 686. 5.010 7.0 36.2 0506 (it switch taper Sere erie 14.70 196 151020) 70810 14.5) Fuel limi ean nt Nexto 7.81098 D810 1.0 381072 Injection pia retaining nuts Mize 24510385) 251035 18.110255) © Crankshate sero Mi2x 1S 98.1 19 107.9 70.010 11.0) 72310795, 2) Tightening Torques for When general use screws, bolts and nuts the tightening torques are not specified, tighten the sorews, bolts and ‘nuts according to the table below. a Tada Faia Rew mato Seaton oo Ionia eat ae na eae wae Me VawsH fa e0H KWwes SA enw [ere laAeew [aw owA [ews law ww Wa i7wae awa! —]aowts2 [seas iaie203awind [sows — [7s MIO p9210451 _[eOw45 [28910333 [40110559 [491057 fib410412ORwIOG [e272 j44G 0521 Mia faa 726 lea e7« ss was p78 is902 [raiea? [pv eaae —fioroweri77 faa wid paaveoee fiia—Yorao os [oe T2R fv 26 [iad io 07d [rad e180 pte 1d eno [rove 200 [eso eT ie os Tor 79s Yao M0 |i. iw zaee so wana —liaa teed aso aoed es w310 [ai TwINT iia [evo zeet [ps0 ro P90 [now wae [oven o3IR [ona es2s Oa wae foeaF oat [ROW sO asd D wD a0 = [ss 193623 [oe 1900 [ons 0 09 [oT wast [7s oad [ari awe si0a [03 sees fooTesRD fei T eas ut the numbers as shown below. pare Sevew and Bolt Materia! Gade Number ‘landard Sere and Bat None ssa1, s20¢ 7 ‘Special Screw and Bole S436, S48C (Refined) ‘Special Serew and Bolt ® 80435 SCMA35 (Ratined ‘Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check.[5] TROUBLESHOOTING Symptom Probable Cause Solution Engine dave nor wart [sterter does not work) 1 Air in the ful system ‘eater in the fu! system 1 Fuel pipe cloned Fut fee clogsed # Excessively high viscosity of fu or 1 Fuel with low eetane number 1 Fuel leak due to 10088 injection pipe «incorrect inpetion timing + Inieetion note clogsed + Injection pump malfunctioning ‘¢ Fuel feed pump malfunctioning * Seizure of erankshat, camshaft, piston, cylinder lier or bearing # Comprastion lak from cylinder + Improper valve reat alignment, valve spring broken, vale saized © Improper vive timing ‘Battery eischargad Starter matfuncsioning «Starter aniten malfunesioning © Wiring disconnectes Replenish foe Replace ful and repair or place fuel system Cleon Clean oF replace Use the specified ful or engine oi Use the specified tue Tighten not Adjust Clean Repair oF replace Repair or replece Aepeir oF replace Replace head garket, tighten evlinger head bel. 1a plug anc nozzle holder Repair or rpiace Corrector replace timing gear Feplece charge Repair or replace | Repair or replace Connect Foal filter clogaed or ity Cisen oF replace 1 Petan ring and nee worn ar stuck Incorrect injetion timing 1 Deficient compression smooth «© Airclesnerclosoed Ciean oF rapace ‘Fue! lak dus to loot injection pipe Tighten nut retaining nt ‘Injection pump malfunctioning Repair or replace «Incorrect ners apening prseure Acjust «Injection naazie stuck or clogged Repair or replace 1 Fuel overflow pipe clogged Clean = Governar malfunctioning epsic Either white ar blue | Excessive engine oi Reduce to the soeifed level Fepaic oF reince Adjust Aust top eleorance Either bask or dark ray exhaust oat ‘obearved Overs 1 Low grade fl used ‘© Fuel filter clogged Air leaner cloaget essen the eas Use the spocitig fue! ean oF replace loan oF ropiace Coupur ® Incorrect injection vmng «# Engine’s moving arts seam to be seizing © Uneven fut injerion 1 Deficient nazze injection 1 Compression leak ‘Adiust Repair or replace Fepsir of replace the injaction pump Repair or place the nozzle Replace head sotet, tighten eylinder head Loot, plow plug and nozzle neldeeSymptom Probable Cause Solution Excasve lubricant 7 Paton nals op Facing the same dvection © Oi ring worn oF stuck # Piston ring groove worn Value stam and guide worn # Crankshaft bering, and crank pin basing worn ‘Shift ring gap dvection eolace Replace the piston Replace Replace Fel mixed nto © Injeetion pump’s plunger worn Feplece pump element or pure Iubrieane oi ‘Fuel feed pump broken Replace Water mixed into ‘= Hood goes cefectve Replace lubricant of 1 Crank cate or cylinder head sawed piace Low oll pressure ‘Engine oll nsutficient Replenish Oi strainer clogses Ctean 4 Oi titer cartridge clogged Fepiace 1 Rliet valve tuck with dirt hese «= Reliot vale aring weaken or broken Repioce © Excessive ai clearance of crankshaft bearing | Replace © Excessive oil clearance of rank pin bearing | Replace * Excessive ai clearance of rockar aim bushing | Replace 01 parsge cloned Clean ‘Different ype of oi #011 pump aatetive Use the specified type of oi Repair or ralace Tigo pressure = Ditterenn ype of of Use the specified wpe af of 1 Fatiot valve detective Feplace Engine overheated ' Engine ol nsutficient Replenish * Far bolt broken or tensionedimproperly | Replace or acjust *# Cooling water insufficient Replenish # Radiator net and radiator fin clogged with cut | Clean ‘ Insice of raeiator corroded ' Cooling woter Hove route corroded Clean a replace Clesn or replace . ‘© Fadiatr coo detvetive Feplace ‘Water pipe demaged place 1 Thermostat detective Replace . 1 Water pump detective Replace fa Mtechanical sea defective Replace 1 Overload running Loosen the tong 1 Head gasket detective eplece * Incorrect injection timing Adjust © Unsuitable fl usec Use the speitig fush, Batary ashy = Battery Hui nsatfenne Feplensh stiles water and charge Sacharoe Fan belt ips Agius Belt tension or replace ring dtcomnectes connect '* Foguletor eatectve Replace AC dynamo detective Replace 1 Battery detective Replace[6] SERVICING SPECIFICATIONS ENGINE BODY [Cylinder Head] Factory Specification ‘Rionabie Line Cylinder head surface tlaness 0,08 mim per $00 mm 10.0019 in, per 3.94 in.) Top clearence 0.80 10 0.80 mm (00236 100.0318 in.) vue 1.151010 mm | {0.0469 100.0512) (casket thickness ES 000812 eee (0.0813 100.0853 in.) : - 02 mm (Gasket shim hikes lady . 309 MPs FNP GoouldletMttd (01.5 tation? 48 oi) (28.7 ge, 397 pi Varines among eying = 10% [Valves (IN., EX.)] T15;6 018 mm Vatu lerance (cola) en - 14 mm Valve ast wath ar, . 0.785 ee Valve st angle ee . D706 ed Vato fae ana ea . 0.78 00.95 mm 12m Eeeeesen | (0.0295 000374 in.) (0.047 in ‘leorancs bewieen va 10.030 00.087 mm ‘0.10 mm 16.6 kgt27 mm, 14.5 Ibs/.063 in.) jane sem L (0.23496 t0 0.23543 int eee (0.23661 to 0.23721 in.) ~ [Valve Timing] Inlet valve one before TOC. . om eee : [Valve Springs} ‘oot {1.244 in.) (1.418 ind 7 _ (0.047 in.) (5.6 kgt/27 om, 12.9 los!9.063 in.) a[Rocker Arm) Fectory Specification ‘ilowable Umit ata gear side clearance (0.0079 t0 0.0201 in.) trom a ; ‘erence between rocker wm 0.096 100.068 mm 0:38 mm rd busing {0.00063 r 000268 in) (0.0089 in) Focker erm shalt 0.0. a ar - (0.41232 10041776 nd Fcker arm busing 1D. eee - (0.41339 100.4500 ind [Camshaft] Carmatatignment oonm Soe es (0.0008 in (0.0031 int {Cam height 1, EX.) Zea 258i = (1.0583 ind (1.0563 int are 10250 t6 0.081 rn 0.15 mm a (0.00197 r 0.00358 ind (0.0089 in. Ccamsatt journal 0.0. jecoalpegealiell - {1.20682 ro 129725 ind a 38,000 10 38.028 mim ~ {8.20021 re 120020 in (Timing Gear] 0.08 760412 mm 0.15 mm “Timing gar backlash aes (0.0016 r 0.0047 in) (0.0059 in. 0.20 100.51 mm ‘08 mm ‘Gaarance between idle gar shaft 0.016 %0 0.085 mm ‘OVtinder (Liner) 1.0. (2.81069 to 2.52063 in.) | (2.59643 to 2.59917 in) and iaie gear bushing (0.00068 t0 0.00177 in. (0.0020 in. | 15.973 70 15984 rm late gear sat 0.0. | - coum | (0.62890 0.62928 in) a ] 16.000 0 16.018 mm lal eer bushing LO | = Saacaenee | {0.62992 0.63063 in) [Cylinder (Liner) ] T4000 %6 64079 mim] 66.000 10 65519 mm O18 mm (0.0088 in.) of wear Oversize of eyliner tine T 705 mm (40.020 in.) [Piston/Piston Ring] rion pn noe ub 1800010 18011 mim 18.08 mm eames (0.70886 0 0.70810 in) (070610. Compresion 1.085 t0 0.112 mm 0.15 mm rionring erence 1882 {0.00395 0 0.00401 a) {0.0050 i.) ema oa 0.02 0.06 mer 0.15 mm a (0.0008 te 0.0024) - {0.059 in) ‘Compression 0.2519 040 mm 1.25 mm i tog 1.2 (0.0096 0 0187 in) (0.04920) aaa van T 0.20 t0. 0.40 mm 1.25 mm. famine (0.0079 100.0187 ind (0.0482 in.) Oversize of piston rings 40.5 mm 140.020 a.) 42[Crankshaft] Faciory Specification “ilowabie Line hem ; cranks agnme eae am a 10.0008 in) {0.9031} ‘i eieance batwoan caniahah 0034 9 0.105 mm 20 mm four and besrng {0.00134 0.00617 nd (0.00790) Front and 39.904 io 39.50 mm oust owe, [tiene (157221 0 157284 0.) wear 45.994 10 43950 mm (1.729690 1,79002 in) Frontand 39.984 to 40.040 mm eeoing uo, [imredate (1.97418:0 1.57628 nd er 49.984 to 44.040 mm (1.73106 to 1.73386 0) ‘i cerance betwen crak pin 0.019 60081 mm 20mm ane being (0.00075 0 0.00319 in) (0.0079 in) Ganka Ob 2960 to ITS mm ~ (1.33697 «© 1.35780 ind Crank pin bearing 1. Se eeeean - (133895 to 1.34016 in) Crank sat ie clearance cpetinn cian (0.0058 %0 00122 in) (0020 in er ze of eaniahat bearing 02, =O rm and eran pin bean (0008 in, 0.016 ind a ‘Ovrsies of het bearing someone s (10.008 in. 0.016) [Connecting Rod] 908 mm Connecting ro alignment - Soa (0.0020 i) ‘i clesranae betwen pion a DOIG To OHITIM 0:18 mm nd small end busing (0.00065 to 0.00158 in.) (0.08 in) mtion ob T8001 to 18009 mm 7 (0:70870t0 0.70902 in 18025 0 18080 mm Sill en busing 1.0 io eae - 1070965 10 0.71028 in. LUBRICATING SYSTEM “atide ~ wre Cre see {0.7 kfem?, 10 pst ated 19670441 KP seed (2010.45 kafem?, 281964 pah - [Oil Pump] Fotor tobe lara . oa {0.0008 i.) Focal clearance biween outer Oa5 10H em 0.30 mm rotor snd pum body (0.005916 0.0063 in.) 2.0118 9) End clearance benweenroror and 0.0810 0.13 mm 0.20 mm cover (0.0031 t0 00054 in) (0.0079 ia (Oil Fitter] Opening preture of bypass valve 8 KPe (1.0 atom, 14.2 alt ol presture difference 43COOLING SYSTEM [Fan Belt ) = aa Belt defiecion under toad of 8B N er (10 kgf, 21 ts) | (02810 0.38 in.) [Radiator ] (not included with the basic model) ] Water tishineer at specified pressure distor water tihnass (137 KPe, 1.4 katfor?, 20 pi) YO second or more of pressure falling ime rom 85 to 59 kPa (0.9 100.8 kaflem?, 13 0 9 psi) Rotor cop opening pressure | completely opens 2 6mm (0.236 in) of opening [Thermostat] “Thermowats valve opening Boston C temperature (1789 0 1823°F) = “Temperatures which thermostat (95°C (203°FF FUEL SYSTEM [Injection Pump} T O58 19 O57 ws, 1S wo TFT Injection timing (static) | need before TOC 0 saconds or more of pressue falling tine wom | 30 seconds oF mare of preaure falling time Tram Fuel tightness of pump element 923 t0 24.22 MPa 30.23 10 34.32 MPs 1400 to 360 katicm®, $689 to 4978 psi) {1400 to 360 kaf/em®, $689 to 4978 pail TO seconds ar more af pressure falling time Wom Fuel rightness of delivery valve | 21.87 r0 20.59 MPa L__ 1220 10210 katiem?, 3129 to 2987 psi) seconds or moce of pressure fling time from 21.57 0 20.59 MPa (220 10 210 katlem*, 3129 10 2987 psi) LInjection Nozzle] T7014 Wa Fuel inection pressre (140 0 150 kgtlem?, 1981 t0 2133 psih ‘No fuel ek a Fuel tightness of nozzle valve set 12.75 Mee 1130 ketlem?, 1849 ps ELECTRICAL SYSTEM [Starter] om Hmm entero O.. cca - 1.2810.) 11.22) faeeaaee a —_ ‘0.05 mm _ 10.0020 in. in ne ‘02mm minal - {0.008 in.) ——- F7 mm 115 mm nat (0.653 in.) (0.453 in) [Glow Plug] Resistance I ‘approx. 1B ohm = [AC dynamo] ([Netead ouraue I AERO veh or more ENO [Regulator] (notincluded with the basic model) [Repuetng vonage I Tat0 15 v0[7] MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below, Senses terval tem cov | eov [eww | eww [een | een Ley] amy ] amy | aay Sos. [100 hrs. |150hrs | 200s, |400 he. |S0Ohre, ["Rarehs”| mosths | year | youre (Checking fuel piper and slams ° t [chansing engine oi [cleaning sir filer element [cleaning fuel firer [checking battery [checking fan belt tension | land domaoe | [checking oi or waver leakage . © lolelole [checking water pipes and clamps e [chaning ot titer ertrigae ° I [chanaing ful fer element ° [changing radiator clasner land coolant |chansing air iter stement orserys Slaninge| [checking vive cievance ° [checking noazie injection pressure ° [Cranging batiery ° [chaning water pipes and clamps [Ghansing fl pipas and clamps Oo A cauTION: © When changing or inspecting, be sure to level and stop the engine, 45[8] CHECK AND MAINTENANCE Checking Engine Oil Level 1 Level the engine. 2. To check the oil level, daw out the dipstick (1), wipe it clean, reinsert i, and draw it out again Check to see that the oll level ties between the two notches. 3. Ifthe level is too low, add new oll to the specified level 4, When using an oil of a diferent maker or viscosity from the previous one, remove all old oll. Never mix two different types of oil NOTE: © Use the proper Engine Oil SAE according to the ambient (1) Dipstick Changing Engine Oil 1. After warming up, stop the engine. 2. To change the used oil, remove the drain plug ( 1) at the bottom of the engine and dain off the oil completely 3, Reinstall the drain plug 4. Fill the new oil up to the upper notch on the dipstick 1a a M-12 0.494 US. gat 0.413 Imp. ge 2918 M-18,25| 0769 US. oa 8.880 Imo. gat Soscified quantity @ IMPORTANT © Engine oil should be MIL-L-46152/MIL-L-21046 or have properties of API classification CC/CD grades, © Change the type of engine oil according to the ambient temperature Above 25°C(77°F) SAE 30 0°C to 25°C(32"F to 77°F) SAE 20 Below 0°C(32°F) SAE10W or SAE 10W-30 (1) Drain Plug 46® trem | PartNo. | unit | Description 1 231059 2 Cap Screw 2 231875 4 Flat Washer 3 301602 1 Fuel Filter Cover 4 231906 2 Washer Lock 5 230141 2 Nut 6 300103 1 Bracket Fuel Filter 7 298605 2 Clamp Adjustable 8 298867 1 Fuel Hose 8 301385, 1 Electric Fuel Pump. 10 298854 1 Fuel Filter Element un 290855 1 Bleod Screw 12 299886 1 O-Ring 13 298853 i Fuel Filter Assembly 47 Changing Engine Oil Filter Cartridge T, Remove the oil filter cartridge with a filter wrench. 2. Apply engine oil to the rubber gasket on the new cart ridge. 3, Serew in the new cartridge in by hand, NOTE: © Over-tightening may cause deformation of the rubber gas ket Alter, the cartridge has been replaced, engine oil norrnally decreases alittle Check the il level and add new oil to the specified level (1) Fitter Cartridge Bleeding Fuel System 1. Fill the fue! tank with fue, end open the fuel cock 2. Loosen the air vent plug of the fuel filter @ few turns. 3. Screw back the plug when bubbles do not come up any 4. Open the air vent cock on top of the fuel injection pump 5. Retighten the plug when bubbles do not come up any NOTE: ‘© Always keep the air vent cock on the fuel injection pump closed except when sir is vented, or it may cause the engine to stop. Checking Fuel Pipe heck the fuel pipes every 50 hours of operation 1. If the clamp is loose, apply oil to the threads and securely retighton it 2. The fuel pipe is made of rubber and ages regardlass of the period of service (Change the fuel pipe together with the clamp every two years. 3, However, If the fuel pipe and clamp are found to be damaged or deteriorate earlier than two years,” then change or remedy. 4, After the fuel pipe end the clamp have been changed, bleed the fuel system, 4 CAUTION: © Stop the engine when attempting the check and change prescribed aboveAntifreeze IF the cooling water freezes, the engine cylinder block, cylinder head and radiator may crack. In cold weather before the temperature drops below 0°C (32°F), drain out the water after operating or add a proper amount of antifreeze © There are two types of antifreeze solutions: permanant tyoe—PT}and-semi-pesmanent type (SPT). For the UNIVERSAL engines, be sure to use the permanent type Go nat tse antiveeee during Nat weather to Keep the engine performance sines the cooling water boiling point rises '© When antifreeze is used for the first time, fill and drain clean water twice or three times so to completely clean the inside of the radiator. ‘© The procedure for mixing water and antifreeze differs according to the make of the antifreeze and the ambient temperature. Basically, it should be refered to SAE J1034 standard, more specifically also to SAE JB14e. © Mix the antifresze and water, then pour the mixture into the radiator. vam Freezing pam Bailing paint amitreeze [76 °F *c °F 20 = = 08) Be 50 37 34 108 226 60 32 62 m 22 10 64 a4 a4 208 At 760mmHg pressure (simospheric). A higher boiling point is obtained by using 2 radiator pressure cap which permits the development of pressure within the cooling system NOTE: © The above data represents industrial standards that necessi- tate a minimum glycol content in the concentrated antifreeze, '© When the cooling water level draps due to evaporation, add water only. In case of leakage, add antifreeze and water in the specified mixing ratio, Antifreeze absorbs moisture. Keep unused antifreeze in 2 tightly sealed container. © Do not use radiator cleaning agents when antifreeze has beon added to the cooling water. (Antifreeze contains an anticorrosive agent, which will react with the radiator cleaning agent forming sludge Which will affect the engine parts.) 48Belt Tension 1, Measure the deflection, depressing the belt halfway between the fan drive pulley and the AC dynamo pulley at 9BN {10 kgf, 22 Ibs) of force. 2. If the measurement is not the specified value, loosen the bolts and the nuts, and relocate the AC dynamo to adjust. ‘approx 10mm Fan ett tension | Factory specification Joe 49Checking Compression Pressure jarm up the engine and stop it 2. Remove the air cleaner and the mutler 43, Remove the nozzle holders from all the cylinders 4. Set a compression tester (Code No. 07909-30200) to the nozzle holder hole. 5, Cut the fuel (pull the stop lever}, and run the engine for 5 to 10 seconds (at 200 to 300 rpm) and read the maxi Execute the test at least twice 6. If the compression pressure is less than the allowable limit, pour a small amount of engine oil through the nozele holder hole and test again. 7. If the compression pressure reaches the allowable timit, check the cylinder liner and the piston rings. If not, check the top clearance, valve and cylinder head, G0 [237 W NOTE: ‘© For the test, use a fully charged battery and the specified valve clearance. © Variances in cylinder compression values should be under 10% Valve Clearance 1. Loosen the lock nut and the adjusting screw on the rocker 2, Turm the adjusting serew to adjust the valve clearance at the top dead center {T.0.C) during the compression stroke of the piston 3, Tighten the lock nut and check the valve clearance again after several turns ofthe flywheel W NOTE: © To get T.0.C. of the piston, find its “TC mark on the flywheel and align it to the punch mark on the rear end plate (See photo), —— Valve Factory 0.35 100.18 om, | clearence pecitiation (0.0088 v0 0.0071 inChecking Fuel Injection Pressure 1, Set the injection nozzle to the nozzle tester 2. Measure the injection pressure 3. If the measurement is not within the factory specifics tions adjust with the adjusting washer inside the nozi hades. a a7 ] uel injection Factory spec. | 140 to 150 ker pressure a 1991 10 2133 ps oa [9] SPECIAL TOOLS Piston Ring Compressor Code No.: 07809-32111 Application: Use exclusively for pushing in the piston with Piston Ring Too! Gode No.: 07909-32121 Application: Use exclusively for removing or installing the piston ring with ease. coanaey Flywheel Puller (For vertical type diesel engines) Code No.: 07916-32011 Application: Use exclusively to take off the flywheel of all vertical type diesel engines safely and easily.corztias Diesel Engine Compression Tester ode No. (07909-30200 Application: Use to measure diesel engine compression and to diagnose the engine for a major overhaul Oil Pressure Tester Code No, Application (0791632031 & tester to measure lubricating oil pressure for all kinds of diesel engines. Valve Seat Cutter Code No. Application: Angle Diameter 07909-33102 Use to reseat values (0.785 rad. (45°) 0.262 rad, (15°) 28.6 mm {1.126 in.) 31.6 mm (1.244 in.) 35.0 mm (1.378 in.| 38,0 mm (1.496 in.| 41.3 mm (1.626 in.| 0.8 mm [2,000 in.|coins Radiator Tester Code No. 07809-31561 53 Application: Use to check radiator cap pressure and leaks from cooling systems. Connecting Rod Alignment Tool Code No.: 07909-31681 Application: Use to check the connecting rod Applicable range: Connecting rod large end I,D, 30 t0 75 mm, (1.18 to 2.95 in dia.) Connecting rod length 65 to 330 mm (2.56 to 12.99 in.) Nozzle Tester Code Ne; 07909-31361 Application: Use to check the fuel injection pressure and spraying condition of nozzle, ‘Measuring range: 9 to 49 MPa (0 to 500 kgf/em?, 0 to 7112 psi) Press Gauge Code No.: 07909-20241 ‘Application: Use to check the oll clearance between crankshaft and bearing, ete. ‘Measuring range: Green — 0.025 t0 0.076 mm (0.01 to 0.03 in.) Red — 0.051 10 0.152 mm (0.02 t0 0.06 in.) Blue — 0.102 to 0.229 mm (0.04 t0 0.09 in.)Red Check (Crack check Code No.: 07908-31377 Application: Use to check cracks on cylinder heads, crank cases, ete, NOTE: Unit: me fn) aoe Spree a come eene eee ee thong ote Faure Injection Pump Pressure Tester ‘al ian Un wo che al igies of ineton pues ae Soaiee Ss a | owen is Saieciens oa mur) S| te 2m ae a + irae meee ae re ; tb) {OL a LL eae 7} te} 7 Saale a = = oralValve Guide Replacing Too! mo Fppliation: Ue to pres Ou ard 10 press fi the valve guide cana goin Sesesseem , eo gf hg 8 ee 38 “oer [ae o <, 20 007 e 10 aoa & aa oor c 10 cose ni mtn Rocker Arm Bushing Replacing Too! {40.18.51 Application: Use to press out and to press fit the rocker 2509112104) tem bushing . ures a w zo coe io aos8 3 03 oo & to 038 Uni mmiar] elle Gear Bushing Replacing Toot 15015911 Application: Use to press out and to press fit the idle gear bushing. 3011.18) 2010.79) é Uo€ e.g] Oa * i ‘sil 35 uNirbuke = Rel “oma [em r i 20 core . 10 | 0039 ie c 03 0.012 [~ CG 10 0.039 “Units mm Un can ‘Small End Bushing Replacing Tool Application: Use to press out and to press fit the small fend bushing, 2510.98) 20 0.79) ee 3 é eo 8] * ag) 3s ee _ 7 qi 20 | a0%e 5 | 7 03 0.012 “Units mm lnCrankshaft Bearing 1 Replacing Too! Application: Use to press aut and to press fit the crankshaft bearing I. owe “chamfer [mm oy c. 20 078 c 7 0.038 cy 03 0012 5 0 ist == Fut mm Cn) Flywheel Stopper Application: Use t0 loosen and tighten the flywheel screw. 2010.79) eval \20 10.391, T 200787 “Unit: me tn.) 57ENGINE BODY CHECKING AND ADJUSTMENT Compression Pressure 1. Run the engine until itis warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders 3, Set a compression tester (Code No.: 07909-30200) with the adaptor to the nozzle holder hole. 4, Run the engine with the starter at 200 to 300 rpm for 5 to 10 seconds and read the maximum compression pressure 5, Measure the compression pressure several times. 6. If the measurement does not reach the allowable limit, apply @ small amount of oil to the cylinder wall through the nozzle holder hole and measure the compression pressure again, 7. IF the pressure is still less than the allowable limit, check the top clearance, valve and cylinder head. 8. IF the pressure increases after applying oil, check the cylinder wall and piston rings. NOTE: © Check the compression pressure with the specified value clearance (See page S-67) 300 va Feciory specitiestion | 31.5 kofem? 4B ost 2.32 MPa Allowable limit 23:7 atlem? 557 pu Compression pressure Top Clearance T. Remove the fozzle holder and lower the piston in the cylinder. 2, Insert 3 high-quality fuse from the nozzle holder hole on the piston [except where it faces the valve or the combus- tion chamber insert.) 3. Rotate the flywheel until the piston is raised and lowered again. 4, Take out the flattened fuse carefully and measure its ‘thickness with vernierealip ‘OL QP | Cheek the ll learners ofthe oes ounal and the Se alee | 5. If the measurement is not within the specified values, ners piston pin. 0.60 t0 0.80mm Top clearance | Foctory specification | 2.60120.80mm59 Valve Clearance Loosen the lock nut and the adjusting screw on the rocker 2. Turn the adjusting screw to adjust the valve clearance at the top dead center (T.D.C) during the compression stroke of the pi 3, Tighten the lock nut and check the valve clearance again after several turns of the flywhe @ NOTE: © To get T.0.C, of the piston, find its “TC” mark on the fiywheel and align it to the punch mark on the rear end plate (See photo) 18 10 018mm (0089 t0 0.0071 in 0.[1] External Components Engine Oil and Cooling Water 1. Open the cack (1) and drain eoaling water 2. Remave the plug (2) and drain engine oil Costing water Tahtening | Oran | 32410373 Nem, 33 103.8 Kal-m : tomue” | pug” | 2399 273.0ine | (1) Drain Cock ° (2) Plug [2] Cylinder Head Injection Pipes, Inlet Manifold and Cylinder Head Cove 1. Remove the injection pipes, overflow pipes and the nozzle holders (1), 2. Remove the inlet manifold (2) 3. Remove the cylinder head cover (3) 4, Remove the dynamo (4) and the il filter (5) (When reassembling) Apply engine oil to the head cover nuts. i yy, 24810343Nm | | tnisction pine ut | 2:8oaugtm” | fa.tt0 259 feos 1025.3 Nem EATER, | | l Tightoning torque | — J 49.0 to 68.6 Nm Nozzle helder 5.010 7.0 ule 36.210 506 os (1) Nozzle Holder 2) Inlet Manifold (3) Cylinder Head Cover (4), Dynamo (5) Oil Filter 60Rocker Arm and Cylinder Head 1. Remove the grow plugs (3) 2, Remove the rocker arms and shaft assembly (1), 3, Remove the push rods and tappets 4. Loosen the hose clamp (4), and remove the screws, the ruts and the cylinder head (21 (When reassembling) © Be sure to place the O-ring (5) (See photo} © Apply engine oil to the head screws and nuts, and tighten them. in the specified sequence (See figure), in several steps and to the specified torque. © After tightening all the screws and the nuts, run the engine until it warms up and tighten them again to the specified torque. onespon 61 [ieato2inem | Grow plug | 201025 kgtm [fasta ta rebs i SBT to 1.28 Nm | | Rocker em nut | 3.00 $01.15 kgfem 3333358 ee | 1 2a5t0775N-m | Criederadsnia | Sao | L 17.410 20.3 ft-lbs _| eee Sxinan pet | Steal [sieseenn. | (1) Rocker Arm Shaft Assembly (2) Cylinder Head (3) Grow Plug (4) Hose Clamp (5) O-ring Valve 1. Remove the valve cap (S} and the valve spring cllets (4), ‘compressing the valve spring (2) with the valve spring retainer (3). 2. Remove the valve spring retainer (3) and the valve spring (21 (When reassembling © Giean the valve stem and valve guide, and apply engine oil to them. © Be sure to adjust the valve clearance after inetalling the valve © Be sure to lap the valve on its seat after replacing the valve, referring to "Correcting Valve and Seat (1) Valve (2) Valve Spring (3) Valve Spring Retainer (4) Colier (5) Valve Cap62 Adjusting Valve Clear “TL. Loosen the lock nut an 2. Turn the adjusting screw to adjust the valve clearance at the top dead center (T.D.C} during compression stroke of the piston. 3, Tighten the lock nut and check the valve clearance again after several turns of the flywheel @ NOTE © To get 7.0.C. of piston, wheel and align it with plate (See photo) W adjusting screw on the rocker ind ts "TC" mark on the fly the punch mark on the rear end 0.145 120.185 mm | 870087? 1010100728 in63 [3] Injection Pump and Levers Injection Pump and Speed Contro! Plate 1, Remove the socket headed screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to harm the spring (4), 3, Disconnect the spring (4) and remove the speed control plate (2), (When reassembling] © Hook the spring (4) to the lever First and install the speed control plate (2), © Be sure to place the copper washers underneathsthe screws (1) (See photo}. : © Slide the control rack (6) until its end is flush with the pump housing (See phot} ‘© Position the slot (7) on the fork lever just under the slot fon the crankcase. © Insert the injection pump so that the contral rack (6) should be pushed by the spring (5) at its end and the pin (8) on the rack engages with the slot (7) on the fark lever” (See photo. 981 wo 1128 W: | 12ate 132 tbe (1) Screw (2) Speed Control Plate (3) Injection Pump (al Spring (51. Spring (61 Control Rack (7) Siot (8) Pin10 10.39) a [4] Gear Case and Flywheel Pulley and Gear Case 1. Prepare the stopper (See figure) and install it to the flywheel so that the crankshasft does not turn, 2. Flatten the metal lock and remove the leck serew and pull ‘ut the pulley with a puller 3. Remove the serews and disconnect the spring, and remove the gear case NOTE © Be sure to remove the bolts behind the fan and inside the gear case, (1) and (2) (When reassembling) © Be sure to tighten spring (3), © Install the pulley to the erankshaft, aligning the marks (4) fon them, Apply engine oil to the lock serew and tighten it to the specified torque. screws (1) and (2), and hook the wigan Lockscew | SDI Hota 7a3'9 fae eb [98110 128 Nom | 2808 1 ieaghem rEatoaas tor | ee saa “Tahtening torave (1) Screw (2) Screw (3) Spring (4) Aligning Markwenn merry — 1. Install the stopper to the flywheel so thet the flywheel does not turn, 2. Remove the screws and the flywheel (When reassembling) © Place the flywheel washer on the flywheel and install ‘them to the crankshaft, noting the location of the holes. T 55910 588 Nem | Tiamening torque | Fivwneetssren | 551060 korem 500 404 feb 65 [5] Timing Gears and Camshafts Wir itis requiced to a ther befare disassemby. the gear backlashes, measure Idle Gear 1. Remove the retaining ring, the thrust washers and the idle eae (1) (When reassembling) © Install the idle gear, aligning the marks an the gears re ferring tothe figure (1) Idle GearGear and Camshaft 1, Remove the serews (3) and draw out the camshatt (4) with the gear on it 2, Remove the retaining plate (1), 3, Remove the screws (5) and draw out the fuel camshat (2} with the governor fork assembly. (When reassembling) © Hook the spring to the fork lever 1 (6) as shown in the figure before installing the fork lever assembly to the crankcase © Install the fork lever assembly so that the pins an the fork position evenly apart from the governor sleeve and make sure that the fork lever 1 is kept apart from the rack plate ‘more than 1.5 mm (0,059 in), (1) Retaining Plate (2) Fuel Camshaft (3) Screw (2) Camshaft (5) Screw (6) Fork Lever 1 (7) Fork Lever 2 66Oil Seal Sleeve and Gear 1. Pull out the oil seal sleeve (2) together with the gear (1) Using 8 gear puller (When reassembling) © Instat the idle gear before installing the sleeve (See figure at “Idle Gear”) © Be sure to place the O-ring (3) before installing the sleeve 2 (1) Gear (2) O11 Seal Sleeve (3) O-ring [6] Crankshaft and Piston Main Bearing Case Cover 1. Remove the screws, and lift the cover (1) by screwing two screws (Soe photo) gradually and evenly. (When reassembling) © Place the case cover and the gasket noting each direction (See photo), and tighten the serews. 1 sate Tze | Trahoingronave | Mainbeaine | 985.014 280rm i ease | (1) Main Bearing Case Cover (A) To lift the cover, serew in two serews. 6768 Crankshaft 4. Remove the oil pan and the s 2, Remove the screws [1] aad the connecting rad caps, and push out the pistons 3. Remove the serews (2) and pull out the crankshaft (When reassembling) © Insect the piston in its eylinder iy such a manner that the mark "1" on its head aligns with the mark ""1" on the crankease (See figure! © Align the marks on the side of the connecting vod. and cap. © Apply engine ol ta the bearing surface and the screws and tighten them to the specitied torque © Be sure to install the O-ring on the pipe extending from the strainar (See photo} Dario lhze Nem 1.00 '0 198 kot-m 7230 832 felon onenirsiod | 1815 Figen Tightening torque L980 157 [14716 186N-m ae Se eee Tasto I Felos i pews 147 10 19.6N-m ow \St020 gta 1OBto 14.5 los (1) Screw (2) Serewpenne reer 69 (When reassembling) © Apply engine oil to the bearing surface and install the bbearing case so that its casting mark "7 3.4" and “7-4 “(Thor the holes face the flywheel Place washers with their round edge on the seat of the screws and apply engine oil to the screws and tighten them to the specified torque, Place the thrust washers with their el groove outside, Tightening torque (1) Casting Mark Piston and Connecting Rod “T. Remove the retaining ring and the piston pin, 2. Remove the piston rings using & piston ring tool (Code No.: 07909-32121). (When reassembling) © Install the piston rings with their manufacturer's mark up ‘and so that their gaps and the expander will not positioned in line, referring to the figure © Apply engine oil to the pistan pin and the bushing, and install the connecting rod so that the mark on its side positions opposite the mark ""1” on the piston, © When inserting the piston pin to the piston, heat the piston in oll (80°C, 176"F) for 10 to 15 minutes, Fitted \[Link] the | Fastary 0.00010 0.000 mm piston gin bushing | speci 0.0000 te 0.0000", |SERVICING trang “Cp arose oes onsRiT enna: 70 [1] Cylinder Head Top Clearance 7. Remove the nozzle holder and lower the piston in the cylinder. 2, Insert a high-quality fuse ffom the nozzle holder hole on the piston except where it faces the valve or the com> bustion chamber insert. 3. Rotate the flywheel until the piston is raised and lowered again, 4, Take out the flattened fuse carefully and measure its ‘thickness fuse with vernier calipers. 5. If the measurement is not within the specified values, ‘check the oil clearances of ‘the crankpin journal and the piston pin. 0.60 19 0.80 mm 6.9238 10.0.0315 in Top clearence | Factory specification Cylinder Head Surface Flatness 1, Clean the cylinder head surface. 2, Place the straight edge on the cylinder head and measure ‘the clearance with a feeler gauge at the positions shown in the figure. 3. If the measurement exceeds the allowable limit, correct itwith a surface grinder. @ NOTE: © Do not place a straight edge over the combustion chamber, insert. 0.55 mm 0.0020 per 3.94 in. Fistnest Allowable limit Cylinder Head Surface Flaw 1, Prepare an air spray red check (Code No.: 07909-31371). 2. Clean the cylinder head surface with the detergent (2). 3. Spray the cylinder head surface with the red permeative Tiguid (1). 44, Wash away the red permeative liquid on the cylinder head, surface with the detergent (21, 5, Spray the cylinder head surface with the white developer (a, 6. If any flaw is found such as a red mark, replace the cylinder head,[2] Valve and Rocker Arm Valve Clearance 1. Loosen the lock nut and the adjusting serew on the rocker 2. Turn the adjusting serew to adjust the valve clearance at the top dead center (T.0.C.) during compression stroke of the piston, 3, Tighten the lock nut and check the valve clearance again after several turns of the flywheel NOTE: © To get T.0.C. of piston, find its "TC" mark on the fly wheel and align it with the punch mark on the rear end plate (See photo) ‘ave clearance try specication | 9.15 120.18 mm : yee 6.0088 t0 0.0071 in Valve Stem Clearance, 1. Romove the carbon from the valve guide, 2, Make sure that the valve stom is straight and insert the valve into the valve guide. 3, Set the dial indicator with its tip on the stem near the end of the valve guide. 4, Measure the clearance, moving the valve sideways. IF the measurement exceeds the allowable limit, replace the valve guide or the valve Factory 0.03016 0087 mm | Closrance between valve 6.00778 to 0.00324 in. | Stomand vate guide | aitowapie 0 1 mee fen 6.008) we guide boweup, | Factory 8010%06025mm eae specication | 0.23861 t00.23721 Factory 5.969 to 5.880 mm erent ‘peciteation | 0.23896 100-2954 Replacing Valve Guide (When removing) - 1. Press out the valve guide toward the head cover using a valve guide ceplacing tool (When installing) 1. Clean the valve guide bore and apply engine oil to the bore, before installing the valve guide 2. Press in the bushing so that its end comes flush with the crlinder block surface using a valve quide replacing tool 3. Press in the valve guide until its end comes flush with the cylinder head surface @ IMPORTANT: ‘© Ream precisely the bore tothe specified dimension shown inthe figure, after installing the valve guide, nValve Seat Width 1, Check the valve seat surface and the width. 2. If the seat width is not within the specified values or (5) Js not equal to (c) (See Figure}, correct the value seat referring to “Correcting Valve and Seat" Tamm Valve saat with 055m, Factory specification were rompers eorsbiant a 2 Correcting Valve and Seat 1. Correct the valve using a valve refacer. 2. Correct the valve seat surface using a valve seat cutter (Code No.: 07909-33102}, following the steps below. 3. Cut the vaive seat surface with a 0.75 rad (45°) valve seat 4. Check the seating surface on the valve face using a red lead. 5. Cut the value seat surface with a 0.29 rad (15°) value seat ‘cutterso that the width A becomes equal to B (See figure). 6. Check the seating surface using a red lead, If needed, repeat the steps above from 3, until the valve contacts correctly. 7. Lap the valve onto its seat using lapping compound, until the valve contacts with its seat evenly, HNOTE: © Before correcting the valve and seat, check the valve stem and the valve guide, and repair them if necessary. Valve Recessing 1. Clean the valve face and install it in its guide. 2. Measure the valve recessing with a depth gauge. 3. If the recessing exceeds the allowable limit, replace the valve, eylinder head or bot. Factory 0.75 19 0.85 mm ane vecening [_soriteaton | 01298 10 00874 in © | atfowable 12mm lime oar,cons Length and Tension length of the spring with vernier calipers. 2. Place the spring on a spring compression tester and compress to the specitied length, and get the tension. 3. If the measurement is ess than the allowable limit, replace the valve spring, unenct neers a6 mm 28.4 mm iigin B47 8 27D mm Facory specitication | 6.8 apt [27.0 mn} 145 fos {1063 in) S491 27.0 mm Allon limit 3 agt [27 0mm) 12.3 fos (1068 ns Free length Alloaable limit Spring tension \Valve Spring Squareness 1. Place the spring on the surface plate and a square at its side, 2, Measure the maximum distance A (See figure), rotating spring, Tame Valve soring savareness | Alowatbu time | 32.0 Rocker Arm Bushing and Shaft Clearance 1, Measure th meter. 2. Measure the rocker arm shaft O.D, with an outside micro meter 3. If the clearance exceeds the allowable limit, replace the bushing. 4. 1f the clearance still exceeds the allowable limit after placing the bushing, replace the rocker arm shaft socker arm bushing 1.D. with an inside micro: Fectory 0015 190068 mm Rocker arm bushing |_secitcation | 0,00069 10 0.00268 in : and shaft clearence’ |Allonstie | 045 mm comme lime 0.0088". Factory 10.500 10 1054) mm Bushing 1D. speciation | 0.41399 t0 0.41500 In, shat 0.0, Fastory 10.473 to 10.484 mm spectestion | 041232 t00.41276 In 7374 Replacing Rocker Arm Bushing (When removing) 1. Press out the rocker arm bushing using a rocker arm bushing replacing tool (When installing) 1, Clean the rocker arm bushing and the bore, and apply engine oil 10 them, 2, Press in the bushing so that its end comes flush with the rocker arm, using a rocker arm bushing replacing tool IMPORTANT: © Be sure to align the oil holes on the rocker arm and the bushing, and check that the seam of the bushing positions is as in figure, [3] Camshaft and Timing Gear Gear Backlash Set a dial indicator (lever type) with its indicator tip on the gear tooth 2. Move the gear to measure the backlash, holding its mating ear, 3, If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oll clearance is proper, replace the gear Idle Gear Side Clearance, 1, Pull the idle gear collar 2 and push the idle gear, and measure the clearance between the idle gear and the ile gear collar with 2 feeler gauge. 2. IF the clearance exceeds the allowable limit, replace the idle gear collar 1. Factory specification | 22012081 mm | 5 (019079 100.0201 in Sige clearence |— ‘Allowable init 28 mm | 00207,Idle Gear Oil Clearance 1, Measure the 1.0. of the idle gear bushing with an inside 2, Measure the O.D. of the idle gear shaft with an outsive 3. If the clearance exceeds the allowable limit, replace the bushing 0016 10.0045 mm 1.00063 £6 0.00177 in 1.05 orn Factory specification (i clearance Allowable limi 16.000 to 1638 mn Bushing 1.0. | Factory specification | 200056 16.078 mes | 75 16973 0 15984 mm shaft 0.0. | Factory specittestion | 1597350 15.984 mm Camshaft Oil Clearance 1, Measure the 1.D. of the camshaft bore on the crankcase with an inside micrometer, 2, Measure the O.D. of the camshaft journal, If the clearance exceeds the allowable limit, replace the shaft, Feciory | 005010 0081 mm 4 peciizanion | 0.00199 10.0 00988 in Allowable | 0.18 mm _ limi 0.0080 in, Comshatibow ie. | Factow | 38.000 10 33028 mm Speciation | 7.28921 to 120020 mn ean aa Faciory | 32.934 10 37.960 mm [cermtciura oo. | Besiaeion | Sese7 See Camshaft Alignment 1. Place the camshaft on the V blocks and seta dial indicator with its indictor tp on the intermediate journal 2. Rotate thecamshett inthe V black and get the eccentricity {halt of the measurement) 3. If the eccentricity excoeds the allowable limit, replace the camshatt. Factory secifieation | 208mm Allowable limit Bons tnconser woreurt a 2 a Camshaft Lobes Height 1, Measure the height of the camshaft lobes at their largest 0.0. with an outside micrometer. 2.1f the measurement is less than the allowable limit, replace the camshaft, Factory Rear Seiteation Noses tn Cae nem, ‘Allowable 25S mm, Tie 110563 in [4] CYLINDER BLOCK cyl wer/Cylinder Wear Measure the 1.0. of the cylinder tiner or the cylinder (linerless type) at six positions (See figure) with a cylinder gauge to find the maximum and minimum I.D's. 2. Get the difference between the maximum and the mini- ‘mum 1.D.'s as the maximum wear. 3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension (Refer to the table) and replace the piston and the piston rings with the oversize ones. 4, When having been oversized and the wear exceeds the allowable limit, replace the cylinder liner or the cylinder. (ners typed = 19] 6490020 64019 em ytiager | racrory | M712 25t869 0 2.57040 Mined 10, |roeetieton £5,000 066.019 mm, M~18,25 aso0e3 to 950817 onimom wan | Movable 2.15 mm, fim 8068 1 (Reference) © Oversize dimension of eylinder Model 1D. S00 0 64.519 mm, M-12 Feb to 284018 6 500 10 66 519 mn, e Beier so 281886 M-18,25 Hone to 12 ta 2:0 um max 606087 io 0 a60078 © Oversize piston and piston rings sa [ ose coartnta [ag se rae Singer foros ee eee - 18,25 M1826 oe osnnmbiy| testes | os oF[5] Cranksahft Crankshaft End Play 1, Set a dial indicator with its indicator tip touching the tend of the crankshaft 2, Measure the end play by moving the crankshaft to the front and rear. 3. If the play exceeds the allowable limit, replace the side bearing. 4. If the same size bearing is useless because of the crank: shaft journal wear, replace it with an oversize one refer: ‘ing to the table and the Figure, cae user er Feciory | 01510051 mm an Spectication | 0.0089 £0 0.092% in, ‘Allowable | 0.5 =m, fie 0.020 in, A (Reference) [48 © Oversize bearings: Oversize Besa ‘Cade Number | Marking 2mm | Sidebearing 162 | 15261.2395" | 020 Os Side bearing 202 _| 15261-23071 | 020 os damm | Side bearing 104 18261-29961 | 040 0s, Side vewri 204 | 15261-23981 | o40 os © Oversize dimensions of crankshaft: Dimension (Al 0.2 mm Oversize 23.20 t0 23.25 mm (0.9134 to 0.9154 in) (0.4 mm Oversize 23.40 t0 23,45 mm, (0.9213 to 0.9232 in) (8) 1.8 to 2.2 mm (0.071 to 0.087 in.) © Finely finish the contact face ta the bearing, to the higher than VUVV (0.48) Crankshaft Alignment 1. Support the crankshaft with V blocks on the surface plate {at both end journals 2, Set @ dial indicator with its indicator tip touching the “intermediate journal 3. Rotate the crankshaft on the V blocks and get the ec centrcity (half of the measurement) 4. If the eccentricity exceeds the allowable limit, replace the camshaft Factory 02m, centric ‘eciteation .0008 " ‘Aliowsbe 0.08 mm, Tie Boast,conneeis casein ci ken il Clearance between _Crankshaft_Journal Bearing 1 1, Measure the 1.0. of the crankshaft bearing 1 with an inside micrometer. 2. Measure the O.D. of the crankshaft front journal with an ‘outside micrometer. 3. Ifthe oil clearance exceeds the allowable limit, replace the crankshaft bearing 1 4, If the same size bearing is useless because of the crank: shaft journal wear, replace it with an undersize one refer ring to the table and the figure. @ IMPORTANT: ‘© Install the bearing using a replacing tool, so that its seam directs toward the exhaust side in the crankcase {See figure). Factory 0.034 190.108 mm coucesrance | tstication | 0.0004 19 00047 in 7 Allowsbie 0.20 mm imi 0.00794. Grankahatt Feewory "39.984 to 40 040 mmm Dearing ID, speciidetion | 1.87418 to 1.87638 n Crankshar Fecouy "39.934 to 39.950 mm journal ©.d. | specication | 1.57221 01.5728 m (Reference) © Undersize bearings: Taaaesee [Bearing Code Number [Marking ‘Damm | Bearing 102 | 158a%-23021 | 020 US Damm | Bearing 104 | 158ar23021 | ona Us © Undersize dimensions of crankshaft: Dimension {A) Oil hole § mm (0.2 in.) dia (8) 0.2 mm Undersize 39.734 to 39.750 mm (1.56433 to 1.56496 in.) 0.4 mm Undersize 39.534 to 39,550 mm (1.55646 to 1.55709 in.) (C) 1.8 t0 2.2 mm (0.071 t0 0.087 in.) R © Finely finish the contact face to the bearing, to higher ‘han VY (0.48). © Chamfer the oil hole with an oilstone.eat Oil_Clearance between Crankshaft _Journal_and 1. Put a strip of Plastigage lengthwise in the center of the journal, 2, Install the bearing cap and tighten the screws to the specified torque, and remove the bearing cap. 3, Measure the amount of the flattening with the scale and get the oil clearance. 4, If the oil clearance exceeds the allowable limit, replace the ‘crankshaft bearing, 5. If the same size bearing is useless because of the crank: shaft journal wear, replace it with an undersize one ¢e- forring to the table and the figure Tew ine “Torening trav | aeaingcap screw | 1300 Sighs =o aisles Fairy 2034 193.002 win Srctidaion | Gorse 00a in tenance B ‘Allowable 0.20 mm fn Sanh, | a Rear Binet | Factory SM SAAD am ayo 16. Spectgation | 1.73166 0 173968 n Caniana | “Poser 4934 42.950 5m B journal 0, specification, 1.72968 to 1.73032 in. Intermediate | Tangs] Foor Wane Bo am toms fa Ean | treet 655% crane —| Poco BIH wo 39950 Simsl Sb, | eson | Taper a era, (Reterence) © Undersizeb rc Teas Noner_[ Working o2mm | Berna 208 | tear zat | oa us sering3o | teen edt_| tao ug Gam | Bewne 304 | Ysa6i 20887] [Link] sang dsa_[ teearent_ | 3 08 © Undersize dimensions of crankshaft: Dimension (A) Oil hole 3 mm (0.12 in.) dia {B) 1.8 to 2.2 mm (0.071 to 0.087 in.) R (C) 0.2mm Undersize 39.734 to 39,750 mm (1.56433 to 1.56496 in.) (0.4 mm Undersize 39.534 to 39.550 mm (1.55646 to 1.55709 in.) (D) 0.2 mm Undersize 43.734 to 43.750 mm (1.72181 to 1.72248 in.) (0.4 mm Undersize 43.534 to 43,550 mm (1.71394 t0 1.71457 in.) © Finely finish the contact face to the bearing, to higher than VY (0.48)congo ours Oil Clearance between Crankpin_and. Connecting Rod Bearing 1. Put a strip of Plastigage lengthwise into the bearing cap. 2. Install the bearing cap noting that the gauge may not meet with the hole on the crank pin, tighten the screws to the specified torque, and remove the cap. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace the ‘connecting rod bearing. 5. If the same size bearing is useless because of the crank. shaft journal wear, replace it with an undersize one ferring to the table and the figure. NOTE: © Be sure not to mave the crankshaft while the bearing cap screws are tightened. 80 44710186 Nem ‘Tightening torque | Bearing cap screw) 1.5 20°19 4gtemn 108 ta 13.7 lbs Factory 0.019 10 0.081 mm a Secteation | 0.00075 to 0.00319 in Hi clesrance lovable | 0.20 mm fie 0.0073%m, Consecting ed | Factory 35,094 10 34040 mm Dearing .D, specication | 1.83895 to 1.34016 I "33,959 10 39.975 mm Crantoin 0.0. 53697 to 1.39760 n. (Reference) (© Undersize bearings: Undersize [Gearing | Coue Number | Morking 02mm Bearing 02 | 18841-22971 _ 020 US Ome Bearing oa | 15841-22981 | 040 US © Undersize dimensions of crankshaft: Dimension {A} 2.3 to 2.7 mm (0.091 to 0.106 in.) R {B) Ol! hole 4 mm (0.16 in.) dia {C) 0.2 mm Undersize 33.759 to 33.775 mm (1.32010 to 1.32973 in.) (0.4 mm Undersize 33.589 to 33.575 mm (1.32122 to 1.32185 in.) © Finely finish the contact face to the bearing, to higher than VV (0.45)ororR wy Crankshaft Sleove 1. Check the wear on the crankshatt sleeve 2. If the wear exceeds the allowable limit or when the engine coll leaks, replace the erankshatt sleeve. congue 81 Diam Whear of sae | Allows limit an [6] Piston and Connecting Rod Piston Pin Hole, 1. Messure the I. of piston pinhole lengthwise and width wise ofthe piston with a cylinder gauge. 2. If the measurement exceeds te allowable limit, replace the piston Factory 78.000 16 18.011 mm Sspectiztion | 0.70886 to 0.70810 in Piston pin hate 1.0, ‘Allowable | 18.05 mee Simi on68' meter. 2. Measure the ILD. of the piston pin bushing with a cylinder geuge. 3. If the clearance exceeds the allowable limit, replace the bushing 4. If the clearance still exceeds the allowable limit after placing the bushing, replace the piston pin. Ciearance Factory 0.076 16 0.039 mm between Speciteation | 0.00009 to 0.0054 in Piston pin ‘Allowable 0.15 mn andushing | fim 6.0088" Piston in Factory 18.025 to 18.080 mm bushing 10. | _speeitigasion | 0.70985 t00.79034 ston in Fociory 18.00% co 18.008 mm oo. spectizaion | 0.708700 0.70902 nconseosi owsrurs congFo96 82 Piston Ring Gap 1. Insert the piston ring into the cylinder and push down to the bottom, where the wear is least, using 2 piston head. 2. Measure the ring gap with a feeler gauge 3. If the ring gap exceeds the allowable limit, replace the ring. Beaond_ | Foctony 3 fing” | specification | 9. Piston Ring Factory 0.20 t0 0.40 mm ap citsing | s2etteation | 0:0079 100.0187 in ® [alowabie [1.2mm time voar'n Piston Ring Clearance. 1. Glean the rings and the ring grooves, and install each ring ints groove. 2. Measure the clearance between the ring and the groove with a fooler gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring, 4. If the clearance stil exceeds the allowable limit after re- placing the ring, replace the piston. | Sieond | Fectory 0.085 00112 mm Ling" | soecitization | 0.00338 to 0.00441 in, Piston ring | Foeiery (0.02 10 0.08 mm erence | ogg | sometiation | 0.0008 to 0.0024 i Allowable | 0.18 mm fie 910089 Connecting Rod Alignment 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod align: ‘ment tool (Code No : 07909-31661), 4, Put a gauge over the piston pin and move it agsinst the faceplate 5. If the gauge does not fit squarely against the faceplate, measure the space between the pin of the gauge and the faceplate 6. If the measurement exoveds the allowable limit, replace the connecting rod. . 085 mm Space between pia | 6.0020 in snd face ‘Allowable limit | (gauge pin span et 100 mm, sein)LUBRICATING SYSTEM CHECKING ones 83 Engine Oil Pressure 1, Remove the oil pressure switch and install the ail pressure adaptor and the oil pressure tester (Code No.: 07916- 32031}, Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed, I the oil pressure is less than the allowable limit, check and repair referring to the causes below. © Engne ol insuicient * oil fiter loge © Dirt invelie valve © Oil eller cloned «© Excesve ol learance © Oil pump detective Tanteingtoave | ox presuresnien | ietozs er moe thn 6 Pa aise | taxes | gon sows’ | seen | OF ig : 198 0481s masure feRaion | 204 tation? At rated 28 to 64 pst a 0.7 kgffem* Sos (The engine oil temperature at 00° 10 95°C, 194° to 203°) Oil Filter and Relief Valve 1. Drain the engine oi 2. Remove the oil filter and check it 3, Check the relief valve for dirt.SERVICING umes conse Pump Rotor and Lobe Clearance 1. Remove the oll pump from the erankcase. 2. Remove the screw and the port plate 3, Measure the clearances between the outer rotor and the housing, and between the outer and inner rotor with a feeler gauge. If the clearance exceeds the allowable limit, replace the pump. Factory | 0.1810 021mm CCesrance berween outer | s00etication | 0(0089 to 0.0083 in rotor snd housing ‘Allowable | 0.30 mm fie 0178. ‘Glasrance borween outer | Allowable | 0.25 mm Snd Inner rotor fa 088". Rotor End Clearance 1. Puta strip of Plastigage on the rotor and install the pump ‘to the crankcase with the port plate 2. Remove the pump and the port plate. 3. Measure the amount of the flattening with the scal {get the clearance. 4. If the clearance is not within the reference values, replace the pump, nd Factory | 0.08%00.13 mm a Speciation | 010031 to 0.008% in.COOLING SYSTEM | cHeckine covet eorgos 85 Belt Tension 1, Measure the deflection, depressing the belt halfway between the fan drive pulley and the AC dynamo pulley at 98 N (10 kof, 22 tbs) of force. 2. 1f the measurement is not the specified value, loosen the bolts and the nuts, and relocate the AC dynamo to adjust. approx 1mm Fan ett vension | Factory specification eas ‘Thermostat Valve Opening Temperature 1, Suspend the thermostat in the water by a string with its ‘end inserted between the valve and the seat 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3. Continue heating and read the temperature when the valve ‘opens approx. 6 mm (0.236 in.) 4. If the measurement is not within the specified values, re- place the thermostat. BOS wo BBC NITES" to 182.0°F) ‘beginning low 95" [203"F) st 6 mm (0.236 in) af opening Opening | Factory temperature | specification Radiator Water Tighteness 1. Fill the radiator with water to the specified amount and ‘warm up the engine. 2. Set a radiator tester and raise the water pressure to the 18.7 kPa (1.4 kgf/em?, 20 psi, 3. Check the radiator for water leaks. 4. For water leak from the pinhole, repair with the radiator ‘cement, and for other leaks, replace the radiator.conse DISASSEMBLY AND ASSEMBLY o1ograss 86 Radiator Cap Opening Pressure 1. Seta radiator tester on the radiator cap. 2. Apply the pressure of 88 kPa (0.9 kaf/em®, 13 psi) and measure the time for the pressure to fall to 59 kPa 0.6 kst/em?, 9 psi) 3, IF the measurement is less than the specified value, replace ‘the radiator cap. more thon 10 cand Feetory from 86 10 59 kPa speciation | tlrom 090058 kallem?, from 1310.9 psil Thermostat 1. Remove the thermostat cover. 2. Remove the thermostat (When reassembling) © Apply liquid gasket (Three Bond 1216 or equivalent) to the gasket, Water Pump 1. Remove the water pump from the gear case cover. 2, Remove the fan, the pulley and the flange (1). 3. Press out the water pump shaft (2) with the impeller (5) con it 4. Remove the impeller from the water shaft. 5. Remove the mechanical seal (4). (When reassembling) © Apply liquid gasket (Three Bond 1215 or equiv the gasket ‘© Replace the mechanical seal with the new one. (1) Water Pump Flange (2) Water Pump Shaft (3) Water Pump Body . (4) Mechanical Seal (5) ImpellerFUEL SYSTEM CHECKING AND ADJUSTMENT 87 [1] Injection Pump. Injection Timing 1. Remove the injection pipes 2. Set the speed control lever to the maximum fuel discharge 3. Turn the flywheel until the fuel fills up to the hole of the elivery valve holder. 4. Tum the flywheel further and stop turning when the fuel begins to flow over again, to check the injection timing 5. If the "FI" mark does not align with the punch mark on the rear plate, add or remove the shim (2) to adjust it (Reference) © 0.026 to 0.035 rad, (1.5° to 2.0°) at flywheel (0.16 mm {0.0088 in.) of shim (1) Injection Puma (2) ShimPump Element Fuel Tightness 1, Install the pressure tester (See page $51) to the fuel in jection pump. 2, With the speed control fever at the maximum position of ‘the fuel injection, rotate the flywheel to raise the fuel pressure to 39.23 MPa (400 kgf/cm”, 5689 psi). 3. Measure the falling time of the fuel pressure from 39.23 to 34.32 MPa (from 400 to 350 kgf/cm?, trom 5689 to 4978 psi. 4, Ifthe measurement is less than the allowable limit, replace the pump element or the injection pump assembly. Factory specification | 60 seconds or more esr aig tie | aCe ae 30 recone @ IMPORTAN © After replacing the pump element, adjust the amount of the fuel injection on the specified test bench, (Reference) © Test Bench: Code No. 105760-0010 (50 Hz) / 1057600020 (60 H2) [DIESEL KIKI CO. LTD] ‘¢_ Test Conditions: adi No. 10578-4760 Privieg Stand | [DIESEL KIKI CO. LTO! oi Nomis ‘owi2s012T. ‘Opening sresure | 13.77 MPa, 120 kaflom™, 1707 pa ‘mm din = 2 mm dia, x 600 mm long, 8.34'n din 0.08 in dia. 223.82 n, fang 1A) 0.12 red 77) 1B) 14mm (0.55 in.) [C) 30mm (1.18 in.) (0) 3mm (0.12 in.) (E)_ 15mm (0.59 in.) (F} 18mm (0.71 in) (G) 12mm (0.47 in.) 88 ual feed pressure [4 KPa, 0,5 kglom®. 7 ps Tes fuel Divse fel No.2-D ee 1.85 to 1.95 mm, 00728 to 0 0768 in rewple (oat vie? ‘Gamarafle | [ee figure © Data for Adjustment: emai amon a ‘Gantrol rack Uirom sop position! 77 to 1 B3ee/t005, 0.9718 to D078, 5 (8008 Tess than O1ee/100e 45mm.017 | 1800%pm 1.0 mm,0.039 in. | 1800 rpm (0,006. 40-/003Delivery Valves Fuel Tightness 1. Install the pressure tester (See page S61) to the fuel in. jection pump. 2. With the speed control lever at the maximum position of the fuel injection, rotate the flywheel to raise the fuel pressure to 21.57 MPz (220 kgf/em®, 3129 psi). 3. Measure the falling time of the fuel pressure from 21.87 to 20.59 MPa (from 220 to 210 kgt/em?, from 3129 t0 2987 psi. 4. IF the measurement is less than the allowable limit, replace the pump element or the injection pump assembly. Factory specifieation [10 second & mare eons, Pressure felling time ‘Allowable limit Sseconds [2] Injection Nozzle & CAUTION © ‘Never to contact with spraying diesel fuel under pressure, Which can have sufficient force to penetrate the skin, causing serious personal injury, © Be sure nobody isin the direction of the spray. Fuel Injection Pressure 1. Set the injection nozzle to the nozzle tester. 2. Measure the injection pressure, 3. If the measurement is not within the specified values, “Teplace the adjusting washer in the nozzle holder to adjust it, Fuel injection | Factory Tagareda ai MPs vessure wafitation | 1400 150 katiem* p ee 1981 102133 p8 (Reference) © Adjusting wesher: ‘Assombly Code No. 15841-98101 {includes 43 sizes below! Adjusting washer | Thieknessime lin) | Code Number |] aiusting washer | Thickness om in (Code Number ‘500 10.800 (0.03843) Teer 98607 1200 7300 1ODA7RAY 16487 S862 025, 0.925 10.03642) 15481-96511 1225 1.225 (0.04820), 18481-98631 0850 (0.950 {0.03740} 15481-98621 1250 1250 (o.o4921) 15451-98681 0075 (0975 (0.03839) 15481-98531 1275 1.275 (0.08020) 15487-98651 1000 1.900 10.03997), 15481-98541 1300 1300 (0.05118) 15481-99651 1025 1.026 10.0405), 15481-90551 1325 1.325 (0.08217) 18481-98672 1050 1.050 (0.04194), 15481-98561 1360 41350 (0.08315), 15481-99081 1075 1.075 (a.0a2321 15481-98571 1375 1378 10.05413), 15481-88691 1100 4.100 (0.04931), 18481-98581 +400 1.400 10:055121 15481-9870 nas 1.25 (0.044291 15481-99591 1425 1.425 (0.08610), 18481-98711 1150 1.380 (0.04828 15483-98601 1450 1.450 1.057091 15481-98721 1175 1.175 (0.046261 15481-99611 1475 1.475 (0.058071 15481-96731