Komatsu Engine Serie SA12V140Z 1 PDF

Shop Manual
CEBM002602
SA12V140Z-1 SERIES DIESEL ENGINE
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
August 2000
Copyright 2000 Komatsu DataKom Publishing Corporation
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FOREWORD
CONTENTS
CONTENTS
01 11 12 13 14 15 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 11-1 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 12-1 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13-1 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . 15-1
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PRODUCT PUBLICATIONS INFORMATION

Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s). DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application PARTS BOOK - MICROFICHE: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application OPERATION AND MAINTENANCE MANUAL: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002602 SAFETY MANUAL
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS). If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.
pubinfok.fm 10/12/99
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
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FOREWORD
The affected pages are indicated by using the following marks. It is requested that necessary actions be taken to these pages according to the table below. Mark G ( ) Mark Page 00-1 00-2 G G 00-2-1 00-2-2 00-2-3 00-2-4 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 Rev ! " ! ! ! ! " " " " " " " " " " " " " " " " 11-1 11-2 11-3 11-4 11-5 11-6 11-7 11-8 11-9 11-10 11-11 11-12 11-13 11-14 11-15 11-16 01-1 01-2 01-3 01-4 01-5 01-6 11-17 11-18 11-19 11-20 11-21 11-22 12-1 12-2 " " Mark Page 01-7 01-8 01-9 01-10 01-11 01-12 Rev Mark Indication New page to be added Page to be replaced Page to be deleted Rev Mark Action Add Replace Discard Page 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 12-11 12-12 12-13 12-14 12-15 12-16 12-17 12-18 12-19 12-20 12-21 12-22 12-23 12-24 12-25 12-26 12-27 12-28 12-29 12-30 12-31 Rev " " " " " " " " " " " " " " " " " " " " " " " " " " " " "
Page 11-23 11-24 11-25 11-26 11-27 11-28 11-29 11-30 11-31 11-32 11-33 11-34 11-35 11-36 11-37 11-38 11-39 11-40 11-41 11-42 11-43 11-44 11-45 11-46 11-47 11-48
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FOREWORD
Mark Page 12-32 12-33 12-34 12-35 12-36 12-37 12-38 12-39 12-40 Rev " " " " " " " " " Mark Page 13-24 13-25 13-26 13-27 13-28 13-29 13-30 13-31 13-32 13-33 13-1 13-2 13-3 13-4 13-5 13-6 13-7 13-8 13-9 13-10 13-11 13-12 13-13 13-14 13-15 13-16 13-17 13-18 13-19 13-20 13-21 13-22 13-23 " " " " " " " " " " " " " " " " " " " " " " " 13-34 13-35 13-36 13-37 13-38 13-39 13-40 13-41 13-42 13-43 13-44 13-45 13-46 13-47 13-48 13-49 13-50 13-51 13-52 13-53 13-54 13-55 13-56 Rev " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " 14-1 14-2 14-3 14-4 14-5 14-6 14-7 14-8 14-9 14-10 14-11 14-12 Mark Page 13-57 13-58 13-59 13-60 13-61 13-62 13-63 13-64 13-65 13-66 13-67 13-68 13-69 13-70 13-71 13-72 13-73 13-74 13-75 13-76 Rev " " " " " " " " " " " " " " " " " " " " G G G G G G G G G G G G G G G G 15-1 15-2 15-3 15-4 15-5 15-6 15-7 15-8 15-9 15-10 15-11 15-12 15-13 15-14 15-15 15-16 ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Mark Page 14-13 14-14 14-15 14-16 14-17 14-18 14-19 14-20 14-21 14-22 14-23 14-24 14-25 14-26 14-27 14-28 Rev
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FOREWORD
Mark G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G Page 15-17 15-18 15-19 15-20 15-21 15-22 15-23 15-24 15-25 15-26 15-27 15-28 15-29 15-30 15-31 15-32 15-33 15-34 15-35 15-36 15-37 15-38 15-39 15-40 15-41 15-42 15-43 15-44 15-45 15-46 15-47 15-48 15-49 Rev ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Mark G Page 15-50 Rev ! Mark Page Rev Mark Page Rev
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FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
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FOREWORD
SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
8.
9.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
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FOREWORD
14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
SAFETY
24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
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FOREWORD
GENERAL
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
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FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Engine volume: Electrical volume: Attachment volume: Issued for every machine model Issued for each engine series Each issued as one to cover all models Each issued as one to cover all models
REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
SYMBOLS
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol Item Safety Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
Caution
FILING METHOD
1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5
Weight
Places that require special Tightening attention for tightening torque torque during assembly. Coat Places to be coated with adhesives and lubricants etc.
Places where oil, water or Oil, water fuel must be added, and the capacity. Drain Places where oil or water must be drained, and quantity to be drained.
REVISED EDITION MARK

When a manual is revised, an edition mark (!"#) is recorded on the bottom outside corner of the pages.
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FOREWORD
HOISTING INSTRUCTIONS
dent can result. Hooks have maximum strength at the middle portion.
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1. Check for removal of all bolts fastening the part to the relative parts. 2. Check for existence of another part causing interface with the part to be removed.
3.
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: 4. Wire ropes (Standard Z or S twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 # Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120 hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious acci-
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FOREWORD
COATING MATERIALS
COATING MATERIALS
# The recommended coating materials prescribed in the shop manuals are listed below. test Category Code LT-1A Part No. 790-129-9030 Quantity 150 g Container Tube LT-1B 790-129-9050 20 g (2 pes.) Polyethylene container Main applications, features Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and nonmetal. Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
LT-2
09940-00030
50 g
Polyethylene container
LT-3 Adhesives
790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120
Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g
Can
Used as adhesive or sealant for metal, glass or plastic.
LT-4 Holtz MH 705 Three bond 1735
Polyethylene container Tube
Used as sealant for machined holes. Used as heat-resisting sealant for repairing engine. Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals. Features: Resistance to heat, chemicals Used at joint portions subject to high temperature. Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
179-129-9140
2g
Aronalpha 201
790-129-9130
50 g
Loctite 648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
Tube
Gasket sealant LG-3 790-129-9070 1 kg Can
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FOREWORD
Category Code Part No. Quantity Container LG-4 790-129-9020 200 g Tube Polyethylene container LG-6 09940-00011 250 g Tube LG-7 09920-00150 150 g Tube
COATING MATERIALS
Main applications, features Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. Used as heat-resisting sealant for repairing engines. Used as lubricant for sliding parts (to prevent squeaking). Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
LG-5
790-129-9080
1 kg
Gasket sealant
Three bond 1211 LM-G Molybdenum disulphide lubricant
790-129-9090
100 g
Tube
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
General purpose type
Grease
SYG2-400CA SYG2-350CA SYG2-400CA-A G2-CA SYG2-160CA SYG2160CNCA Molybdenum disulphide lubricant
Various Various
Used for normal temperature, light load bearing at places in contact with water or steam.
SYG2-400M
400 g (10 per case)
Belows type
Used for places with heavy load.
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FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 13.2 1.4 31.4 2.9 65.7 6.8 112 9.8 177 19 279 29 383 39 549 58 745 78 927 98 1320 140 1720 190 2210 240 2750 290 3280 340 kgm 1.35 0.15 3.20 0.3 6.70 0.7 11.5 1.0 18 2.0 28.5 3 39 4 56 6 76 8 94.5 10 135 15 175 20 225 25 280 30 335 35
Thread diameter of bolt mm 6 8 10 12
Width across flats mm 10 13 14 27 Nm 7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85 kgm 0.8 0.2 1.9 0.5 4.1 0.6 8.4 0.8
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FOREWORD
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts. Nominal No. 02 03 04 05 06 10 12 14 Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49 Tightening torque kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts. Thread diameter mm 10 12 16 Width across flat mm 14 17 22 Nm 65.7 6.8 112 9.8 279 29 Tightening torque kgm 6.7 0.7 11.5 1 28.5 3
TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.
Thread diameter mm 14 18 22 24 30 33 36 42
Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6
Tightening torque kgm 2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
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FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Nominal number 0.85 2 5 15 40 60 100 Number of Dia. Of strands strand (mm) 11 26 65 84 85 127 217 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) 2.4 3.1 4.6 7.0 11.4 13.6 17.6 Current rating (A) 12 20 37 59 135 178 230 Applicable circuit Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Circuits Priority Classification Primary Code Color Code 2 Color Code 3 Color Auxiliary Code Color Code 5 Color Code 6 Color 1 Charging W White WR White & Red WB White & Black WL White & Blue WG White & Green Ground B Black Starting B Black BW Black & White BY Black & Yellow BR Black & Red Lighting R Red RW Red & White RB Red & Black RY Red & Yellow RG Red & Green RL Red & Blue Instrument Y Yellow YR Yellow & Red YB Yellow & Black YG Yellow & Green YL Yellow & Blue YW Yellow & White Signal G Green GW Green & White GR Green & Red GY Green & Yellow GB Green & Black GL Green & Blue Other L Blue LW Blue & White LR Blue & Red LY Blue & Yellow LB Blue & Black
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FOREWORD
CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (a) Locate the number 50 in the vertical column at the left side, take this as !, then draw a horizontal line from !. (b) Locate the number 5 in the row across the top, take this as ", then draw a perpendicular line down from ". (c) Take the point where the two lines cross as #. This point # gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. " Millimeters to inches 0 0 10 20 30 40 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 # ! 50 60 70 80 90 1.969 2.362 2.756 3.150 3.543 2.008 2.402 2.795 3.189 3.583 2.047 2.441 2.835 3.228 3.622 2.087 2.480 2.874 3.268 3.661 2.126 2.520 2.913 3.307 3.701 2.165 2.559 2.953 3.346 3.740 2.205 2.598 2.992 3.386 3.780 2.244 2.638 3.032 3.425 3.819 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850 1 mm = 0.03937 in 8 0.315 0.709 1.102 1.496 1.890 9 0.354 0.748 1.142 1.536 1.929
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FOREWORD
CONVERSION TABLES
Millimeters to Inches 0 0 10 20 30 40 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850
1 mm = 0.03937 in 8 0.315 0.709 1.102 1.496 1.890 9 0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to Pound 0 0 10 20 30 40 0 22.05 44.09 66.14 88.18 1 2.20 24.25 46.30 68.34 90.39 2 4.41 26.46 48.50 70.55 92.59 3 6.61 28.66 50.71 72.75 94.80 4 8.82 30.86 51.91 74.96 97.00 5 11.02 33.07 55.12 77.16 99.21 6 13.23 35.27 57.32 79.37 101.41 7 15.43 37.48 59.53 81.57 103.62
1 kg = 2.2046 lb 8 17.64 39.68 61.73 83.78 105.82 9 19.84 41.89 63.93 85.98 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
00-14 !
FOREWORD
CONVERSION TABLES
Liter to U.S. Gallon 0 0 10 20 30 40 0 2.642 5.283 7.925 10.567 1 0.264 2.906 5.548 8.189 10.831 2 0.528 3.170 5.812 8.454 11.095 3 0.793 3.434 6.076 8.718 11.359 4 1.057 3.698 6.340 8.982 11.624 5 1.321 3.963 6.604 9.246 11.888 6 1.585 4.227 6.869 9.510 12.152 7
1 L = 0.2642 U.S. Gal 8 2.113 4.755 7.397 10.039 12.680 9 2.378 5.019 7.661 10.303 12.944
1.849 4.491 7.133 9.774 12.416
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 0 0 10 20 30 40 0 2.200 4.399 6.599 8.799 1 0.220 2.420 4.619 6.819 9.019 2 0.440 2.640 4.839 7.039 9.239 3 0.660 2.860 5.059 7.259 9.459 4 0.880 3.080 5.279 7.479 9.679 5 1.100 3.300 5.499 7.699 9.899 6 1.320 3.520 5.719 7.919 10.119
1 L = 0.21997 U.K. Gal 7 1.540 3.740 5.939 8.139 10.339 8 1.760 3.950 6.159 8.359 10.559 9 1.980 4.179 6.379 8.579 10.778
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
00-15 !
FOREWORD
CONVERSION TABLES
kgm to ft. lb. 0 0 10 20 30 40 0 72.3 144.7 217.0 289.3 1 7.2 79.6 151.9 224.2 296.6 2 14.5 86.8 159.1 231.5 303.8 3 21.7 94.0 166.4 238.7 311.0 4 28.9 101.3 173.6 245.9 318.3 5 36.2 108.5 180.8 253.2 325.5 6 43.4 115.7 188.1 260.4 332.7 7 50.6 123.0 195.3 267.6 340.0
1 kgm = 7.233 ft. lb. 8 57.9 130.2 202.5 274.9 347.2 9 65.1 137.4 209.8 282.1 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.5
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.2
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0
1135.6 1207.9 1280.1
1142.8 1215.1 1287.5
1150.0 1222.4 1294.7 1367.0 1439.4
1345.3 1352.63 1359.8 1417.7 1424.9 1432.1
00-16 !
FOREWORD
CONVERSION TABLES
kg/cm 2 to lb/in2 0 0 10 20 30 40 0 142.2 284.5 426.7 568.9 1 14.2 156.5 298.7 440.9 583.2 2 28.4 170.7 312.9 455.1 597.4 3 42.7 184.9 327.1 469.4 611.6 4 56.9 199.1 341.4 483.6 625.8 5 71.1 213.4 355.6 497.8 640.1 6 85.3 227.6 369.8 512.0 654.3
1 kg/cm 2 = 14.2233lb/in2 7 99.6 241.8 384.0 526.3 668.5 8 113.8 256.0 398.3 540.5 682.7 9 128.0 270.2 412.5 554.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1138 1280
725.4 867.6 1010 1152 1294
739.6 881.8 1024 1166 1309
753.8 896.1 1038 1181 1323
768.1 910.3 1053 1195 1337
782.3 924.5 1067 1209 1351
796.5 938.7 1081 1223 1365
810.7 953.0 1095 1237 1380
825.0 967.2 1109 1252 1394
839.2 981.4 1124 1266 1408
100 110 120 130 140
1422 1565 1707 1849 1991
1437 1579 1721 1863 2005
1451 1593 1735 1877 2034
1465 1607 1749 1892 2048
1479 1621 1764 1906 2062
1493 1636 1778 1920 2077
1508 1650 1792 19324 2091
1522 1664 1806 1949 2105
1536 1678 1821 1963 2119
1550 1693 1835 1977
150 160 170 180 190
2134 2276 2418 2560 2702
2148 2290 2432 2574 2717
2162 2304 2446 2589 2731
2176 2318 2460 2603 2745
2190 2333 2475 2617 2759
2205 2347 2489 2631 2773
2219 2361 2503 2646 2788
2233 2375 2518 2660 2802
2247 2389 2532 2674 2816
2262 2404 2546 2688 2830
200 210 220 230 240
2845 2987 3129 3271 3414
2859 3001 3143 3286 3428
2873 3015 3158 3300 3442
2887 3030 3172 3314 3456
2901 3044 3186 3328 3470
2916 3058 3200 3343 3485
2930 3072 3214 3357 3499
2944 3086 3229 3371 3513
2958 3101 3243 3385 3527
2973 3115 3257 3399 3542
00-17 !
FOREWORD
CONVERSION TABLES
Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. C F C F C F C F -40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8 -37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6 -34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4 -31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2 -28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
00-18 !
PRODUCT PUBLICATIONS INFORMATION

Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s). DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application PARTS BOOK - MICROFICHE: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application OPERATION AND MAINTENANCE MANUAL: Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002601 SAFETY MANUAL
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS). If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.
pubinfok.fm 10/12/99
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM AND RETURN TO

<
DataKom Publishing Corporation

440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME
SHIP TO
<
ATTN. STREET ADDRESS
PURCHASE ORDER NO.
ORDER DATE
TYPE or PRINT ONLY
<
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK QTY. PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
SERIAL NUMBER
KDC91D 022597
CURRENT PRICES WILL BE CHARGED
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 VIEW FROM LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 VIEW FROM RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 VIEW FROM FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 VIEW FROM REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 VIEW FROM TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8 ENGINE PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 WA800-2LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 WA900-1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10 330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
01-1
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Engine model Applicable machine Number of cylinder Bore x Stroke Total piston displacement Firing order Overall length Dimensions Overall width Overall height (excluding exhaust pipe) Flywheel horsepower Gross horsepower Performance Maximum torque, gross Maximum torque, net mm mm mm mm cc WA800-2LE SA12V140Z-1 WA900-1LC 12 140 x 165 30,480 R1 LI R5 L5 R3 L3 R6 L6 R2 L2 R4 L4 1887.7 1320.1 1658 1887.7 1320.1 1658 1887.7 1320.1 1658 330M
kW(HP)/rpm kW(HP)/rpm Nm(lb/ft)/rpm Nm(lb/ft)/rpm
588(789)/2,000 621(833)/2,000
636(853)/2,000 669(897)/2,000
753(1010)/2,000 783(1050)/2,000
3806(2807)/1,400 4100(3024)/1,300 4628(3414)/1,400 3279(2750)/1,400 4034(2975)/1,300 4560(3363)/1,400
High idling speed Low idling speed
rpm rpm
2,25050
+ 50 650 0
2,25050
+ 50 650 0
2,35050 650
+ 50 0
Minimum fuel consumption at full g/kWh(lb/HPh) power Dry weight Fuel injection pump Governor Lubricating oil amount (total system) (minimum required) Coolant amount (engine only) (total system) Alternator Starting motor Battery Turbocharger Air compressor kg
194 (.319) 3,271
193 (.317) 3,271 BOSCH RP 39 BOSCH RE 33
193 (.317) 3,271
l
(US Gal)
l
(US Gal)
148(39.1) 132(34.9) 85(22.4) 310(81.9) 24 V, 75 A
148(39.1) 132(34.9) 85(22.4) 310(81.9) 24 V, 75 A
148(39.1) 132(34.9) 85(22.4) 228(60.2) 24 V, 75 A
24 V, 11kW 50 MT 24 V, 11kW, 50 MT 24 V, 11kW, 50 MT x1 x1 x1 12V 200 Ah x 4 12 V 200 Ah x 4 12 V 200 Ah x 4 H x 60 x 2 Holset TC676 H x 60 x 2 Holset TC676 H x 60 x 2 Holset TC676
01-2
GENERAL
GENERAL ASSEMBLY DRAWING

VIEW FROM LEFT SIDE
01-3
GENERAL
VIEW FROM RIGHT SIDE
01-4
GENERAL
VIEW FROM FRONT
01-5
GENERAL
VIEW FROM REAR
01-6
GENERAL
VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)
01-7
GENERAL
VIEW FROM TOP
01-8
GENERAL
ENGINE PERFORMANCE CURVE

WA800-2LC
Curves above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions of 100 kPa (29.61 in. Hg) barometric pressure [91 m (300 ft.) altitude], 25C (77F) inlet air temperature, and 1kPa (0.30 in. Hg) water vapor pressure with No. 2 diesel fuel. The engine may be operated without changing the fuel setting up to 3048 m (10,000 ft.) altitude. For sustained operation at high altitudes, the fuel rate of the engine will be adjusted to limit performance by 4% per 305 m (1,000 ft.) above 3048 m (10,000 ft.) altitude and 2% per 11C above 38C (1% per 10F above 100F).
01-9
GENERAL
WA900-1LC
01-10
GENERAL
330M
01-11
11
STRUCTURE AND FUNCTION
GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Rocker arm housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Fuel injection nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Piston cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Liner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 MAIN REVOLVING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Front seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16 VALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18 FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19 Rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19 LUBRICATING OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20 Piston cooling, connecting rod, overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21 Front gear train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 FULL FLOW LUBRICATING OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24 LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26 OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27 Regulator valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27 LUBRICATING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 LUBRICATING OIL BYPASS FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29 LUBRICATING OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31
11-1
TABLE OF CONTENTS
FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 RIGHT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33 LEFT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37 THERMOSTAT HOUSING FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38 COOLING FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40 COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41 CORROSION RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42 ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44 Unloader valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 ALTERNATOR WITH REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47 ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11-2
GENERAL STRUCTURE
GENERAL STRUCTURE
1. 2. 3. 4. 5. 6. 7. 8.
Front cover Cylinder block Cylinder liner Rocker lever housing Cylinder head cover Exhaust valve Intake valve Piston
9. 10. 11. 12. 13. 14. 15. 16.
Turbocharger Cam follower Camshaft Flywheel Flywheel housing Main bearing cap Crankshaft Oil pan
17. 18. 19. 20. 21. 22. 23.
Connecting rod Connecting rod cap Oil strainer Lubricating oil pump Crankshaft gear Vibration damper Crankshaft pulley
11-3
GENERAL STRUCTURE
24. 25. 26. 27. 28. 29.
Cylinder head Intake manifold Electrical intake air heater Lubricating oil cooler Intake connector pipe Rocker lever
30. 31. 32. 33.
Aftercooler Nozzle holder Push rod Piston cooling nozzle
11-4
INTAKE AND EXHAUST SYSTEM

INTAKE SYSTEM
1. 2. 3. 4. 5. A.
Intake manifold (Right bank) Electrical intake air heater Aftercooler cover (Right bank) Aftercooler cover (Left bank) Intake manifold (Left bank) Air intake
11-5
EXHAUST SYSTEM
1. 2. 3. 4.
Exhaust manifold (Left bank) Exhaust manifold (Right bank) Turbocharger (Right bank) Turbocharger (Left bank)
11-6
TURBOCHARGER
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
V band clamp Turbine Housing Turbocharger heat shield Drive screw Lock nut Split ring seal Split ring seal Dataplate Regular hexagon nut Thrust collar Oil slinger Oil seal plate V band clamp Oil baffle
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Shaft and wheel Turbo thrust bearing Turbo compressor impeller Compressor housing Turbo bearing housing Roll pin Retaining pin Retaining ring Turbocharger bearing Retaining ring O-ring seal Oil control sleeve
11-7
AFTERCOOLER
1. Aftercooler cover 2. Aftercooler core 3. Intake manifold H The diagram above shows the right bank.
A. B. C. D.
Intake air inlet (from turbocharger) Intake air outlet (to cylinder head) Water inlet (to cylinder head) Water outlet (to thermostat)
11-8
ENGINE BODY
ENGINE BODY
CYLINDER HEAD
1. 2. 3. 4. 5. 6.
Fuel spill tube Air vent tube Rocker lever housing Cylinder head Head cover Nozzle holder retainer
7. Fuel injection nozzle holder assembly 8. Head cover mounting bolt 9. Cylinder head mounting bolt 10. Fuel inlet connector
B. C. d. e.
Intake Exhaust To fuel tank To radiator
11-9
ENGINE BODY
Specifications
Direct fuel injection type 4-valve Divided type (One cylinder head for one cylinder) Injection nozzle and fuel inlet connector assembled in rocker arm housing and cylinder head Cylinder head bolt: Tighten bolts by the plastic range turning angle method
Valve seat
Press fitted insert for intake and exhaust
Rocker arm housing cover

Floating type seal
Fuel injection nozzle

Mount: Dry type (without sleeve)
11-10
ENGINE BODY
CYLINDER BLOCK
1. 2. 3. 4. 5. 6.
Cylinder block Cylinder liner Crevice seal Liner seal Liner seal Main bearing cap bolt
7. 8. 9. 10.
Main bearing cap Main bearing Piston cooling nozzle Thrust bearing
11-11
ENGINE BODY
Specifications
Crankshaft: 7 bearings Camshaft: 7 bearings Main bearing cap bolt: Tightening bolts by the plastic range turning angle method. With piston cooling nozzle
Cylinder liner
Wet type Treatment: Plateau honing finish Tuffride treated TOP:Crevice seal (Ethylene propylene rubber) MIDDLE: O-ring (Ethylene propylene rubber) BOTTOM: O-ring (Silicon rubber)
Liner seal

Piston cooling
11-12
ENGINE BODY
MAIN REVOLVING SYSTEM
1. 2. 3. 4. 5. 6. 7. 8.
Piston Piston pin Connecting rod bushing Top ring Second ring Oil ring Crankshaft pulley Vibration damper
9. 10. 11. 12. 13. 14.
Crankshaft Crankshaft gear (No. of teeth: 45) Connecting rod bearing Connecting rod cap Connecting rod Connection rod cap bolt
11-13
ENGINE BODY
Crankshaft
Stamp forging Journal and filet portion: Induction hardening Top ring Second ring Oil ring
Piston
Ductile cast iron (FCD) Both faces keystone. Barrel face. Hard chrome plating. Keystone inner cut. Tapered face. Hard chrome plating. M-shape steel ring. Hard chrome plating with coil expander.
Connecting rod
Stamp forging: With lubrication hole
11-14
ENGINE BODY
TIMING GEAR
H 1. 2. 3. 4. 5. 6. 7. 8. 9.
Circled numbers indicate spur gear. Other gears are helical. Accessory drive gear (No. of teeth: 22) R-Sub-idler gear (No. of teeth: 50) R-Idler gear (large) (No. of teeth: 75) R-Camshaft gear (No. of teeth: 60) Idler gear (small) (No. of teeth: 45) L-Camshaft gear (No. of teeth: 60) L-Idler gear (large) (No. of teeth: 75) L-Sub-idler gear (No. of teeth: 50) L-Fuel injection pump drive gear (No. of teeth: 60) 10. 11. 12. 13. 14. 15. Air compressor drive gear (No. of teeth: 30) Crankshaft gear (No. of teeth: 45) Oil pump drive gear (No. of teeth: 27) Water pump drive gear (No. of teeth: 25) R-Fuel injection pump drive gear (No. of teeth: 60) Front seal
R, L, A, B, B1, B2, C, D: Match marks for timing gears
11-15
ENGINE BODY
Front seal
Single lip with dust seal
11-16
ENGINE BODY
VALVE SYSTEM
11-17
ENGINE BODY
1. Camshaft gear (No. of teeth: 48) 2. Thrust plate 3. Camshaft 4. Cam follower 5. Cam roller 6. Rocker arm shaft 7. Cam follower shaft 8. Rocker arm adjustment screw 9. Lock nut 10. Push rod 11. Rocker arm 12. Crosshead adjustment screw
13. 14. 15. 16. 17. 18. 19.
Locknut Crosshead Valve guide Exhaust valve Valve spring (outer) Valve spring (inner) Valve spring seat (lower) 20. Valve spring seat (upper) 21. Intake valve 22. Cam roller pin
Valve timing
Camshaft
Drawn steel bar Journal and cam portion: Induction hardening
11-18
ENGINE BODY
FLYWHEEL AND FLYWHEEL HOUSING
1. 2. 3. 4. A. B.
Ring gear (No. of teeth: 142) Flywheel Flywheel housing Crankshaft rear seal Timing sensor pickup port RPM sensor port
Rear seal
Dry type: Single lip oil seal Wet type: Double lip oil seal
11-19
LUBRICATING OIL SYSTEM
1. 2. 3. 4. 5. 6. 7.
Full flow filter head Full flow filter(s) Lubricating oil pump High pressure regulator Suction tube Lubricating oil cooler Low pressure and lubricating oil cooler bypass regulator 8. Signal line 9. Cold oil flow 10. Hot oil flow
11. 12. 13. 14. 15. 16. A. B. C. D.
Bypass filters Oil cooler bypass valve Bypass valve spring Regulator valve Regulator valve spring Valve body From main gallery (signal line) From oil cooler To oil pan To oil filter
11-20
Piston cooling, connecting rod, overhead

1. 2. 3. 4. 5. 6. 7. Crankshaft oil drillings Main oil drilling Connecting rod wrist pin oil supply Upper rocker lever oil supply Piston cooling oil drilling Cam follower oil drilling Piston cooling nozzle
11-21
Front gear train

1. 2. 3. 4. Right bank (large) idler gear Right bank (small) idler gear Piston cooling oil supply drillings Left bank (large) idler gear
11-22
Turbocharger
1. Piston cooling oil supply drilling 2. Turbocharger oil supply 3. Turbocharger oil drain
11-23
FULL FLOW LUBRICATING OIL FILTERS
1. Oil supply 2. Oil drain 3. Full flow filters
11-24
LUBRICATING OIL PUMP
1. 2. 3. 4. 5.
Pump body Pump drive (No. of teeth: 27) Drive gear Driven gear Pump cover
Specifications
Type: Gear pump Pump speed: Engine speed x 1.67
a. Suction (From oil pan) b. Discharge (To oil cooler)
11-25
MAIN RELIEF VALVE
1. Valve spring 2. Main relief valve 3. Valve body
Specifications
Cracking pressure: 8.5 0.5 kg/cm2 121 7 psi
11-26
OIL COOLER BYPASS VALVE

1. 2. 3. 4. 5. A. B. C. D. Oil cooler bypass valve Bypass valve spring Regulator valve Regulator valve spring Valve body From main gallery From oil cooler To oil pan To oil filter
Specifications
Cracking pressure (differential pressure) 2.3 0.2 kg/cm2 3.3 2.5 psi
Regulator valve
Cracking pressure: 4.1 0.5 kg/cm2 58 7.1 psi
11-27
LUBRICATING OIL FILTER
1. 2. 3. 4.
Filter head Filter connector Cover Cartridge
A. Oil inlet port B. Oil outlet port
Specifications
Filtering area: 3.6 m2 38.75 sq.ft.
Safety valve
Cracking pressure: 2.0 0.2 kg/cm2 28.44 2.8 psi
11-28
LUBRICATING OIL BYPASS FILTER
1. Filter head 2. Cartridge A. Oil inlet port B. Oil outlet port
Specifications
Filtering area: 2.8 m2 [30.1 sq. ft.]
11-29
LUBRICATING OIL COOLER
1. Oil cooler cover 2. Cooler element: 12 cores a. Oil inlet or outlet b. Oil inlet or outlet c. Cooling water
Specifications
Effective area: 0.986 m2 10.61 sq. ft.
11-30
FUEL SYSTEM
FUEL SYSTEM
FLOW DIAGRAM
1. 2. 3. 4. 5. 6.
Fuel tank Prefilter Fuel connection block Fuel lift pump Fuel filter EHAB
7. 8. 9. A. B. C.
Fuel injection pump Fuel injection nozzle Electronic governor Fuel supply (From tank) Fuel overflow valve Fuel gallery outlet
D. E. F. G.
Fuel gallery inlet Fuel out to lift pump Fuel in from fuel filter Fuel drain (to tank)
11-31
FUEL SYSTEM
FUEL INJECTION PUMP
Specifications
Maker:BOSCH Type:RP39
11-32
FUEL SYSTEM
RIGHT BANK PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9.
Fuel injection pipe (No. 6 cylinder) Fuel injection pipe (No. 5 cylinder) Fuel injection pipe (No. 4 cylinder) Fuel injection pipe (No. 3 cylinder) Fuel spill tube Fuel injection pipe (No. 2 cylinder) Fuel injection pipe (No. 1 cylinder) Pump drive gear (No. of teeth: 60) Pump drive shaft
10. 11. 12. 13. 14. 15. 16. 17.
Housing Coupling Air bleed plug Oil outlet pipe Fuel injection pump Adapter Feed pump Emergency stop valve
11-33
FUEL SYSTEM
LEFT BANK PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Fuel injection pipe (No. 1 cylinder) Fuel injection pipe (No. 2 cylinder) Fuel injection pipe (No. 3 cylinder) Fuel spill tube Fuel injection pipe (No. 4 cylinder) Fuel injection pipe (No. 5 cylinder) Fuel injection pipe (No. 6 cylinder) Emergency stop valve Air bleed plug Oil inlet pipe
11. 12. 13. 14. 15. 16. 17. 18.
Feed pump Fuel injection pump Oil outlet pipe Hand priming pump Coupling Pump drive shaft Housing Pump drive gear (No. of teeth: 60)
11-34
FUEL SYSTEM
FUEL INJECTION NOZZLE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Inlet connector Nozzle holder Adjusting shim Spring Spring seat Spacer Nozzle Retaining cap Needle #1 RB and #1 LB injector with needle lift sensor
Specifications
Type: Multi-hole type Adjusting injection pressure: Shim adjusting type
a. Fuel inlet (From injection pump) b. Injection (To cylinder) c. Fuel return (To fuel tank)
11-35
FUEL SYSTEM
FUEL FILTER
1. Filter head 2. Cartridge a. Fuel inlet (From transfer pump) b. Fuel outlet (To injection pump) H Additional ports are marked indicating flow direction.
Specifications
Filtration area: 2.0 m2 (1.0 x 2 pcs)
11-36
COOLING SYSTEM
COOLING SYSTEM
1. 2. 3. 4. 5. 6. 7.
Aftercooler Water outlet Aftercooler water inlet Water pump impeller Bypass flow Water outlet to block Water inlet
8. 9. 10. 11. 12. 13.
Bypass flow Water filters Cylinder liner coolant cavity Cylinder head coolant passage Oil coolers Vent line flow
11-37
COOLING SYSTEM
THERMOSTAT HOUSING FLOW
1. 2. 3. 4. 5.
Thermostat Water outlet Coolant from block Closed thermostat flow Open thermostat flow
11-38
COOLING SYSTEM
COOLING FAN BELT
1. 2. 3. 4. 5. 6. 7. 8.
Fan hub Air crossover Coolant temperature sensor Oil pan Fan idler tensioner Water filters Engine barring location Full flow oil filters
11-39
COOLING SYSTEM
WATER PUMP
1. 2. 3. 4. 5. 6. 7. 8.
Pump shaft Water seal Pump body Water pump drive gear (No. of teeth: 25) Ball bearing Oil seal Impeller Pump cover
Specifications
Type: Centrifugal gear drive Pump speed: Engine speed x 1.80
a. From thermostat b. From radiator (water inlet) c. To oil cooler (water outlet)
11-40
COOLING SYSTEM
COOLING FAN
1. 2. 3. 4. 5. 6.
Fan Fan pulley Fan belt (poly V-belt) Crank pulley Tension pulley Idler pulley
Pulley outside diameter (mm) Fan pulley 405 Crank pulley 203 Tension pulley 150
A. Wind direction
11-41
COOLING SYSTEM
CORROSION RESISTOR
1. 2. 3. 4.
Head Cartridge Element (Chemicals) Valve
Specifications
Filtration area:0.373 m2 x 2 4.01 sq. ft. x 2
a. Water inlet b. Water outlet
11-42
ACCESSORY
ACCESSORY
AIR COMPRESSOR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Cylinder head Unloader valve Piston Piston ring Piston pin Cylinder Connecting rod Crankcase Crankshaft Bushing Cover Thrust bearings Unloading assembly
a. b. c. d. e. f. g.
Air inlet Air outlet Unload pressure (from air governor) Oil inlet Water inlet or outlet Water inlet or outlet Oil outlet
11-43
ACCESSORY
Specifications
Type: Water cooled, two cylinder Unloader valve method: intake valve, open type Cylinder O.D. x stroke: 92.08 x 50.8 mm Discharge volume: 1352 cc/rev Weight: 33.5 kg
Unloader valve
Governor controlled Max 125 psi
11-44
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
1. 2. 3. 4.
Alternator Adjustment molt Alternator drive pulley Alternator bracket
a. Alternator pulley b. Alternator drive pulley
11-45
ELECTRICAL SYSTEM
ALTERNATOR WITH REGULATOR
1. Alternator 2. Alternator pulley
11-46
ELECTRICAL SYSTEM
STARTING MOTOR
DELCO 50MT 24V

1. Solenoid 2. Pinion gear 3. Starting motor
11-47
ELECTRICAL SYSTEM
ELECTRICAL INTAKE AIR HEATER
1. Heater body 2. Heater coil 3. Terminal
Specifications
Rated voltage: 11V Rated current: 86A
11-48
12
TESTING, ADJUSTING AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 FUEL PUMP INSTALLATION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 CHECKING INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 USING PROXIMITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 USING FUEL PUMP LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15 SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 TIMING SENSOR (WITH FLYWHEEL TIMING HOLES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 2ND DESIGN (FLYWHEEL TIMING LUGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 FUEL OVERFLOW VALVE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20 ADJUSTING FUEL INJECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21 PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 IN SERVICE RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 ENGINE DYNAMOMETER RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 INSITE SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 FUEL FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23 MEASUREMENT OF FUEL CONSUMPTION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24 DYNAMOMETER WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25 ENGINE DYNAMOMETER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26 COOLANT PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26 GENERAL ENGINE TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26 ENGINE THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27 TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 12-28 FUEL INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28 FUEL DRAIN LINE RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29 INTAKE MANIFOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29 INTAKE AIR RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29 EXHAUST RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29 ENGINE BLOWBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30 LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 LUBRICATING OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33 STARTING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33 ENGINE RUN-IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34 TEST LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34 TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39 CHECKING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
12-1 !
TESTING AND ADJUSTING
TABLE OF CONTENTS
330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39 WA800/WA900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39 CHECKING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39 ADJUSTING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40 DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
12-2 !

12 #
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Adjust clearance between crosshead and rocker arm.
Adjusting method of valve clearance

1. Remove the rocker arm housing cover 2. Rotate the crankshaft in a clockwise direction. While watching the movement of the intake valve of the R6 cylinder, bring the R1 cylinder into the top dead center position of the compression stroke and align the R1.6 TOP line on the vibration damper (1) with the pointer (2).
# #
Hold with a wrench in position B in the diagram on the right, then crank the engine in the direction of the arrow. When the R1 cylinder comes near the top dead center of the compression stroke, the R6 intake valve will start to move (open)
3. Loosen locknut (6) of adjustment screw (5) of R1 cylinder, insert the feeler gauge A corresponding to the specified clearance between crosshead (4) and rocker arm (3), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly. # Valve clearance (When engine is cold) Intake valve: 0.43 mm Exhaust valve: 0.80 mm
4. Tighten locknut in this position, secure adjustment screw. Locknut: 58.8 5.9 Nm (43.4 4.4 lbf-ft)
5. Follow the same procedure to align the line with the pointer and adjust the valve clearance of each cylinder according to the firing order.
# #
Firing order: R1 L1 R5 L5 R3 L3 R6 L6 R2 L2 R4 L4 The lines and marks shown in the diagram are on the outside circumference of the damper.
12-3 !

12
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

Method of measuring compression pressure
Avoid touching the exhaust manifold or muffler when measuring compression. Be careful of rotating parts. Do NOT wear loose fitting or torn clothing. Remove ALL jewelry when working. Warm up the engine before measuring the compression pressure. (Oil temperature 40 - 60 C)
1. Adjust valve clearance. # For details, see ADJUSTING VALVE CLEARANCE on page 12-3 2. Power to EHAB must be OFF. 3. Remove the nozzle holder assembly from the cylinder to be measured. 4. Install adapter A1 in the mount of the nozzle holder of the cylinder to be measured, then secure with retainer (2). Mounting bolt: 66.2 7.4 Nm (48.8 5.5 ft-lb)
5. Connect compression gauge A to the adapter. 6. Crank the engine with the starting motor and measure the compression pressure. # # # Measure the compression pressure at the point where the gauge indicator remains steady. If the adapter mount is coated with a small amount of oil, it will prevent leakage. For details of the standard values for compression pressure, see Standard value table.
12-4 !

12
FUEL SYSTEM
FUEL SYSTEM
FUEL PUMP REMOVAL
# Rotate the crankshaft to the engine timing specification before removing the right bank fuel pump.
1. Install a protective cover to prevent any dirt or dust from getting into the discharge port of the injection pump or the inlet port of the nozzle connector. Clean the debris from around the inline fuel injection pump. 2. Remove electrical connections (1) and fuel lines (2). Remove all of the oil lines (3). # # Right bank and left bank pumps are removed and installed at the right bank timing location. If the fuel pump is to be reused, remove the timing lock pin and install in the locked position, as shown, to preserve the pump timing.
3. Remove the four capscrews (1), washers and nuts holding the pump to the drive housing.
4. Remove the injection pump bracket mounting bolts (2). # The right bank fuel pump bracket has six mounting bolts. The left bank fuel pump bracket has three mounting bolts.
12-5 !

12 5. Move pump away from housing. Disengage the pump driveshaft gear from the spline coupling. Remove the pump from the drive housing.
FUEL SYSTEM
6. If pump is to be recalibrated, remove spline drive gear from pump. Use spline coupling with bar attached to prevent pump rotation while removing large nut. Use flange gear puller to remove gear.
Remove locking pin to prevent damage.
7. Remove capscrews from mounting support and remove support.
8. Install drive spline after repair. Remove locking pin. Spine retaining nut:407 Nm (300 ft-lb) 9. Install locking pin and cap. Locking pin and cap:27 Nm (20 ft-lb)
12-6 !

12 FUEL
FUEL SYSTEM
PUMP INSTALLATION AND TIMING
1. Rotate the engine clockwise until the crankshaft damper pointer aligns with the specified engine timing, which is provided on the engine dataplate before TDC for the right bank No. 1 cylinder on the compression stroke. # Right bank and left bank pumps are installed at the right bank setting location.
2. Remove the No. 1 cylinder rocker cover and verify that the No. 1 cylinder is at TDC, right bank.
3. Remove the fuel injection pump timing pin cap and verify that the pump is locked.
4. Install the timing pin, plug, and sealing washer. Timing pin plug:30 Nm (22 ft-lb)
5. Install the mounting bracket onto the fuel pump. Do NOT tighten the capscrews. 6. Install the spline coupling onto the pump drive shaft gear (1). 7. Install new o-rings.
12-7 !

12
I
FUEL SYSTEM
If the pump does not align, do NOT force the pump and drive into alignment. Forcing will result in fuel pump damage. 8. Engage the spine coupling and install the pump drive shaft gear into the drive housing. Install the flange mounting capscrews (1) and the fuel pump mounting capscrews (2). # The injection pump assembly MUST be at an angle to the engine block.
If the pump does not align, remove fuel pump and the cover plate on the front gear cover to gain access to the fuel pump drive gear.
9. Loosen (2 to 3 turns) the large nut securing the two-piece drive gear to the drive shaft. Using the barring tool to hold the engine in position, remove the two opposing capscrews securing the fuel pump drive gear to the hub.
10. Fabricate two jackscrews (M12x1.5) using bolts, Part No. 01011-31265. Remove 25mm of thread from the end of each capscrew to form a 6mm diameter. The remaining 25 mm of thread will be used to install the jackscrews. 11. Install the two jackscrews. 12. Tighten the jackscrews through the gear and hub until making contact with the thrust plate. 13. Tighten each capscrew with 1/4 turn until the two-piece gear assembly pops off the drive shaft taper. 14. Remove the jackscrews.
12-8 !

12 15. Engage the spline coupling and install the pump drive shaft gear into the drive housing. Install the flange mounting capscrew (1) and the fuel pump mounting screw (2). # The injection pump assembly MUST be at an angle to the engine block.
FUEL SYSTEM
16. Tighten the two pumps to bracket capscrews (1). 17. Tighten the four flange mounting capscrews (2). 18. Tighten the fuel pump mounting capscrews (3). All capscrews:65 Nm (48 ft-lb)
19. Install large nut securing gear to shaft Gear nut: 24 Nm (17 ft-lb)
20. Remove fuel pump locking pin. # If locking pin is difficult to remove, install metric capscrew into end of pin to aid in removal.
12-9 !

12 21. Tighten large nut securing gear to shaft. Large nut: 109 Nm (80 ft-lb) 22. Install and tighten two attaching bolts in gear. Mounting bolt:14 Nm (84 ft-lb)
FUEL SYSTEM
23. Rotate the engine clockwise until the crankshaft damper pointer aligns with the specified engine timing, which is provided on the engine dataplate.
24. Install the injector pump lock pin. Verify the timing pin will still engage. 25. Remove the lock pin. 26. Tighten the large nut securing the two-piece drive gear to the drive shaft. Large nut: 407 Nm (300 ft-lb)
27. Install the cover plate on the front gear cover. 28. Tighten the capscrews. Capscrew: 65 Nm (48 ft-lb)
12-10 !

12 29. Install the electronic connections (1) and fuel lines (2) and all the oil lines (3) High pressure lines:24 Nm (17 ft-lb) Low pressure lines:27 Nm (20 ft-lb)
FUEL SYSTEM
30. Install the timing pin, cap and sealing washer in the unlocked position. Timing pin cap:30 N m (22 ft-lb)
31. Pass the NBF connector through the hole in the rocker lever cover. 32. Press fit the grommet into the rocker lever cover (3). 33. Install the valve cover and gasket (2). Mounting bolt:7 Nm (62 in-lb) 34. Connect BF connector to ECM connection.
12-11 !

12
CHECKING INJECTION TIMING

USING PROXIMITY SENSOR
A Proximity Sensor and Lights Tool (Bosch # 0 986 612 174) is the most accurate method of adjusting fuel pump timing. The timing marks for the right bank are used to time both pumps. 1. Remove the rocker cover of right bank cylinder 1. (The left bank is illustrated.)
Before barring engine, make sure that the lock pins in both of the fuel pumps are disengaged, to prevent damage to the fuel pump. If a lock pin is difficult to remove from its engaged position, install a metric capscrew into the exposed end of the pin to aid in its removal.
The normal direction of rotation for 12V140Z-1 engines is clockwise, when viewing from the front of the engine. A wrench may be used to turn the engine from the center of the engine barring location. (A ).
If the front barring point is not readily accessible, the optional barring tool may be used at the flywheel housing.
12-12 !

2. Rotate the engine to the R 1-6 mark on the crankshaft damper.
3. Make sure that right bank cylinder 1 is at TDC of the compression stroke by checking that both right bank cylinder 1 valve rocker levers are loose and the adjusting screws are the same height. If not, then rotate the engi ne 360
4. Rotate the crankshaft counter-clockwise to approximately 40 degrees before TDC of the compression stroke for right bank cylinder 1.
5. Remove the timing pin plug, the timing pin, and the sealing washer from the pump to be timed.
12-13 !

# Use only compressed air to clean the probe end of the sensor to prevent damage.
6. Align the slot in the sensor with the slot in the fuel pump timing window. Securely hand tighten the sensor (A) and install the ground clamp (B).
7. Slowly bar the engine in the normal direction of rotation. One light on the service tool will illuminate as the pump nears the injection point. It is not important if this is light A or light B. The crank angle at which the second light first illuminates is the current pump timing. If timing does not meet specifications, refer to fuel pump timing installation section.
8. Double check the pump timing, remove the sensor, and install the lock pins in the disengaged position. Install the timing pin plugs with sealing washers. Timing pin cap:30 N m (22 ft-lb)
9. Install needle lift sensor wire (3). 10. Install the rocker cover with a new gasket and tighten the bolts to specification (The left bank is illustrated). Mounting bolt:7 Nm (62 in-lb) 11. Connect needle lift sensor connector (1)
12-14 !

12 USING
FUEL PUMP LOCK PIN
If a Proximity Sensor Lights Tool is not available, fuel injection timing may be adjusted through the use of the fuel pump lock pins. The timing marks for the right bank are used to time both pumps. 1. Remove the rocker cover of right bank cylinder 1. (The left bank is illustrated.)
Before barring the engine, make sure that the lock pins in both of the fuel pumps are disengaged, to prevent damage to the fuel pump. If a lock pin is difficult to remove from its engaged position, install a metric capscrew into the exposed end of the pin to aid in its removal.
The normal direction of rotation for 12V140Z-1 engines is clockwise, when viewing from the front of the engine. A wrench may be used to turn the engine from the center of the engine barring location (A).
If the front barring point is not readily accessible, the optional barring tool may be used at the flywheel housing.
12-15 !

2. Rotate the engine to the R 1-6 mark on the crankshaft damper.
3. Make sure that the right bank cylinder 1 is at TDC of the compression stroke by checking that both right bank cylinder 1 valve rocker levers are loose and the adjusting screws are the same height. If not, then rotate the engine 360.
4. Rotate the crankshaft clockwise to approximately 6.5 degrees before TDC of the compression stroke for right bank cylinder 1.
5. Bar the engine back and forth near this point until the lock pin can be installed in the engaged position.
12-16 !

If timing does not meet specifications, refer to fuel pump installation section.
12-17 !

12
SENSOR INSTALLATION
SENSOR INSTALLATION
SPEED SENSOR
1. Bar engine to align tooth of flywheel ring gear with center of sensor mounting hole.
2. Install sensor, hand tighten until contact. 3. Back out sensor 1/4 to 1 1/4 turn for alignment of mounting capscrew hole. 4. Install capscrew. Capscrew: 7 Nm (62 in-lb)
5. Connect pin connector to harness.
TIMING SENSOR (WITH FLYWHEEL TIMING HOLES)

1. Bar engine and check alignment of reference hole in flywheel through mounting hole. Reference hole should NOT be visible.
12-18 !

2. Install sensor. Hand tighten until contact with flywheel surface. 3. Back out 1/4 to 1 1/4 turn until alignment with mounting capscrew hole. 4. Install capscrew. Capscrew: 7 Nm (62 in-lb)
SENSOR INSTALLATION
2ND DESIGN (FLYWHEEL TIMING LUGS)

1. Remove sensor mounting assembly. 2. Rotate 180 to place sensor over flywheel surface or bar engine until one of seven timing lugs appear in sensor hole.
3. Install sensor. Hand tighten until contact. 4. Back out 1/4 to 1 1/4 turn until aligns with mounting capscrew hole. 5. Install capscrew. Capscrew: 7 Nm (62 in-lb)
6. Connect harness to sensor. 7. Install sensor cover into housing. 8. Connect harness from sensor to engine harness.
12-19 !

12
FUEL OVERFLOW VALVE pressure
FUEL OVERFLOW VALVE PRESSURE

1. Install pressure gauge between lift pump outlet and fuel filter inlet. # Lift pump gauge installation will require modified capscrew for hose connection.
1. Operate engine for 3 - 5 minutes or until pressure is stable. Minimum: 245 kPa (35 psi)
Maximum: 280 kPa (40 psi)
If overflow valve is defective, fuel pump assembly must be recalibrated with new valve.
If lift pump is defective, main pump calibration is not required. Capscrew and fuel connection: 24 Nm (17 ft-lb)
12-20 !

12
ADJUSTING FUEL INJECTION PRESSURE
ADJUSTING FUEL INJECTION PRESSURE

1. Remove retaining cap (8). 2. Confirm thickness of adjustment shim (3). 3. Insert correct shim (3) in response to the adjustment value of injection pressure. 4. Tighten retaining cap (8), then confirm the fuel injection pressure using nozzle tester. Retaining cap:83.4 4.9 N m (61.5 3.6 ft-lb) # Fuel injection racking pressure:
203 30 1.4 MPa (4350 psi) 0 0
Adjustment value per shim thickness of 0.025 mm: 0.34 MPa (49.3 psi) Prepared shims: 0.5 to 1.975 mm (at intervals of 0.025 mm) Refer to the parts book for part numbers of the prepared shims. 0.031 x 7 hole cup 1600 PPH (725 kgH) flow
12-21 !

12
PERFORMANCE TEST
PERFORMANCE TEST
ENGINE TESTING
This section outlines engine testing and engine run-in recommendations for 12V140Z-1 engines. All engines must be run-in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or pistons. Incorrect or insufficient break-in of the piston rings will lead to early oil consumption or high blowby complaints. Adherence to these run-in guidelines will allow the full durability of new pistons, liners, and rings to be realized. Before running the engine, make sure the engine is filled with the proper coolant. Also, make sure the lubricating oil system is filled and primed.
IN SERVICE RUN
The following in-service run-in guidelines are recommended for 12V140Z-1 engines after a repair involving replacement of one or more of the piston ring sets, cylinder liners or pistons where engine or an engine dynamometer and/or chassis dynamometer run-in cannot be performed. The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. However, light load/high rpm operation must be avoided during the run-in period.
ENGINE DYNAMOMETER RUN-IN

This is the preferred method of run-in engines that have been rebuilt out-of-chassis. It is not practical, nor recommended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has been performed in-chassis. There is no requirement, nor is it recommended for an engine that has been run-in and tested on an engine dynamometer to be run-in again after it has been reinstalled in the vehicle or equipment.
PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN

When it is not possible to load an engine immediately after rebuild or repair, (example: a standby generator or fire pump that cannot be operated because of customer restrictions, a fire truck that cannot be loaded with the water pump, etc.), the engine must be run-in on a portable dynamometer or load bank following the recommendations outlined in the attached procedures.
INSITE SERVICE TOOL

The preferred method of obtaining test information and determining corrective action is using service tool 3886188 to read fault codes and engine data. See INSITE information in this section.
12-22 !

12 FUEL
PERFORMANCE TEST
FLOW MEASUREMENT
Accurate fuel flow measurement is important for evaluation of engine performance and troubleshooting on an engine or chassis dynamometer. The only way accurate fuel flow measurement can be obtained is through proper use of available equipment.
INSTALLATION
When installing the fuel measuring device, it is important to reduce the amount of air that can be introduced into the system when the device is not in use. Therefore, the plumbing used must include non-restrictive shutoff valves, such as ballcock valves, to contain fuel in the device after each use. Additional installation considerations are: A separate fuel supply for use on the dynamometer is recommended. All fuel used in the measuring device must be clean for consistent operation. Care must be taken to reduce fuel line restriction to and from the engine. Minimum recommended hose sizes are No. 10 for the engine fuel inlet, and No. 8 for the engine fuel drain. The length of either hose must not exceed 15 feet. For accurate fuel consumption or flow measurement while testing on a chassis dynamometer, it is recommended to use a fuel cooler to maintain inlet temperature to the fuel gear at 49C (120F) or below.
MEASUREMENT OF FUEL CONSUMPTION RATIO

1. Measure the length of time required for lowering of the fuel level from A to B. Method for calculation of fuel consumption ratio. g = (rb)/(Pt) X 3600. g = Fuel consumption ratio (g/kWh(g/HPh)) r = Specific gravity of fuel b = Fuel consumption (cc) within measuring time P = Shaft output (kW(HP)) t = Fuel consumption time (second) Typical measurement at test bench
12-23 !

Simple measuring method
PERFORMANCE TEST
SPECIFICATIONS
Maintain the following limits during the engine test/run-in procedures: Due to variations in ratings of different engine models, refer to the specific Engine Data Sheet for the particular engine model being tested. Intake restriction (Maximum at advertised horsepower) Clean air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 mm H2O (15 in H 2O) Dirty air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H2O (25 in H 2O)
Exhaust back pressure (Maximum at advertised horsepower) .................................................... 75 mm Hg (3 in Hg) Blowby * (Maximum at advertised horsepower) New or rebuilt engines (Maximum 3600 hours). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Tables Used engines (Over 3600 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Tables
Oil pressure (With 15W-40 oil at 107C (225F)) Low idle (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 kPa (20 psi) At 1200 RPM or torque peak (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 kPa (36 psi)
Fuel inlet restriction measured at fuel pump inlet (Maximum at advertised horsepower) * Clean fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm Hg (4 in Hg) Dirty fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 mm Hg (8 in Hg) Maximum allowable fuel inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71C (160F) Blowby checking tool, Part No. 3822566 - 0.302 inch orifice.
Blowby Limits (using 0.302 inch diameter orifice at rated load and speed) Engine HP (RPM Rating) All ratings New/Rebuilt 305 mm H2O (12 in H2O) Used Engine Limit 762 mm H2O (30 in H2O)
12-24 !

12 DYNAMOMETER Date: ESN: Complaint:
PERFORMANCE TEST
WORKSHEET
Repair Order No.: CPL: Operator: Fuel Pump Code: SC Code: ACTUAL READING
PARAMETER CODE SPECIFICATIONS Fuel Rate (lb/hr) Intake Mfd. Pressure (in.Hg) See Fuel Pump Code Intake Mfd. Temperature *Intake Air Restriction 25 in H2O Maximum *Exhaust Air Restriction 3 in Hg, Maximum *Fuel Inlet Restriction 8 in Hg (Dirty Filter), Maximum *Fuel Drain Line Restriction 3 psi, Maximum Engine Blowby See Tables * - Recorded at Maximum horsepower speed and full load
Road Speed Limit Check Oil Level
Low
High Turbo Inlet Air Temp
OK Intake Manifold Temp/Press
Engine High Speed Limit Fuel Quality OK
Not OK Lube Oil Press HP or Torque
Engine Speed
Fuel *Rate/Press
Fuel Temp
Coolant Temp/Press
Engine Blowby
* Be sure that the fuel rate is corrected for temperature.
Fuel Temperature Less than 7C (45F) 7 to 13C (45 to 55F) 13.0 to 20.0C (55 to 68F) 20.0 29C (68 to 85F) 29 to 42C (85 to 108F) 42 to 56C (108 to 132F) 56C above (132F)
Correction for Flow Rate Flow meter not accurate Subtract 2% from flow rate reading Subtract 1% form flow rate reading No correction Add 1% to flow rate reading Add 2% to flow rate reading Flow meter not accurate
Pressure Conversions
1 in. H2O = 0.074 in. Hg = 0.036 psi 1 in. Hg = 13.514 in. H 2O = 0.491 psi 1 psi = 2.036 in. Hg = 27.7 in. H 2O
12-25 !

12
ENGINE DYNAMOMETER TESTING

SETUP
# Be sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine rated horsepower. If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer.
1. Use engine lifting fixture, Part No. 3375109, to install the engine to the test stand. Align and connect the dynamometer. Refer to the manufacturer s instructions for aligning and testing the engine.
Refer to Service Bulletin No. 3666005, Dynamometer and Road Engine Testing, for detailed instructions on auxiliary aftercooling system attachment.
COOLANT PLUMBING
2. Connect the coolant supply to the water inlet connection. 3. Connect the coolant return to the water outlet connection. 4. Connect vent lines. 5. Install the drain plugs and close all of the water drain cocks.
GENERAL ENGINE TEST PROCEDURES

# The lubricating oil system must be primed before operating the engine after rebuild to avoid internal component damage. Do not prime the system from the bypass filter as the filter will be damaged.
6. Remove the large plug from the oil cooler housing.
7. Use a pump capable of supplying 205 kPa (30 psi) continuous pressure. Connect the pump to the front of the engine oil cooler as shown. 8. Use a supply of clean oil. Turn the pump to the ON position. Check the engine oil pressure gauge. When the gauge indicates oil pressure, begin monitoring the oil level in the oil pan.
12-26 !

9. Check the engine coolant level to be sure it is filled to the proper level.
Check the coolant level only when the engine is stopped. Wait until the coolant temperature is below 50C (120F) before removing the pressure cap. Failure to do so can cause personal injury from heated coolant spray.
Do not add cold coolant to a hot engine. This can cause engine casting damage. Allow the engine to cool below 50C (120F) before adding coolant. 10. Check the engine lubricating oil level to be sure it is filled to the proper level.
Use a known source of good quality No. 2 diesel fuel.
This is very important since No. 1 diesel fuels, along with most other alternate fuels, are lighter (lower specific gravity, higher API gravity) than No. 2 diesel fuel. The lighter the fuel, the lower the energy content (BTU) per liter (gallon).
ENGINE THROTTLE CONTROL

Engines that are run on the engine dynamometer require that the engine harness be installed, and connected to the engine. Additionally, a special engine dynamometer version of the OEM wiring harness and throttle control must be installed. A special wiring harness and throttle control has been developed to enable engine operation out of the chassis.
12-27 !
TESTING PROCEDURE
To properly monitor engine performance, record the following parameters. To limit dynamometer operating time, instrument the engine to make as many checks as possible. Engine speed rpm with a verified tachometer Fuel rate (Use service tool, Part No. 337637) Fuel temperature (if needed to correct fuel rate) Fuel inlet restriction Fuel drain line restriction Intake manifold pressure Intake air restriction Exhaust air restriction Coolant temperature Engine blowby Lubricating oil pressure Coolant pressure Inlet manifold air temperature Turbocharger inlet air temperature
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER

1. Use a digital optical tachometer, Part No. 3377462, to check and verify speed.
FUEL INLET RESTRICTION

2. Measure the fuel inlet restriction. Install a vacuum gauge, Part No. ST-434, between the primary fuel filter and the lift pump inlet. Do not measure fuel inlet restriction with the fuel measuring device installed. This will not measure the inlet restriction of the vehicles supply plumbing.
12-28 !
TESTING AND ADJUSTING FUEL DRAIN LINE RESTRICTION

3. Use Pressure Gauge, Part No. ST-1273, to measure fuel drain line restriction. # Do not measure fuel drain line restriction with the fuel measuring device installed. This will not measure the drain line restriction of the vehicles return plumbing.
INTAKE MANIFOLD PRESSURE

4. Measure the intake manifold pressure (turbocharger boost). Install pressure gauge, Part No. ST-1273, in the intake manifold crossover. 5. Observe the reading on the pressure gauge.
INTAKE AIR RESTRICTION

6. Measure the inlet air restriction. Install the vacuum gauge, Part No. ST-434, or a manometer in the intake air piping. # The gauge adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe at a minimum of one pipe diameter before the turbocharger.
EXHAUST RESTRICTION
7. Measure the exhaust air restriction. Install the pressure gauge, Part No. ST-1273, or a manometer in the exhaust air piping. # The gauge adapter must be installed near the turbocharger in a straight section of pipe at the turbine outlet.
12-29 !
TESTING AND ADJUSTING ENGINE BLOWBY

# Excessive blowby indicates an air compressor, a turbocharger, or an engine malfunction, allowing combustion gases or air to enter the crankcase and build a pressure higher than normal.
This procedure describes how to measure crankcase pressure and how to determine the component that is malfunctioning. Use one of the three blowby tools and a water manometer, Part No. ST-1111-3. Maximum gauge capacity is 1270 mm-H 2O (50 in-H2O). The engine blowby tools are similar in design. The difference between the tools is in the size of the orifice. Blowby Tool Part No. 382256: 0.302 orifice 8. Use a length of hose (1) to attach the blowby tool to one of the crankcase breathers. 9. Plug all of the other breathers. 10. Attach a manometer to the location shown (2).
11. Operate the engine at rated rpm and full load (wide open throttle) until a steady reading is obtained. 12. Compare the blowby readings to previous readings on the engine. If previous readings for the engine are not available, compare the blowby reading to new engine specifications. # A sudden increase in blowby indicates a problem. A gradual increase over a period of time is normal (due to wear of internal engine components).
Blowby Limits (using 0.302 inch diameter orifice at rated load and speed) Engine HP (RPM Rating) All ratings New/Rebuilt 305 mm H2O (12 in H2O) Used Engine Limit 762 mm H2O (30 in H2O)
12-30 !

13. If the blowby is higher than normal, check the crankcase breathers and breather tubes to see if they are plugged.
14. Check the engine oil level. If the level is too high it can cause a higher than normal crankcase pressure.
15. Isolate the air compressor to determine if it is malfunctioning and causing the high blowby pressure. 16. Relieve the air pressure on the first air tank in the system after the air compressor (wet tank). 17. Disconnect the air inlet and outlet connections. Plug the intake manifold or air piping where the inlet connection was removed.
18. Operate the engine at rated speed and full load (wide open throttle) until a steady blowby reading is obtained. 19. Compare the blowby readings to the previous value. If the blowby is now acceptable, replace the air compressor.
12-31 !

A sudden increase in blowby or a high reading that is not steady indicates that there is internal damage in the engine.
LUBRICATING OIL PRESSURE

20. Use a pressure gauge, Part No. 3375275, to measure lubricating oil pressure. 21. Install the pressure gauge to the main oil rifle (1) or air filter head (2). 138 kPa (20 psi) 207 kPa (30 psi)
COOLANT PRESSURE
22. Measure the coolant pressure at the water manifold (1). 241 kPa (35 psi)
LUBRICATING OIL TEMPERATURE

23. Drain oil and remove plug from oil pan. Install master gauge. Fill pan with oil and operate engine. Compare temperature of original and master gauge. # If defect is found, replace defective part.
12-32 !
TESTING AND ADJUSTING AIR COMPRESSOR

All air compressors must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or non-operating mode. 24. Connect a source of compressed air capable of producing 665 kPa (95 psi) to the air compressor unloader (1). This air line must contain a valve between the source and the unloader # The compressed air load in the accompanying illustration must be attached to the air compressor outlet (2).
25. Use an air tank (2). Install an air regulator (3) capable of maintaining 345 to 517 kPa (50 to 75 psi) air pressure at both minimum and maximum engine rpm. 26. Install a steel tube or high temperature hose (1). 235C (500F) 27. Connect the tube or hose (1) to the air compressor outlet.
STARTING MOTOR
Always connect the negative (-) cable first to avoid arcing that can ignite explosive battery gases. 28. Inspect the voltage rating on the starting motor before installing the electrical wiring. 29. Install the electrical wiring to the starting motor and batteries, if used. # If another method of starting the engine is used, follow the manufacturer s instructions to make the necessary connections.
12-33 !

12 ENGINE
RUN-IN INSTRUCTIONS
TEST LOAD
Rated RPM 2100 2100 2100 2100 Rated Horsepower 1050 950 850 760 Torque Rise ALL ALL ALL ALL Test Load 1157 Nm (854 ft-lb) 1047 Nm (772 ft-lb) 937 Nm (691 ft-lb) 838 Nm (618 ft-lb)
The run-in test must be performed with the engine operating at torque peak rpm. Operate a generator set engine at rated rpm. Example: The test load for a 475 up engine rated at 2,000 rpm with a 15 percent torque rise is (300 ft-lb) # This chart assumes the dynamometer constant is 5,252. If the dynamometer constant is not 5,252, use the following formula to determine the correct test load:
Correct test load = (Dynamometer constant) x (Test load) \ 5,252. Example: The dynamometer constant for testing the engine in the above example is 4,000. Correct test load = (4,000 x 300) \ 5,252 = (228 ft-lb) # This chart assumes engine run-in on a chassis dynamometer.
Do not crank the starting motor for more than 30 seconds. Excessive heat will damage the starter. 1. START the engine. If the engine does not begin operating after 30 seconds, allow two minutes for the starting motor to cool.
If the oil pressure is not within specifications, STOP the engine immediately. Both low and high oil pressure will cause engine damage. Main oil rifle pressure at idle: Minimum: 138 kPa (20 psi) Maximum: 483 kPa (70 psi)
12-34 !

2. Operate the engine at the IDLE position. Check for leaks.
Do not operate the engine at IDLE for longer than specified. Excessive carbon formation will cause engine damage.
3. Adjust the engine rpm to 1,200 rpm. Adjust the dynamometer load to the test load as previously determined. Operate the engine at this setting until the coolant temperature indicates 70 C (160F). 4. Check for leaks. Fix all leaks. 5. Check all of the gauges and record the readings. Do not proceed to the next step until the blowby becomes stable within specifications.
6. Adjust the engine rpm to the torque peak rpm. Adjust the dynamometer load to equal two times the test load. Operate the engine for two minutes. 7. Check all the gauges and record the readings. Do not proceed to the next step until the blowby becomes stable within specifications.
8. Maintain the engine rpm at torque peak rpm. Increase the dynamometer load to equal three times the test load. 9. Operate the engine at this load for 2 minutes. 10. Check all the gauges and record the readings. Do not proceed to the next step until the blowby becomes stable within specifications.
12-35 !

11. Move the throttle lever to the FULL OPEN position. Increase the load until the engine rpm is at torque peak rpm. 12. Operate the engine at this setting for 10 minutes or until the blowby becomes stable within the specifications. 13. Check all the gauges and record the readings.
14. Decrease the dynamometer load until the engine rpm increases to the rated rpm. 15. Operate the engine at this load for 5 minutes. 16. Check all the gauges and record the readings.
17. Decrease the dynamometer load completely.
Do not turn the engine OFF immediately. The engine must be allowed to cool. 18. Move the throttle lever to the LOW IDLE position. Operate the engine at this setting for 3 to 5 minutes. This will allow the turbocharger and the other engine components to cool.
Do not operate the engine at IDLE longer than specified. Excessive carbon formation can cause engine damage. 19. Turn the engine OFF.
12-36 !

12
TESTING AND ADJUSTING TOOL LIST

No. Testing and Measuring Item 1 2 3 Engine Speed Digital Optical Tachometer Battery Specific Gravity Freezing Temperature of Coolant Water Temperature 4 Oil Temperature Air Temperature 5 Exhaust Temperature Lubrication Oil Pressure 6 Fuel Pressure Intake Manifold Pressure Exhaust Pressure 7 Blow-by Pressure Intake Restriction 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Compression Pressure Valve Clearance Exhaust Gas Color Water and Fuel Content in Oil Fuel Injection Pressure and Pattern Coolant quality, Molybdate and Nitrite Cooling Pressure Valve Function, Leakage Radiator Wind Speed Engine Barring Electrical Circuit Testing Fuel Injection Timing Fuel Pump Locking Pin Performance Options Alternator Belt Tension Fan Belt Tension Insite Service Tool Tension Gauge Tension Gauge Part of Pump Assembly 3886188 ST1293 Burroughs BT-33-72B Compression Gauge Feeler Gauges Smoke Meter Engine Oil Testing Nozzle Tester Fleetguard Coolant Test Kit Radiator Cap Tester Anemometer Barring Device Multimeter Proximity Sensor and Lights Commercially Available Commercially Available Commercially Available Commercially Available 3376946 CC2602 Commercially Available Commercially Available 3201740 3377161 Bosch # 0 986 612 174 Slack Tube Manometer ST1111-30 Pressure-Vacuum Meter 3824645 Contact Pyrometer 3376336 Digital Thermometer 3822666 Specific Gravity Tester Fleetguard Coolant Test Kit 3377462 Commercially Available CC2602 Tool Description Hand Tachometer Part Number 3823782
12-37 !

12
Engine model Applicable machine model Classification Performance Item Condition, etc. High idling speed rpm Low idling speed 0 C Necessary starting speed 20 C (with starting aid) Intake resistance Intake pressure Intake and exhaust system Exhaust pressure (Turbine inlet pressure) Exhaust temperature (Turbine inlet temp.) At all speed At rated output At rated output All speed (intake air temp.: 25 C) Quick acceleration (Low idling to High idling) Exhaust gas color At rated output At high idling Valve clearance (when engine is hot or cold) Engine body Compression pressure (SAE30 oil) Intake valve mm Exhaust valve Oil temperature: 40 60 C (Engine speed: 160-200rpm) At rated output Water temperature: Min. 70 C At rated outputSAE30 oil MPa (kg/cm2) 0.80 Min. 3.1 (Min. 32) Bosch scale mmH 2O mmHg mmHg rpm Min. 100 Max. 380 1321 600 - 700 Min. 110 Unit
12V140Z-1 330M Standard value 2100 - 2200 Permissible value 2100 - 2200 600 - 700 635 WA900 Standard value 2100 - 2200 650 - 700 Min. 110 Min. 100 Max. 380 1170 Permissible value 2100 - 2200 650 - 700 635 WA800 Standard value 2100 - 2200 650 - 700 Min. 110 Min. 100 Max. 380 1016 Permissible value 2100 - 2200 650 - 700 635
Engine speed (adjustable)
Max. 750
750
Max. 750
750
Max. 5.0 Max. 0.6 Max. 0.6 0.43
7.0 1.0 1.0 2.2 (22)
Max. 5.0 Max. 1.0 0.43 0.80 Min. 3.1 (Min. 32)
7.0 1.5 2.2 (22)
5.0 1.0 0.43 0.80 Min. 3.1 (Min. 32)
7.0 1.5 2.2 (22)
Blowby pressure (SAE30 oil)
mmH 2O
305
635
305
635
305
635
0.3 0.44 (3.0 4.5) 0.25 0.39 (2.5 4.0) MPa (kg/cm2) Min. 0.1 (Min. 1.0) Min. 0.1 (Min. 1.0) C % 80 110 Max. 0.5
+1.0
0.21 (2.1) 0.18 (1.8) 0.07 (0.7) 0.07 (0.7) 120 1.0
0.25 0.39 (2.5 4.0) 0.20 0.34 (2.0 3.5) Min. 0.1 (Min. 1.0) Min. 0.1 (Min. 1.0) 80 110 Max. 0.5
+1.0
0.18 (1.8) 0.13 (1.3) 0.07 (0.7) 0.07 (0.7) 120 1.0
Lubrication system
Oil pressure (Oil temperature: Min. 107C (225F))
SAE10W oil
At low idlingSAE30 oil
SAE10W oil Oil temperature Oil consumption ratio All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption)
80 110
+1.0
120
Fuel system
30 - 0 Fuel injection pressure Nozzle tester MPa (psi)
30 - 0
30 - 0
+200 4350 - 0
+200 4350 - 0
+200 4350 - 0
Fuel injection timing Cooling system Radiator pressure valve Fan speed Fan belt tension
B.T.D.C. Opening pressure (Differential pressure) At rated engine speed
degree
6.5
6.5 0.5 0.1 0.015 (1.0 0.15)
6.5 0.07 0.01 (0.70 0.1) 1000 30
6.5 0.5 0.07 0.01 (0.70 0.1)
6.5 1000 30
6.5 0.5
MPa 0.1 0.015 (kg/cm2) (1.0 0.15) rpm mm 1000 30
Autotension
Autotension
Autotension
The values given in the Testing and Adjusting data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump.
12-38 !
COOLING SYSTEM
COOLING SYSTEM
CHECKING FAN BELT TENSION
330M
1. Install belt tension gauge (Burroughs # BT-33-72B) New belt tension: 2660 N (600 lb) Used belt tension: 2220 N (500 lbF) Range: 1780 N (400 lbF)
2. If tension is below specifications, loosen nuts (1) and (2). Tighten nut 2 until tension is correct. Lock nut: 81 Nm (60 ft-lb)
WA800/WA900
Use same procedure for retension. New belt requires moving lock nut (1) to end of rod and moving second idler to contact belt. Tighten second idler and repeat new belt tensioning procedure.
ALTERNATOR BELT
CHECKING BELT TENSION
Push belt (4) at mid-point between alternator and alternator drive pulley with a force of approximately 58.8 N (1.3 lbf) and measure the distance the belt moves.
12-39 !
ALTERNATOR BELT
ADJUSTING BELT TENSION

Turn the lockout adjustment bolt (1) in the direction to extend the belt (3). Adjust the belt to specifications. Tighten the lock bolt (2) and the locknut. Locknut: 55 Nm (40 ft-lb)
DRIVE BELT TENSION

SAE Belt Size Belt Tension Gauge Part No. Click-type Burroughs 0.380 in 0.440 in 1/2 in 11/16 in 3/4 in 7/8 in 4 rib 5 rib 6 rib 8 rib 10 rib 12 rib 12 rib K section # # # 3822524 3822524 3822524 3822524 3822524 3822524 3822524 3822524 3822525 3822525 3822525 3822525 3822525 Belt Tension New N lbf 620 620 620 620 620 620 620 670 710 890 1110 1330 1330 140 140 140 140 140 140 140 150 160 200 250 300 300 Belt Tension Range Used* N lbf 270 to 490 270 to 490 270 to 490 270 to 490 270 to 490 270 to 490 270 to 490 270 to 530 290 to 580 360 to 710 440 to 890 530 to 1070 890 to 1070 60 to 110 60 to 110 60 to 110 60 to 110 60 to 110 60 to 110 60 to 110 60 to 120 65 to 130 80 to 160 100 to 200 120 to 240 200 to 240
ST-1138 ST-1138 ST-1138 ST-1138 ST-1138 ST-1138 ST-1293 ST-1293 3823138 3823138 3823138
This chart does not apply to automatic belt tensioners. A belt is considered used if it has been in service for ten minutes or longer. If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
12-40 !
13
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 SETTING ENGINE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 GENERAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Engine cooling water and engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Muffler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 Intake connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Intake manifold, aftercooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Air compressor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 Fuel pump drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11 Oil cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 Cylinder head assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15 Accessory drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15 Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Main relief valve, suction tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Front support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 Gear case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19 WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23 WASHING CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23 WASHING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25 WASHING CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25 MEASURING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 MEASURING CURVATURE OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 MEASURING OUT-OF-ROUNDNESS OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 MEASURING SURFACE ROUGHNESS OF OUTSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 MEASURING DEPTH OF CYLINDER LINER COUNTERBORE . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 MEASURING MAIN BEARING BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28 MEASURING CURVATURE OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28 MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28 MEASURING HEIGHT OF CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
13-1!"
TABLE OF CONTENTS
13-29 13-29 13-29 13-30 13-30 13-31 13-31 13-31 13-32 13-33 13-33 13-34 13-34 13-35 13-35 13-47 13-53 13-57 13-58 13-58 13-58 13-58 13-59 13-60 13-60 13-60 13-63 13-64 13-65 13-67 13-67 13-68 13-70 13-71 13-71 13-72 13-73 13-74 13-74 13-75
MEASURING PISTON RING GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING OUTSIDE DIAMETER OF PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING LENGTH OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD . . . . . . . . . . . . . . MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD . . . . . . . . . . . . . . . . . MEASURING CURVATURE, TWISTING OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . STANDARD PRESSURE FOR PARTS PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main relief valve, suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake manifold, aftercooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2 "

12
DISASSEMBLY
DISASSEMBLY
SPECIAL TOOLS
No. A B C D E Part Number 3375960 3823137 3376015 3375629 3823495 3825190 Part Description Valve Spring Compressor Piston Ring Expander Liner Puller Protrusion Gauge Fuel Injector Puller
WASHING
Before disassembling the engine, check all parts for any cracks or damage, then clean the whole engine carefully with steam so that the disassembly work can be carried out swiftly. A) Before washing, remove starting motor assembly (1), alternator assembly (2), and electric wiring. B) Cover all the openings of the engine with tape. C) Using a washing machine, clean engine. Carefully wash all mating surfaces where mud tends to collect
SETTING ENGINE STAND

Prepare a stable engine stand that will prevent the engine from falling over, then set the engine assembly on the stand and secure it in position.
Engine assembly: Approx. 3,200 kg (7,056 lb) (The weight differs according to the machine mounting the engine.)
GENERAL DISASSEMBLY
Engine cooling water and engine oil
1. Drain engine cooling water and engine oil. Engine oil: Approx. 147 L (39 gal) (The amount of oil differs according to the engine model.)
Government agencies have determined that used engine oil is toxic and carcinogenic. Avoid inhalation, ingestion, and prolonged contact with used engine oil.
13-3 "

2. Filter Engine equipped with filters A) Using filter wrench, remove corrosion resistor (1), oil filter (2), and fuel filter (3). B) Remove bypass filter C) Remove mounting brackets and filter head.
DISASSEMBLY
Muffler assembly
1. Disconnect komaclone tube (4), then remove muffler assembly (5) and muffler bracket.
Fan
1. Using nylon sling, sling fan, then remove mounting bolts. 2. Remove fan (1).
Fan: 75 kg (165 lb) (The weight differs according to the machine model.)
3. Fan belt
The fan belt idler is under tension. Do NOT place your hands between the idler and the belt or the fan hub. Personal injury can result. A) Loosen locknuts (1) and (2). B) Slowly remove nut (1) until the spring tension is relieved and remove the belt.
13-4!"

4. Fan pulley assembly A) Using nylon sling, sling fan pulley assembly, and remove mounting bolts. B) Remove fan pulley assembly (2) Fan pulley assembly: 85 kg (187 lb)
DISASSEMBLY
Intake connector
1. Remove intake connectors. Loosen V-band clamp, slide Oring connector into crossover.
2. Remove capscrews and air crossover
Turbocharger assembly
1. Disconnect turbocharger oil supply tube (1) and drain tube (2). 2. Remove turbocharger assembly (3).
13-5 "
DISASSEMBLY AND ASSEMBLY Intake manifold, aftercooler assembly

1. Left bank A) Remove tubes for aftercooler. B) Remove heater relay wiring. C) Disconnect air supply to air compressor.
DISASSEMBLY
D) Remove engine harness mount clamps. E) Remove sensor connections.
2. Right bank A) B) C) D) Remove tubes for aftercooler Remove wiring of electrical intake air heater. Remove sensors. Remove engine harness clamps and engine harness with mounting panel.
E) Sling intake manifold and aftercooler assembly (11),and remove mounting bolts. # To prevent the electrical intake air heater from falling off, install a guide bar in the mounting bolt hole of the intake manifold below. F) Remove intake manifold and aftercooler assembly. Intake manifold, aftercooler assembly: 50 kg (110 lb)
13-6!"

3. Aftercooler core A) Remove connector (12). B) Remove cover (13). C) Remove aftercooler core (14).
DISASSEMBLY
Exhaust manifold assembly

Remove exhaust manifold assembly (1).
Exhaust manifold assembly: 30 kg (66 lb)
Fuel Injector
1. Fuel injection spill pipe A) Remove fuel injection pressure lines (1). B) Remove drain tube (2). # Install a protective cover to prevent any dirt or dust from getting into the discharge port of the injection pump or the inlet port of the nozzle connector.
2. Fuel injection pump assembly # Rotate the crankshaft to the engine timing specification before removing the right bank fuel pump. Install a protective cover to prevent any dirt or dust from getting into the discharge port of the injection pump or the inlet port of the nozzle connector. Clean the debris from around the inline fuel injection pump. A) Remove electrical connections (1) and fuel lines (2). B) Remove all of the oil lines (3).
13-7 "

# If the fuel pump is to be reused, remove the timing lock pin and install in the locked position, as shown, to preserve the pump timing.
DISASSEMBLY
C) Remove the four capscrews (1), washers and nuts holding the pump to the drive housing. D) Remove the injection pump bracket mounting bolts (2). # The right bank fuel pump bracket has six mounting bolts. The left bank fuel pump bracket has three mounting bolts.
E) Disengage the pump driveshaft gear from the spline coupling. F) Remove the pump from the drive housing.
Air compressor assembly

1. Remove air inlet, air outlet, water inlet, and water outlet connections.
13-8!"

The component weighs more than 23 kg (50 lb). To avoid personal injury, use a hoist or get assistance to lift the component. 2. Remove the air compressor support mounting capscrews (5). 3. Remove the capscrews (6) from the air compressor mounting bracket. 4. Remove the air compressor. Remove the splined coupling (1). 5. Remove and discard the gasket.
DISASSEMBLY
Fuel pump drive assembly

1. Remove the fuel pump drive gear cover plate on the front gear cover.
2. Loosen (2 to 3 turns) the large nut securing the two-piece drive gear to the drive shaft. 3. Remove the two opposing capscrews securing the fuel pump drive gear to the hub.
4. Fabricate two jackscrews (M12x1.5) using capscrews, Part No. 01011-31265. Remove 25 mm of thread form the end of each capscrew to form a 6 mm diameter. The remaining 25 mm of thread will be used to install the jackscrews. A) Install the two jackscrews. B) Tighten the jackscrews through the gear and hub until making contact with the thrust plate.
13-9 "

C) Tighten each capscrew with 1/4 turn until the two-piece gear assembly pops off the drive shaft taper. # Check to make sure the drive gear assembly will be supported by the gear train. If NOT, use a wire to prevent it from dropping into the oil pan. D) Remove the jackscrews. E) Remove the nut and washer.
DISASSEMBLY
5. Remove the four capscrews securing the flange mount housing assembly to the rear gear cover. 6. Remove two capscrews from support bracket. 7. Remove the housing assembly.
8. Fuel pump drive disassembly
A) Remove retaining nut (1). (Use modified spline coupling to hold shaft at spline (2).) B) Remove shaft toward pump mount. C) Remove spline retaining nut (3) (Use modified coupling to hold shaft)
D) Use puller to remove spline coupling (2) E) Drive bushing (4) from housing (5).
13-10!"

F) Fuel pump drive case assembly i) Remove drive spline. ii) Pull out drive shaft (3) towards portion A. iii) Left bank: Short Right bank: Long iv) Remove oil seal (4). v) Pull bushings (5) out from drive case (6).
DISASSEMBLY
Water pump assembly

1. Remove the water bypass connection and water transfer tube.
2. Remove the four water pump mounting capscrews.
Two of the mounting capscrews are installed from the front of the water pump and two from the back.
3. Remove the water pump assembly and gasket. Discard the gasket.
Breather
1. Remove alternator bracket (1). # The alternator bracket is on the right bank only. 2. Remove clamp, then remove tube (2). 3. Remove breather (3).
13-11 "
DISASSEMBLY AND ASSEMBLY Oil cooler assembly

1. Remove front oil cooler assembly (1). 2. Remove manifolds (2) and (3). 3. Remove rear oil cooler assembly(4).
DISASSEMBLY
4. Oil filter, oil level gauge A) Remove bracket, then oil filler (1). B) Remove oil level gauge guide (2). Loosen the nut at the root of the level guide, then remove the guide.
Rocker lever cover

1. Remove rocker lever cover (1). 2. Remove turbocharger oil supply tube (2) and drain tube (3). 3. Remove air vent tube (4). 4. Remove fuel drain line.
Remove fuel supply connection before removing injector to prevent damage to the rocker lever housing.
13-12!"

5. Nozzle holder, connection A) Loosen locknut, and remove connection (1). B) Remove holder (2).
DISASSEMBLY
C) Using tool E, remove nozzle holder (3). # # Mark each nozzle holder with the cylinder number, keep it in a safe place, and be careful not to damage the tip. Check that the gasket is fitted to the tip of the nozzle holder.
Rocker lever
1. Remove rocker lever (1)
To prevent pressure on the push rod when installing, loosen the locknut and turn the adjustment screw back 2 to 3 turns before removing the rocker lever assembly.
2. Push rod Remove push rod (2). 3. Crosshead Remove crosshead (3). 4. Rocker lever housing Remove rocker lever housing
13-13 "
DISASSEMBLY AND ASSEMBLY Cylinder head assembly

1. Remove mounting bolts (1), then remove cylinder head assembly (2). 2. Remove gasket (3) of each cylinder head.
DISASSEMBLY
3. Cylinder head disassembly
A) Using spring pusher A, compress valve spring, then remove cotter (4). B) Remove upper seat (5), outer spring (6), and inner spring (7). C) Remove seals.
D) Remove lower seat (8). E) Raise cylinder head, and remove valve (9). # Use tags to mark the assembly portion of the valves of each cylinder.
Cam follower assembly

1. Remove cover (1). 2. Remove mounting bolts (2), then remove cam follower assembly (3). # The mounting bolt of the cam follower is a special bolt, so keep it in a safe place and be careful not to lose it.
13-14!"
DISASSEMBLY AND ASSEMBLY Thermostat housing

1. Remove connector tube (1). 2. Screw eyebolts (Thread dia. 10 mm, Pitch 1.5 mm) [0.3937 in, P 0.0591 in] into thermostat case (2), sling thermostat case assembly (2), (3), then remove it. 3. Disconnect thermostat case (2) and thermostat housing. 4. Remove thermostat (4) from thermostat case. 5. Remove seal (5).
DISASSEMBLY
Accessory drive assembly

1. Remove pulley (1). 2. Remove drive assembly (2).
3. Accessory drive disassembly A) Pull out hub (3), and remove thrust plate (4). B) Remove shaft (5), thrust plate (6), and gear (7) as one unit. C) Remove gear (7) from shaft (5). D) Pull out oil seal (9) and bushings (10) form housing (8).
13-15 "
DISASSEMBLY AND ASSEMBLY Damper, crankshaft pulley assembly

1. Sling damper and crankshaft pulley assembly (1), and remove mounting bolts. 2. Remove damper and crankshaft pulley assembly.
DISASSEMBLY
Damper, crankshaft pulley assembly: 56 kg (123 lb)
Do not use an impact wrench to loosen bolts, to prevent possible damage to threads.
Oil pan
1. Raise cylinder block assembly, and set stand under flywheel housing and front support. 2. Support oil pan with transmission jack, and remove mounting bolts, then remove oil pan (1).
Oil pan: 45 kg (99lb) Government agencies have determined that used engine oil is toxic and carcinogenic. Avoid inhalation, ingestion, and prolonged contact with used engine oil.
Main relief valve, suction tube

1. Remove main relief valve (2). 2. Remove bracket (3), then remove suction tube (4).
Front support
Raise cylinder block assembly and remove front support (1).
Sensors
Remove rpm (1) and timing (2) sensors.
13-16!"
DISASSEMBLY AND ASSEMBLY Flywheel

1. Using eyebolts (3), (Thread dia. 12 mm, Pitch 1.75 mm) [0.4724 in, P 0.0689 in] sling flywheel (2), then remove mounting bolts (1), and screw in forcing screws (4), (Thread dia. 12 mm, Pitch 1.75 mm) [0.4724 in, P 0.0689 in] to remove flywheel (2).
DISASSEMBLY
Flywheel: 136 kg (300 lb)
Do not use an impact wrench to loosen bolts, to prevent possible damage to threads. 2. Flywheel housing, rear seal A) Remove 2 3 mounting bolts, then install guide bolts. B) Sling flywheel housing (1), then remove remaining mounting bolts, and remove flywheel housing (1). Support the housing by hand when removing it to prevent it from falling over. Flywheel housing: 102 kg (225 lb) C) Remove rear seal.
Gear case
1. Using eyebolts (1) (Thread dia. 10 mm, Pitch 1.5 mm) [0.3937 in, P 0.0591 in], sling gear case cover (1), then remove mounting bolts, install guide bolts, and remove gear case cover (1).
Gear case cover: 72 kg (159 lb) 2. Remove front seal.
3. Idler gear (large) Remove mounting bolts, then remove plate (1) and idler gear (large) (2).
13-17 "

4. Oil pump assembly Remove oil pump assembly (1).
DISASSEMBLY
5. Idler gear (small) Remove mounting bolts, then remove plate (1) and idler gear (small) (2).
6. Camshaft assembly Remove bolt from hole in cam gear, then pull out camshaft assembly (1). # When removing the camshaft, rotate it while pulling it out to prevent damage to the cam bushing.
7. Timing gear case A) Using eyebolts (A) (Thread dia. 10 mm, Pitch 1.5 mm) [0.3937 in, P 0.0591 in], sling gear case, then remove mounting bolts. B) Install guide bolts, and remove gear case (1). Timing gear case: 65 kg (143 lb)
13-18!"
DISASSEMBLY AND ASSEMBLY Cylinder Block

1. Piston cooling nozzle Remove mounting bolts, then remove each piston cooling nozzle (1). # Before removing the piston and connecting rod assembly, remove the piston cooling nozzle. # Rotate 90 so that it does not contact the piston when it is removed.
DISASSEMBLY
2. Piston and connecting rod assembly A) Using dial gauge (1), measure connecting rod side clearance to act as a guide when assembling. # Check the stamped number on the connecting rod cap. (The cap number and cylinder number must match. The number is stamped on the cam side.) If there is no stamped mark, mark the cylinder No. with an electric pen before removing. Do not stamp a mark.
B) Rotate the crankshaft so that the piston to be removed is at bottom dead center. C) Loosen connecting rod bolt (1) 5 6 turns. If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.
D) Tap head of connecting rod bolt with a plastic hammer, then disassemble connecting rod cap and connecting rod. E) Remove carbon from top wall of liner with fine sandpaper. F) Rotate crankshaft, and align with top dead center, then remove connecting rod cap (2). G) Push in piston and connecting rod from oil pan end with push bar (1), and support piston (3) at cylinder head end while removing it. # Be careful not to damage the inside surface of the liner with the corner of the connecting rod when removing it.
13-19 "

H) Remove other piston and connecting rods in the same way. # # Keep in a safe place and be careful not to damage the piston sliding surface and the bearing. Assemble the connecting rod and cap temporarily and keep together with the bearing to prevent mistakes when reassembling.
DISASSEMBLY
I)
Disassemble the piston and connecting rod assembly. i) ii) Remove snap ring (4). Support connecting rod (5) with hand, then pull out piston pin (6), and disassemble piston (7) and connecting rod. iii) If the piston pin is stiff and cannot be removed, heat it in hot water (100C [212F], 5 min.) before removing it. iv) Remove snap ring on the opposite side.
v) Using piston ring tool B, remove piston ring (8). vi) Remove oil ring expander (9). # Keep the piston, connecting rod, connecting rod bearing, piston ring, and piston pin in sets for each cylinder.
3. Crankshaft A) Before removing the crankshaft, use dial gauge (1) to measure end play of crankshaft, and use it as a guide when assembling.
13-20!"

B) Remove mounting bolts (2) of main cap (1). C) Insert bolt in hole of main cap, and move the main cap from side to side to remove it.
DISASSEMBLY
Lower thrust bearing (3) is installed to the No. 7 main cap, so after removing it, mark the assembly position.
D) Using wire, lift off crankshaft (4). # When raising the crankshaft, be careful not to hit it against the cylinder block and damage it. After removal, keep it in a safe place. Crankshaft: 210 kg (463 lb)
E) Remove upper thrust bearing (5). F) Remove upper bearing (6). # Use tags or a felt pen to mark the assembly position of the main cap, main bearing, and thrust bearing, then keep them in sets for each cap in a safe place.
13-21 "

4. Cylinder liner A) Before removing cylinder liner, use tool D and dial indicator (1) to measure protrusion of cylinder liner. # When measuring the protrusion of liner, tighten the liner with a plate to prevent the liner from floating up on the O-ring. Plate mounting bolt: 7 10 kgm (51 72 ft-lb)
DISASSEMBLY
B) Using liner puller C, pull out cylinder liner (1).
13-22!"

12
WASHING
WASHING
Wear protective eyewear to prevent fluid from possible contact with the eyes. When washing, divide the parts into small parts and large parts, and wash the small parts in a bath like the one shown on the right. Before washing disassembled parts, remove the gasket carbon with a wire brush. After washing, dry the washing fluid off completely with compressed air. Make sure that no cleaning fluid remains in the bolt holes. Bolts may not be properly tightened if fluid is present.
WASHING CYLINDER BLOCK

1. Before washing the cylinder block, remove the plugs of the oil line in the cylinder block. # # Timing case end: 7 places Flywheel end: 5 places
2. Clean with a stiff wire brush to prevent any metal particles from remaining in the oil line. 3. Use sandpaper to polish the O-ring contact surface smooth at the bottom of the liner bore and to remove the burrs and flashes from the liner bore.
4. Clean the oil line thoroughly with the jet cleaner nozzle of the cleaning machine. 5. Dry off the cleaning fluid completely with compressed air. # Make sure that no cleaning fluid remains in the bolt holes. Bolts may not be properly tightened if fluid is present.
13-23 "

12 6. Press fit plug with push tool. Outer circumference of plug: Thread tightener (LT-2) # If the plug is bent when it is pushed in, it will cause leakage of water, so be careful to insert it straight.
WASHING
Unit: mm Inside diameter of plug 30 [1.1811 in] 29.5 D [1.1614 0 0.0039 26.5 d [1.0433 0 0.0039 H t in] [1.4331
0 0.0039 0 0.1 0 in] [1.15512 0.0039 in] 0 0.1
40 [1.5748 in] 39.4

0 0.1
36.4
0 0.1
in]
6.4 0.1 8.9 0.1 [0.252 0.0039 in] [0.3504 0.0039 in] 1.0 [0.0394 in] 1.0 [0.0394 in]
13-24!"

12 WASHING
WASHING
CRANKSHAFT
If the engine is disassembled, wash the crankshaft before inspecting.
1. Clean the crankshaft with a steam cleaner, then use a wire brush like the one shown in the diagram on the right to clean all the oil holes. 2. After washing, dry the cleaning fluid off thoroughly with compressed air. 3. Use a small magnet to completely to completely remove all the metal particles from the oil holes.
WASHING CONNECTING ROD

1. Clean the connecting rod with a steam cleaner, then use a wire brush to clean the oil holes. 2. If the inside surface of the hole at the big end of the connecting rod is black, but the problem is small and the dimensions are still within the specified value, the connecting rod can be used as it is. If the black portion is to be removed, use sandpaper (#800 #1000) and polish lightly. # Polish lightly so that the original honing grain is not removed. If the polishing removes the honing grain, and the wave on the inside surface exceeds the limit, the connecting rod must not be used again.
3. Blow with air and use a cloth to remove all the dirt inside the big end of the connecting rod.
13-25 "

12
MEASURING PARTS
MEASURING PARTS
Before reassembling disassembled parts, check visually that there are no cracks, damage, or abnormal wear. Inspect for reuse. If no abnormalities are found during the visual inspection, use an accurate measuring device to measure the specified position precisely. Action and judgement on whether the parts can be reused shall be in accordance with the maintenance standard.
MEASURING CURVATURE OF CRANKSHAFT

1. Support the center of both ends of the crankshaft with lathes, put the indicator of the dial gauge perpendicularly in contact with the journal at the center, and set it to 0. # If no lathe is available, support the No. 1 and No. 7 journals in a V block.
2. Rotate the crankshaft one turn, and measure the difference between the maximum reading and minimum reading of the dial gauge. # Do not measure with both ends of the crankshaft supported on V blocks. This method produces an error because of the eccentric wear of the journal.
MEASURING OUTSIDE DIAMETER OF JOURNAL

Using a micrometer, measure the outside diameter of the main journal and pin journal in the X and Y directions.
MEASURING OUT-OF-ROUNDNESS OF JOURNAL

Measure the outside diameter of the journal in the X and Y directions and calculate the difference.
13-26!"

12 MEASURING
MEASURING PARTS
SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL

Check the surface roughness using the surface roughness standard piece shown in the diagram below. Part No. Standard piece # 790-101-8110
When measuring the surface roughness, compare the surface roughness of the journal with the standard piece. If there are any scratches or dents in the surface of the crankshaft journal, correct the surface roughness. However, if the outside diameter of the journal is close to the standard value and there is no margin for correction (the scratches and dents cannot be removed by correcting the surface roughness), correct by grinding.
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE

1. Set the depth gauge (2) on gauge block (1), then set the gauge indicator to 0. 2. Set the gauge block parallel with the top surface of the cylinder block, and measure the depth of the counterbore. When doing this, slide the measurement portion and measure at several places. # Clean the counterbore and top surface of the cylinder block before measuring.
13-27 "
MEASURING PARTS
MEASURING MAIN BEARING BORE

1. Install the main bearing cap to the cylinder block, and tighten to the specified torque. 2. Using a dial bore gauge to inside micrometer, measure the main bearing bore. # When measuring the main bearing bore, measure in two directions (X and Y).
MEASURING CURVATURE OF CAMSHAFT

1. Support the center of both ends of the camshaft with lathes, put the indicator of the dial gauge perpendicularly in contact with the journal at the center, and set it to 0. 2. Rotate the camshaft one turn, and measure the difference between the maximum reading and minimum reading of the dial gauge.
MEASURING OUTSIDE DIAMETER OF JOURNAL

Using a micrometer, measure the outside diameter of the camshaft journal.
13-28!"
MEASURING PARTS
MEASURING HEIGHT OF CAM

Using a micrometer, measure cam height H for the intake and exhaust.
MEASURING PISTON RING GROOVE

Special tools
No. A Part No. 795-901-1130 Part Name Wear gauge Qty 1
1. Measuring keystone ring groove Push piston ring wear gauge A lightly into the ring grooves of the top ring and second ring, and measure the wear of the ring groove.
# #
If the shoulder of the wear gauge contacts the piston, replace the piston. Carry out the measurements at 8 places around the circumference.
2. Measuring straight ring groove Assemble the piston ring to the cylinder liner, push the piston ring into the area of the cylinder where there is least wear, then measure the piston ring end gap with a feeler gauge. # Insert the piston ring so that it is at right angles to the sliding portion of the liner.
MEASURING PISTON RING END GAP

Assemble the piston ring to the cylinder liner, push the piston ring into the area of the cylinder where there is least wear, then measure the piston ring end gap with a feeler gauge. # Insert the piston ring so that it is at right angles to the sliding portion of the liner.
13-29 "

12 MEASURING
MEASURING PARTS
OUTSIDE DIAMETER OF PIS-
TON
Use a micrometer to measure the dimension L at the piston skirt (45 mm from bottom, at right angles from pin hole).
MEASURING LENGTH OF CONNECTING ROD

1. Tighten the mounting bolts of the connecting rod cap to the specified torque. # # Check that the number at the rod and cap ends of the connecting rod are the same. Do not assemble the connecting rod bearing.
2. Assemble a new piston ring pin in the hole at the small end of the connecting rod. # Coat the piston with grease (G2-LI) before installing.
3. Support both ends of the piston pin on V blocks, and support both ends of the connecting rod on square blocks 4. Measure the distance A between the big end and small end with a height gauge. 5. Measure the inside diameter of the big end and small end. # Calculate the value for the length B of the connecting rod as follows.
Connecting rod dimension B ID of big end + ID of small e n d 2
-------------------------------------------------------------------------------- + A
If the value exceeds the permitted value, replace the connecting rod.
13-30!"
MEASURING PARTS
MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD

Use an inside micrometer to measure the dimension at positions (a) and (b) in the X and Y directions. # If the value exceeds the permitted value, replace the bushing.
MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD

Use an inside micrometer to measure the dimension at positions (c) and (d) in the X, Y, and Z directions. # If the value exceeds the permitted value, or if there are scratches on the inside diameter at the large end, replace the connecting rod. Do not re-use any connecting rod if there has been seizure of the bearing.
MEASURING CURVATURE, TWISTING OF CONNECTING ROD

1. Method for measuring curvature A) Tighten the mounting bolts of the connecting rod to the specified torque. Do not assemble the connecting rod bearing. B) Assemble a new piston pin in the hole at the small end of the connecting rod, place V blocks on a flat surface, then set both ends of the piston pin on the V block. Coat the piston pin with grease (G2-LI) before installing. C) Stand the connecting rod perpendicularly, and support both sides of the big end with square blocks. D) Set the indicator of height gauge (1) at the front of the hole at the big end, set it in contact with the bottom, then set the gauge to 0. E) Move the height gauge to the opposite side by a distance equal to the width of the big end, and read the measurement of the gauge.
13-31 "

2. Method for measuring twisting
MEASURING PARTS
A) From the condition described above, remove the square blocks, lay the connecting rod down, and support the big end on the tip of a conical jack.
B) Measure the big end in the same way as when measuring the curvature. Calculate the value for the curvature and twisting as follows.
Curvature, twisting
Dimension A ------------------------------- Actual measured value Dimension B
STANDARD PRESSURE FOR PARTS PRESSURE TESTING

Cylinder head: 3 3.5 kg/cm 2 (42.6 49.8 psi) Oil cooler element: 16 kg/cm2 (227.5 psi) Between oil cooler and cover: 2 kg/cm2 (28.4 psi) Aftercooler: 4 kg/cm2 (56.9 psi)
13-32!"

12
ASSEMBLY
ASSEMBLY
TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD
The important bolts on the 12V140Z-1 series engine use the plastic range turning angle method for tightening. This method uses special bolts, and by tightening the bolts to the load where the bolt starts to deform permanently (plastic range), it is possible to get an accurate, high tightening force. (Of the methods used for tightening bolts, the method using checking of torque is the most common, but because of the influence of friction factors, it is difficult to control the tightening force accurately.) The tightening method using the plastic range turning angle method uses the initial tightening torque and the turning angle to tighten the bolts. Bolts tightened with the plastic range turning angle method on the 12V140Z-1 series engine. Cylinder head mounting bolts Main cap mounting bolts Connecting rod cap mounting bolts With the plastic range turning angle method, there is a permanent deformation remaining after tightening. Therefore, there is a limit to the number of times that the bolt can be used, so please observe the following. After tightening, make one punch mark. If any bolt has more than 5 punch marks, do not use it again; replace it with a new bolt. When tightening to an angle greater than the specified angle, loosen completely before tightening again. (In this case, make two punch marks.) The target for the tightening angle should be the standard value tolerance.
13-33 "

12 SPECIAL
ASSEMBLY
TOOLS
Part Description Valve Spring Compressor Piston Ring Expander Protrusion Gauge Liner Driver Piston Ring Compressor Wrench (Angle/Torque) Seal Installer (front) Seal Installer (rear)
No. Part Number A 3375960 B 3823137 D 3823495 E ST1229 F 3822736 G 790-331-1110 795-602-2200 H 795-602-2300 .
Wash all parts clean, and check that there are no dents, scratches, or casting defects. Check also that all oil or water passages are clear before assembling
PREPARATORY WORK
Before inserting the cylinder liner, take the following action with the cylinder block. 1. Remove the rust and scale from surfaces (A) and (B) with sandpaper until the machining surface appears. 2. Polish portions (R) and (r) with #200 sandpaper so that the R surface is smooth. 3. Polish potions (B), (R), and (r) with #200 sandpaper so that they become smooth. If the corner of the R portion is sharp or there are burrs, polish with a scraper or sandpaper. Be sure to finish this surface particularly smoothly so that is does not scratch the O-ring. 4. If surface (R) is pitted and rough, and cannot be corrected, replace the cylinder block. 5. If surface (A) and portions (R) and (r) are pitted and rough, finish them smoothly. 6. Inspect the counterbore, and remove any burrs or flashes. If there are any metal particles or dirt on surface (C), the liner will not fit properly in close contact, and this may cause problems such as leakage of water or protrusion of liner. # If there is any drooping, corrosion, or pitting left in the counterbore, carry out additional machining.
13-34!"

12 GENERAL
ASSEMBLY
ASSEMBLY
Cylinder block
1. Cylinder liner # Replace the liner O-ring and clevis seal with new parts immediately before assembling the liner. A) Installing liner O-ring and clevis seal i) Check the cylinder liner O-ring groove and outside circumference of the liner to confirm that there is no rust or pitting. If the surface is rough and pitted, it may cause leakage of water, so replace the liner. Coat the liner O-ring and clevis seal with soapy water. Oil causes the clevis seal and O-ring to swell and deteriorate, so do not leave them soaking in oil. If oil is used, coat with a small amount of clean engine oil (SAE30) with a brush immediately before assembly. iii) Assemble the liner O-ring and clevis seal to the liner as shown in the diagram on the right. ii)
B) After installing the liner O-ring, check for twisting. If any twisting is found, use a smooth bar (approx. 10) [ 0.3937 in] to remove the twisting.
To prevent the clevis seal from twisting when it is installed, press it around the whole circumference so that it fits into the seal groove. Assemble the clevis seal with the chamfered side facing down.
13-35 "

C) Inserting cylinder liner. i) Using a cloth, wipe off all the dirt and oil from the contact surface of the liner lip and the cylinder block counterbore.
ASSEMBLY
Coat the mating surface (a) of the cylinder block and cylinder liner counterbore with silicon-based gasket sealant (LG-6). Width of gasket sealant: 1.5 2.0 mm (0.0590 0.0787 in)
ii)
Make an overlap of 6 6 mm (0 0.4724 in) at the beginning and end when coating with gasket sealant LG-6.
13-36!"

D) When machining the bottom contact surface of the counterbore liner lip and using a shim. i) Coat the bottom of the shim thinly with gasket sealant LG-6, then assemble the shim. ii) Next, coat with gasket sealant LG-6 in the same way as when not using a shim.
ASSEMBLY
E) Coat the liner O-ring, clevis seal, and cylinder block contact surface with a small amount of engine oil (SAE #30) immediately before press fitting the liner. # # Coat the contact surface of the cylinder block uniformly around the whole circumference by hand. There are two different types of pistons and cylinder liners. Small piston Part No. 6212-31-2151 must be used with small liner Part No. 6211-21-2230. Large piston Part No. 6212-31-2161 must be used with large cylinder liner Part No. 6211-21-2240.
F) Set the T mark on the top surface of the liner facing the front, then insert cylinder liner (1) into the cylinder block, taking care not to damage the O-ring. G) Use your weight and push the liner in with both hands. If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes. H) Using a liner driver E, press fit cylinder liner (1) into the cylinder block.
I)
Using the following procedure, squeeze out the gasket sealant coated on the counterbore. i)
Tighten the cylinder head temporarily with a used head gasket. Bolt (7) may be tightened partially.
13-37 "

Remove the cylinder head, and wipe off gasket sealant that comes out from between the cylinder liner and cylinder block. If the gasket sealant sticks to the head gasket grommet, the grommet will be deformed. This will cause water leakage, so be sure to wipe off all excess gasket sealant. ii)
ASSEMBLY
J) After press fitting the cylinder liner, use tool D to measure the protrusion of the cylinder liner. When measuring the protrusion of the cylinder liner, hold the cylinder liner down with plate (1) to prevent the cylinder liner from being forced up by the elasticity of the O-ring during measurement. Measurement positions: (a), (b), (c), (d) (4 places) Plate mounting bolt: 69 98 Nm (51 72 ft-lb) Protrusion of cylinder liner: 0.080 0.185 mm (0.0031 0.0073 in) If it is not within the standard value, take the action given in the MAINTENANCE STANDARD.
# #
2. Crankshaft A) Align the protrusion of upper main bearing (6) with the notch in the cylinder block, then assemble in the cylinder block. Upper bearing: With oil hole The bearing for No. 4 is wider than the other bearings, so be careful not to mistake it when assembling. Width a of bearing No. 4 bearing: 52 mm (2.0 in) Other bearings: 48 mm (1.9 in) Check that there is no dirt at the rear face of the bearing before tightening. Do not coat the rear face of the bearing with oil. B) Knock in roll pin so that protrusion from end face of block is 2.7 3.4 mm (0.11 0.13), then install upper thrust bearing (5). Install the thrust bearing with the side with the groove on the crankshaft side.
# # #
# #
13-38!"

C) Coat inside surface of upper main bearing with engine oil (SAE#30). # Check for the following before assembling the crankshaft. Abnormality in the front, rear side threaded portion (The bolt must go in smoothly when turned by hand.) Scratches or dents on the pin or main journal portion. Dirt stuck to the inside of the oil hole.
ASSEMBLY
D) Raise crankshaft (4), and assemble to the mounting position, taking care not to hit the cylinder block.
E) Align the protrusion of lower bearing (5) with the notch in the main cap, and install. Check that there is no dirt at the rear face of the bearing before tightening. Coat the inside surface of the bearing with engine oil (SAE#30). Do not coat the rear face of the bearing with oil.
13-39 "

# # # Lower bearing: No oil hole The bearing for No. 4 is wider than the other bearings, so be careful not to mistake it when assembling. Width a of bearing No. 4 bearing: 52 mm (2.0 in) Other bearings: 48mm (1.9 in)
ASSEMBLY
F) For No. 7 cap, knock in the roll pin so that the protrusion from the end face of the cap is 2.7 3.4 mm, then install lower thrust bearing (3) on both sides. Install the thrust bearing with the side with the groove on the crankshaft side. G) Coat the journal surface of the crankshaft with engine oil (SAE#30), check that the stamped number on each main cap (2) matches the number on the cylinder block, then install the main caps. Assemble the main cap with the cast part number facing the front of the engine. H) Coat the washer and the mounting bolt thread of the main cap with engine oil (SAE#30), then screw in the bolts in turn to insert the main cap completely. Do not use an impact wrench to tighten the bolts. This may damage the threads. Always tighten with a hand tool. I) When tightening, start from the center main cap and work in order to the outside. Tighten the bolts to the specified tightening torque using the following steps.
i)
Tighten main cap mounting bolts in three steps, as follows:
Tighten both bolts to first torque value. 271 299 Nm (199 220 ft-lb)
Tighten both bolts to second torque value. 559 579 Nm (413 426 ft-lb)
Reference marks on the bolt and cap; then turn the bolt an additional 90.
13-40!"

ii) After tightening, make one punch mark on the bolt head. If the bolt head has five punch marks, do not reuse it. Replace the bolt with a new bolt.
ASSEMBLY
J) After tightening bolts, rotate crankshaft, and check that it rotates smoothly. Starting torque of shaft: Max. 147 Nm (108.5 ft-lb)
# # #
K) Measure end play of crankshaft with dial gauge (1). End play: 0.140 0.32 mm (0.0056 0.0125in) Lever the center portion of the counterweight and measure the end play. If it is within the standard value, take the action given in the maintenance standard.
3. Piston, connecting rod assembly A) Assemble piston and connecting rod. i) Fit oil ring expander (9) in oil ring groove. ii) Using piston ring tool B, assemble oil ring, second ring, and top ring in order.
# # #
Assemble each piston ring as shown in the diagram. Set each ring with the stamped mark facing up, then assemble to the piston. When assembling the oil ring, first take out the expander and fit it to the piston, then assemble the oil ring. When doing this, check that the expander is fitted completely into the ring groove. The end gap of the expander coil must be at 180 to the end gap of the oil ring.
13-41 "

B) Install snap ring (10) on one side. There are two different connecting rods. The left bank uses connecting rod, Part No. 6215-31-3200 (small piston) ONLY. The right bank uses connecting rod, Part No. 6215-31-3100 (large piston) ONLY. Using the wrong part will cause engine failure.
ASSEMBLY
# #
C) Set piston (7) and connecting rod (5) in position. Align the casting mark [EX F] on the piston with the chamfered side of the hole at the big end of the connecting rod when assembling. D) Coat the piston pin boss and the inside of the connecting rod bushing with engine oil (SAE#30), face the connecting rod in the position described above, then insert piston pin (6). E) Install snap ring (4) on the opposite side. Rotate the left and right snap rings to check that the snap rings are completely fitted into the ring groove. Check that the connecting rod moves smoothly. F) Align the protrusion of connecting rod upper bearing (11) with the notch in the connecting rod, then install Check that there is no dirt at the rear face of the bearing before assembling. Do not coat the rear face of the bearing with oil. Check that the hole in the bearing at the big end and the bushing at the small end of the connecting rod are aligned with the oil hole in the connecting rod. Before assembling the connecting rod, check that there is no dirt stuck inside the connecting rod oil hole.
# # #
G) Align the protrusion of connecting rod lower bearing (12) with the notch in the connecting rod cap, then install. Check that there is no dirt at the rear face of the bearing before assembling. When assembling, do not coat the rear face with engine oil.
13-42!"

# H) Coat cylinder liner with engine oil (SAE#30). Coat the whole circumference uniformly with engine oil by hand.
ASSEMBLY
I) #
Rotate the crankshaft and set pin journal of cylinder for insertion at top dead center There are two different types of pistons and cylinder liners. Small piston Part No. 6212-31-2151 must be used with small liner Part No. 6211-21-2230. Large piston Part No. 6212-31-2161 must be used with large cylinder liner Part No. 6211-21-2240. J) Check number of piston and connecting rod assembly, and insert in cylinder at position shown in the diagram on the right. Set the cylinder block so that the cylinder faces the side in order to prevent the piston and connecting rod assembly from entering the cylinder suddenly when it is inserted. K) Original engine assembly has large piston and liner on one bank. The small piston and liner are on the other bank.
Piston assembly position
13-43 "

12 L) Align end gap of each piston ring in the position shown in the diagram below
ASSEMBLY
M) Coat piston ring uniformly with engine oil (SAE#30). N) Tighten piston ring with piston ring holder F, then push in piston head with wooden bar.
# #
O) Using connecting rod pulling tool shown in the diagram on the right, pull connecting rod, and fit it in close contact with pin journal. Check that the connecting rod bearing is correctly in position. To make a connecting rod pulling tool, weld a bar to an old connecting rod bolt. P) Coat crankshaft pin journal with engine oil (SAE#30).
13-44!"

Q) Rotate crankshaft 180 while pulling connecting rod. R) Coat connecting rod lower bearing (12) with engine oil (SAE #30), check cap number, then align with dowel pin, and install connecting rod cap (2).
ASSEMBLY
# #
When coating with engine oil, spread the oil with a finger over the whole part. When assembling a new connecting rod, mark the cylinder number with an electric pen. (Do not make a stamped mark) Do not change combination of connecting rod and cap under any circumstances.
S) Coat thread and washer of connecting rod bolt with engine oil (SAE #30).
T) Tighten connecting rod bolts (1) in turn until connecting rod cap is in tight contact. If an impact wrench is used to tighten the bolts, there is danger of damage to the thread, so tighten the bolts with a hand tool.
13-45 "

U) Rotate crankshaft 180, and insert piston and connecting rod assembly of other bank using procedure in Steps H) T). Tighten the connecting rod bolts as follows. If impact wrench is used to tighten bolts quickly, there is danger of damage to thread, so tighten the bolts with hand tool. 1st step: Tighten to 69 78 Nm (51 57 ft-lb) in order shown in diagram. 2nd step: Tighten again to 69 78 Nm (51 57 ft-lb) in order shown in diagram. 3rd step: Using wrench G, turn 90
+30 0
ASSEMBLY
# #
to tighten.
When not using wrench G, tighten as follows. Tighten bolts. 69 78 Nm (51 57 ft-lb)
Place reference marks on bolt and cap, then tighten the bolt an additional 90.
After tightening, make one punch mark on the bolt head. If the bolt head has five punch marks, so not reuse it. Replace the bolt with a new bolt. After assembling the connecting rod, check that the crankshaft rotates smoothly. V) Using dial gauge (1), measure side clearance on connecting rod. Standard for side clearance: 0.3 0.454 mm (0.0119 0.0178 in) If the connecting rod does not move, remove the connecting rod cap and check that there is no mistake in assembly, and that there are no burrs, or dirt caught anywhere.
# #
13-46!"

4. Piston cooling nozzle A) Install cooling nozzle (1). Mounting bolts:34 74 Nm (26 54 ft-lb) # Before installing, check for cracks in the nozzle, and check that there is no clogging inside the nozzle. Face the tip of the nozzle to the side with the mounting hole at the top, insert into the piston, taking care that it does not hit the piston, then turn 90 to install. Before installing, check for cracks in the nozzle, and check that there is no clogging inside the nozzle. B) Rotate crankshaft slowly and check that there is no interference between piston cooling nozzle and piston, crankshaft.
ASSEMBLY
Gear Case
1. Timing gear case Fit gasket and install timing gear case (1). # Coat the gasket thinly in several places with gasket sealant and stick it in position to prevent it from coming off. Exercise caution when inserting the camshaft, to prevent injury to fingers.
2. Camshaft assembly A) Coat cam bushing with engine oil (SAE#30). B) Install camshaft assembly (1), then align with mounting hole of thrust plate, and tighten nylock bolts. Replace the nylock bolts with new parts. Tighten nylock bolts. Nylock Bolts:54 122 Nm (40 90 ft-lb) # When inserting the cam shaft, rotate it while inserting it in order to prevent damage to the cam bushing.
13-47 "

3. Idler gear (small) A) Align match mark D of cam gear and idler gear (2), and install idler gear. B) Fit plate (1) and tighten mounting bolts.
ASSEMBLY
4. Oil pump assembly Fit O-ring, set oil pump assembly (1) in mounting position, then tighten mounting bolts. Mounting Bolts:34 74 Nm (26 54 ft-lb)
5. Idler gear (large) (right bank) A) Align match mark of gear and install idler gear (large). i) Align mark D of cam gear (1) and idler gear (small) (2). ii) Align mark A of idler gear (small) (2) and sub-idler gear (3). iii) Align mark R of idler gear (larger) (3) and crankshaft gear (5). B) Fit plate (6) and tighten mounting bolts. Set plate (6) with the OUT mark facing the outside, then assemble. Check that match marks D, A, and R at four places are aligned.
# #
13-48!"

6. Idler gear (large) (left bank) A) Align match of gear and install idler gear (large). i) Align mark C of cam gear (1) and sub-idler gear (2). ii) Align mark L of idler gear (large) (2) and crankshaft gear (4). B) Fit plate (5) and tighten mounting bolts. Set plate (5) with the OUT mark facing the outside, then assemble. Check that match marks C and L at three places are aligned. After assembling each gear, check the timing mark of the gear again.
ASSEMBLY
# #
7. Measuring backlash of gear A) Fit gear (1) to rear compressor and install temporarily.
B) Install water pump assembly (2) temporarily.
Measure the backlash and end play of each gear with a dial gauge.
13-49 "

12 Standard value for backlash of each gear
Standard Position Judgement position mm AA Right idler gear (small) and right sub-idler gear 0.130 0.390 0.051 0.469 0.051 0.469 0.129 0.391 0.129 0.391 0.052 0.481 0.137 0.421 0.106 0.381 0.085 0.492 0.141 0.425 0.141 0.425 in 0.0052 0.0153 0.0021 0.0184 0.0021 0.0184 0.0051 0.0153 0.0051 0.0153 0.0021 0.0189 0.0054 0.0165 0.0042 0.0150 0.0034 0.0193 0.0056 0.0167 0.0056 0.0167
ASSEMBLY
B1 B1 RIght sub-idler gear and right injection pump gear B1 B1 Left sub-idler gear and left injection pump gear CC DD EE FF GG HH LL RR Left sub-idler gear and left cam gear Right idler gear (small) and right cam gear Right idler gear (large) and water pump drive gear Right idler gear (large) and oil pump gear Left injection pump gear and compressor gear Right cam gear and accessory drive gear Crankshaft gear and right idler gear (large) Crankshaft gear and right idler gear (large)
Standard value for end play of each gear

Part Name mm Idler gear (large) Idler gear (small) Injection pump drive gear Oil pump drive gear Accessory drive gear Crankshaft gear Camshaft gear 0.07 0.18 0.07 0.18 0.07 0.20 0.03 0.088 0.1 0.4 0.14 0.32 0.10 0.25 Standard in 0.0027 0.0070 0.0027 0.0070 0.0028 0.0078 0.0012 0.0034 0.004 0.0157 0.0056 0.0125 0.004 0.098
Position 1 2 3 4 5 6 7
8. Front oil seal, sleeve Take the following action according to the wear of the crankshaft seal contact surface. A) If crankshaft is new, or if there is no wear of surface in contact with seal oil. # Measure dimension of portion (b) of front cover and check for a bolt hole in the end face of the cover. Then use the table below and press fit the oil seal to press-fitting depth a.
13-50!"
ASSEMBLY
Dimension of portion b1 109 mm 114 mm
Bolt hole 6 12 x 1.75 No Yes
Press-fitting depth a for oil seal 13 14 mm 18 19 mm
B) If there is wear of oil seal contact on the surface of crankshaft, and it is possible to correct by moving mounting position of oil seal. Push in a new oil seal and install it at a point where the lip of the oil seal does not reach the wear groove on the crankshaft. Use plastic sleeve supplied with seal to guide seal over nose of crankshaft.
C) If crankshaft has already been corrected in Step B). Install sleeve to crankshaft, then install oversize oil seal.
D) Install sleeve as follows. i) Remove all rust from sleeve press-fitting portion of crankshaft (range of 60 mm from tip). ii) Coat whole of inside surface of sleeve with gasket sealant (LG-7).
13-51 "

iii) Using a plastic hammer, tap end face of sleeve around circumference and install sleeve (1) parallel to crankshaft. The sleeve is symmetrical, so it can be installed in either direction.
ASSEMBLY
# #
iv) Using tool H1, press fit sleeve (1) to specified position. Tighten the bolts uniformly. After press fitting the sleeve, wipe off the gasket sealant that has been squeezed out. (If the gasket sealant that has been squeezed out gets on the seal lip, it will cause oil leakage.)
# #
E) Using tool H1, install front oil seal (2). Tighten the mounting bolts uniformly. The press-fitting depth for the oil seal differs according to the condition of the crankshaft. Select one of the following three types. i) When crankshaft is new, or there is no wear on seal contact surface, insert spacer (1) of 1.8 2.8 mm between installer and oil seal, then install.
ii)
When changing mounting position of oil seal to install, install oil seal with installer H1.
iii) When using sleeve on crankshaft, fit one washer between the installer and crankshaft and install. Before assembling the oil seal, clean the outside circumference of the crankshaft, then coat the whole circumference with engine oil (SAE#30). iv) Use plastic sleeve supplied with seal to guide seal over the nose of the crankshaft.
13-52!"
ASSEMBLY
9. Gear case cover Using eyebolts (A),

(Thread dia. 10 mm, Pitch 1.5 mm) [0.3937 in, P 0.0591 in]
sling then fit gasket and install gear case cover.
Flywheel
1. Rear oil seal, sleeve Take the following action according to the wear of the crankshaft seal contact surface. A) If crankshaft is new, or if there is no wear of surface in contact with seal oil. i) Install at the standard dimension from the end face of the crankshaft. ii) Use plastic sleeve supplied with seal to guide seal over the nose of the crankshaft.
B) If there is wear of oil seal contact surface of crankshaft, and it is possible to correct by moving mounting position of oil seal. Push in a new oil seal and install it at a point where the lip of the oil seal does not reach the wear groove on the crankshaft.
13-53 "

# C) If crankshaft has already been corrected in Step B). Install sleeve to crankshaft, then install oversize oil seal.
ASSEMBLY
D) Install sleeve as follows. i) Remove all rust from sleeve press-fitting portion of crankshaft (range of 60 mm from tip). ii) Coat whole of inside surface of sleeve with gasket sealant (LG-7).
iii) Using a plastic hammer, tap end face of sleeve around circumference and install sleeve (1) parallel to crankshaft. The sleeve is symmetrical, so it can be installed in either direction.
# #
iv) Using tool H2, press fit sleeve (1) to specified position. Tighten the bolts uniformly. After press fitting the sleeve, wipe off the gasket sealant that has been squeezed out. (If the gasket sealant that has been squeezed out gets on the seal lip, it will cause oil leakage.)
13-54!"

E) Rear oil seal Using tool H2, install rear oil seal (2). Tighten the mounting bolts uniformly.
ASSEMBLY
The press-fitting depth for the oil seal differs according to the condition of the crankshaft. Select one of the following three types.
i)
When crankshaft is new or there is no wear on seal contact surface, insert two washers between installer and crankshaft. When changing mounting position of oil seal to install, do not use any washer between the installer and crankshaft.
ii)
iii) When using sleeve on crankshaft, fit two washers in the same way as in Step i).
F) After installing flywheel housing, using dial gauge (1) to measure face runout and radial runout. SAE No. 00: Max. 0.30 mm (0.012 in) SAE No. 0: Max. 0.25 mm (0.010 in)
13-55 "

2. Flywheel A) Using guide bolt, install flywheel (1). B) Align dowel hole in crankshaft with dowel hole in flywheel. This will establish timing position of flywheel.
ASSEMBLY
Coat the thread and washer of the bolt with engine oil (SAE #30). C) Tighten bolts in turn until flywheel is in tight contact.
If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.
D) Secure flywheel with housing (1). # One capscrew has a large shoulder to prevent movement. Install capscrew next to timing hole.
Tighten the mounting bolts as follows. Flywheel mounting bolt Target Step kgm 1st 2nd 3rd 10 30 55 ft-lb 72 217 398 kgm 8 12 ft-lb 58 86 Range
28 32 203 231 53 57 384 412
13-56!"

E) Using dial gauge (1), measure face runout and radial runout. Face runout: Max. 0.30 mm (0.0118 in) Radial runout: Max. 0.30 mm (0.0118 in)
ASSEMBLY
For speed and timing sensor installation information, refer to section 12.
3. Flywheel housing Fit gasket, raise flywheel housing (2), then install and tighten bolts (1).
Tighten the flywheel housing mounting bolts in the order shown in the diagram using the following procedure. Flywheel housing mounting bolt Step 1st 2nd 3rd Procedure Tighten to 345 49 Nm (255 ft-lb) Loosen completely. Tighten to 411 20 N m (303 ft-lb)
Sensor
Install RPM (1) and timing (2) sensors.
13-57 "

12
ASSEMBLY
Front support
Fill oil groove of front support (1) with grease and install. # Amount of grease: Approx. 20 cc (1.2 cu.in) Groove of front mount: Coat with G2-LI
Lower the cylinder block assembly on the stable stand.
Main relief valve, suction pipe

1. Fit gasket and install main relief valve (2). 2. After fitting O-ring, fit suction pipe (4), install bracket (3), and secure in position.
Oil pan
1. Stick gasket to oil pan. 2. Support oil pan (1) with transmission jack, set in mounting position, then tighten bolts.
Damper, crankshaft pulley assembly

1. Raise crankshaft pulley and damper assembly (1), then align dowel pin of crankshaft and install.
Coat the thread and washer of the bolts with engine oil (SAE #30). 2. Tighten bolts in turn until damper and crankshaft pulley are in tight contact.
If an impact wrench is used to loosen the bolts, there is danger of damage to the threads, so loosen the bolts with a hand tool
13-58!"

A) Tighten crankshaft pulley mounting bolts as follows: i) Tighten bolts to first torque value.
ASSEMBLY
54 93 Nm (40 68 ft-lb) ii) Tighten bolts to second torque value.
225 264 Nm (167 195 ft-lb) iii) Tighten bolts to third torque value. 725 764 Nm (536 564 ft-lb) iv) Tighten damper mounting bolt. 97 117 Nm (73 86 ft-lb)
Accessory drive assembly

1. Assemble accessory drive. A) Press fit bushings (10) and oil seal (9) to housing (8). Press fit the bushing 2 mm (0.0787 in) below the end face. Inside surface of bushing: Engine oil (SAE #30) # Press fit the oil seal 1.5 mm (0.0591 in) below the end face. Lip of seal: Grease (G2-LI) Fill 50 80% of the space at the lip.
B) Press fit gear (7) to shaft (5). C) Assemble thrust plate (6) to shaft and gear assembly, then insert from rear of housing. D) Assemble thrust plate (4) to shaft, and press fit hub (3). # Be careful not to damage the seal lip. 2. Fit O-ring and install drive assembly (2). 3. Install pulley (1).
13-59 "
DISASSEMBLY AND ASSEMBLY Thermostat housing

1. Press fit seal (5) to thermostat case (2). 2. Make sure that the seal is not at an angle when press fitting. 3. Assemble thermostat (4) in thermostat case. 4. Fit gasket, then install thermostat case (2) to thermostat housing (3), and tighten mounting bolts. 5. Screw eyebolts (Thread dia. 10 mm, Pitch 1.5 mm) [0.3937 in, P 0.0591 in] into thermostat case, and sling. 6. Fit gasket and install thermostat case assembly (2), (3) to cylinder block. 7. Fit gasket and install connector tube (1).
ASSEMBLY
Cam follower assembly

1. Install cam follower assembly (3), then tighten mounting bolts (2) and secure in position. 44 58 Nm (33 43 ft-lb)
2. Fit gasket and install cover (1). 34 44 Nm (26 32 ft-lb) Fit the seal washers to 4 bolts under the cover and tighten.
Cylinder head assembly

1. Assemble cylinder head A) Coat valve stem and inside surface of valve guide with engine oil (SAE #30), and assemble valve (9). B) Raise cylinder head, and assemble lower seat (8). Check part number of valve for proper location.
13-60!"

C) Install a stem seal to valve (5). Knock in until bottom surface a of the jig contacts lower seat (795-130-1720).
ASSEMBLY
Assemble and install valve springs with closed coils down. D) Fit inner spring (7) and outer spring (6), and assemble upper seat (5). E) Using spring pusher A , compress valve spring, then assemble valve cotter (4).
Tap the valve stem with a plastic hammer, and check that the cotter is fitted securely in the valve stem groove.
2. Check that there is no dirt or dust inside cylinder and mounting surface of cylinder head, and set cylinder head gasket (3) in position. # # When installing the gasket, check that the grommet has been fitted and has not come out of position. The grommets in the head gasket may become deformed by swelling, so do not coat them with gasket sealant.
13-61 "

3. Install cylinder head assembly (2), and tighten mounting bolts (1).
ASSEMBLY
Coat under the bolt head with SAE 140 and coat the bolt thread with SAE 30 lubricant.
Tighten cylinder head mounting bolts 1-6 as follows: Tighten bolts to first torque value. 137 157 Nm (102 115 ft-lb)
Tighten bolts to second torque value. 210 220 Nm (156 162 ft-lb)
Tighten bolts an additional 9030.
Tighten bolt 7. 59 73 Nm (44 54 ft-lb)
# #
After tightening, make one punch mark on the bolt head. If the bolt head has five punch marks, do not reuse it. Replace it with a new bolt.
13-62!"
DISASSEMBLY AND ASSEMBLY Rocker lever

1. Rocker lever housing Fit gasket and install rocker lever housing (2). Tighten mounting bolts. 44 50 Nm (33 43 ft-lb)
ASSEMBLY
2. Crosshead A) Install crosshead (3). Adjust the crosshead as follows. i) Loosen locknut, and turn back adjustment screw. ii) Hold top surface of crosshead lightly, and screw in adjustment screw. iii) After adjustment screw contacts valve stem, screw in a further 20. iv) Tighten locknut to hold in position. 53 65 Nm (39 47ft-lb)
3. Push rod Install push rod (2). # Check that the push rod is fitted in the cam follower.
4. Rocker lever Assemble rocker cover. A) Using push tool, align oil hole of bushing, and knock in rocker lever (2). B) Assemble adjustment screw (3) and locknut (4) to rocker lever.
13-63 "

C) Coat rocker shaft with engine oil (SAE #30), set side with plug facing exhaust rocker lever, then insert rocker shaft. Exhaust end rocker lever: Long Intake end rocker lever: Short
ASSEMBLY
# #
# #
D) Install rocker lever (1) Install with the wide end face of the rocker lever shaft facing down. Check that the ball of the adjustment screw is fitted securely into the socket of the push rod, then tighten the mounting bolts. 93 103 Nm (68 75 ft-lb)
Rocker lever cover

1. Nozzle holder, connection # Check that there is no dirt or dust inside the nozzle holder sleeve. A) Fit O-ring (7) and coat with engine oil (SAE #30). Check that there are no scratches on the O-ring. B) Install gasket (6) to nozzle holder. C) Align with mounting hole of connection of nozzle holder (5), and insert nozzle holder.
Align the match mark, and make sure that the inlet connector tap hole (nozzle holder end) and inlet connector insertion hole (rocker housing end) do not move out of position. D) Insert connection (2) in rocker arm housing, and tighten temporarily. E) Fit holder (4), then fit spherical washer to mounting bolt (3), and tighten. Set one holder on top of the head of the rocker housing mounting bolt, and tighten it.
13-64!"

12 F) Tighten connection (2), then tighten locknut (1). Mounting bolt: 63 73 Nm (44 54 ft-lb) Connection: 34 40 Nm (26 29 ft-lb) Locknut: 34 44 Nm (26 32 ft-lb) # No. 1 injector is equipped with timing control. Lead wire must NOT be pinched.
ASSEMBLY
2. Adjusting valve clearance Adjust valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance.
3. Head cover, turbocharger lubrication tube A) Fit gasket and install air vent tube (4). B) Fit gasket and install turbocharger drain tube (3), then install oil supply tube (2). C) Fit gasket and install head cover (1). D) Install fuel drain tubing Mounting bolt: 5 Nm (48 in-lb) Fuel drain mounting banjo capscrew:9 Nm (80 in-lb)
Oil cooler assembly

1. Oil level gauge, oil filler A) Install oil level gauge guide (2). Fit the O-ring and tighten the nut at the root of the level gauge guide to secure it in position. 50 Nm (38 ft-lb) B) Fit O-ring and install oil filler (1), then secure with bracket.
13-65 "

2. Oil cooler installation A) Install oil coolers B) Tighten capscrews Capscrews:66 Nm (49 ft-lb)
ASSEMBLY
C) Install the o-rings into the back of the oil transfer connection. D) Install the oil transfer connection and capscrews onto the cylinder block. Tighten the capscrews Capscrews:66 Nm (49 ft-lb)
E) Install the lubricating oil bypass valve with gasket. Tighten the capscrews. Capscrews:66 Nm (49 ft-lb)
F) Install the O-rings on the aluminum oil transfer connection. G) Install the connection to the cylinder block and the other oil transfer connection.Tighten the capscrews. Capscrews:66 Nm (49 ft-lb)
13-66!"
DISASSEMBLY AND ASSEMBLY Breather

1. Breather with O-ring groove A) Fit O-ring and install breather (3). B) Fit tube (2), then tighten with clamp. C) Install alternator bracket (1). The alternator bracket is installed to the right bank only.
ASSEMBLY
2. Breather with no O-ring groove. A) Install breather (3). Breather mounting surface: Gasket sealant (LG-7) Breather:25 29 Nm (18.0 21.5 ft-lb) B) Install tube (2), and secure with clamp. C) Install alternator bracket (1).
Water pump assembly

1. Lubricate the O-ring with soapy water and install on the water pump. 2. Install the water pump into the gear case. # Make sure that the threaded plug has been installed into the water pump.
3. Install the four mounting capscrews. 4. Tighten the capscrews. # Two of the capscrews install from the back side. Capscrews:113 Nm (83 ft-lb)
13-67 "

5. Use vegetable oil and lubricate the O-ring on the bypass tube. 6. Install the bypass tube. 7. Install the bypass connection gasket. 8. Tighten the capscrews. Capscrews:40 Nm (30 ft-lb) 9. Install water connection from water pump to block. Water connection:40 Nm (30 ft-lb) 10. Install water filter head and new O-rings. Filter head:40 Nm (30 ft-lb)
ASSEMBLY
Fuel pump drive

1. Fuel pump drive assembly A) Assemble bushings (4) into housing (5) with press and mandrel. B) Align oil hole in bushing with oil hole in housing. C) Coat bushings with engine oil.
D) Lubricate shaft (7) and thrust washer (4). E) Insert shaft through housing (5) with thrust washer (4), washer (6), spline (2), and retaining nut (3).
13-68!"

F) Install thrust washer (5), washer (6), and retaining nut (8) on end of shaft.
ASSEMBLY
G) Use fabricated tool to secure spline coupling (2) while torquing retaining nut (3) and retaining nut (8). Nut (3): 406.7 Nm (300 ft-lb) Nut (8): 542.3 Nm (400 ft-lb)
H) Install injection pump drive case. I) Install new O-rings on front of housing.
J) Install upper support capscrews and four flange mount capscrews. K) Install ECM mount on both sides (1).
2. Injection pump drive gear A) Install assembled hub and gear (1) and (2) on taper shaft. B) Hand tighten large nut (3) and (4). Do not torque until pump timing is set. Hub to gear capscrews: 114 Nm (84 ft-lb)
13-69 "
DISASSEMBLY AND ASSEMBLY Air compressor assembly

1. Install the gasket and the cover plate (support bracket) on the compressor. Do not tighten the six capscrews. The support must be adjusted.
ASSEMBLY
Do not install the splined coupling or the mounting gasket.
2. Install the compressor on the rear of the front gear cover.
3. Install the four capscrews (6). Do not tighten. The compressor must be turned to align the support bracket.
The support MUST be flat against the block. Rotate the compressor until the support is aligned properly against the block. If the support is NOT flat, the compressor will fail. 4. Tighten the four capscrews (6). 60 Nm (45 ft-lb) # The bracket must remain flat against the block. Tighten the support capscrews (7) that are accessible. 45 Nm (35 ft-lb) 5. Remove the four capscrews (6). Remove the compressor.
6. Tighten the two remaining support to compressor capscrews. 45 Nm (35 ft-lb)
13-70!"

7. Install the splined coupling (1), the gasket, and the compressor.
ASSEMBLY
The support MUST be flat against the block. Rotate the compressor until the support is aligned properly against the block. If the support is NOT flat, the compressor and/or accessory will fail. 8. Install the four capscrews (6) and two capscrews (5).
Capscrew (6): 60 Nm (45 ft-lb) Capscrew (5): 45 Nm (35 ft-lb) 9. Install the lubricating oil inlet line to the air compressor. 10. Install the air inlet and outlet connections to the air compressor. Tighten the clamps. Clamp: 6 Nm (50 in-lb) 11. Install water inlet and outlet tubes.
Fuel injection pump

For details on fuel injection pump installation and timing, refer to section 12.
Exhaust manifold assembly

1. Fit gasket and install exhaust manifold assembly (1). 44 54 Nm (33 40 ft-lb) # Fit a spacer to the bolt before tightening.
2. Tighten the mounting bolts in the order shown in the diagram.
13-71 "

Coat the thread of the bolt and the bottom of the bolt head with anti-friction compound (LM-P) before tightening.
ASSEMBLY
Intake manifold, aftercooler assembly

1. Install aftercooler core as follows. A) Fit gasket and install aftercooler core (14). Install with the welded aftercooler core at the top. B) Fit gasket and install cover (13). C) Fit gaskets and install connectors (12). D) Tighten high pressure fuel line clamps.
2. Fit gaskets to both ends of electrical intake air heater and install aftercooler and intake manifold assembly (11). # To prevent the electrical intake air heater from falling out, fit a guide bar into the bottom mounting bolt hole of the intake manifold when installing. Mounting bolt: 59 73 Nm (44 54 ft-lb)
Tighten the mounting bolts in the order shown in the diagram. A) Install electronic control modules B) Install wiring harness and manifold sensors. C) Install harness support clamps and connectors.
13-72!"

3. Right bank A) Install electrical intake air heater wiring (10). B) Fit O-ring and install tube (8).
ASSEMBLY
4. Left bank A) Install clamp (1) of fuel injection tubes and secure injection tubes.
B) C) D) E)
Install heater relay wiring (5). Install tube (3) for aftercooler. Install tubes (1) and (2) for air compressor. Install harness supports, ground connections, and connect sensors.
Turbocharger assembly
1. Install turbocharger assembly (3). Mounting bolt: 44 54 Nm (32.6 39.7 ft-lb) When installing the turbocharger mounting bolts, install each connection, then align the center and tighten fully.
2. Fit gasket and connect turbocharger drain tube (2). 3. Connect turbocharger oil supply tubes (1).
13-73 "
DISASSEMBLY AND ASSEMBLY Intake connector

Fit gaskets and O-rings at each end, then install intake connector (1). # Rotate offset connector for alignment
ASSEMBLY
Fan
1. Fan pulley assembly Using a nylon sling, sling fan pulley assembly (2), set in mounting position, then tighten mounting bolts. # Check that the fan pulley rotates smoothly.
2. Fan belt For details on fan belt installation, refer to section 12. 3. Fan Using a nylon sling, sling fan (1), set in mounting position, then tighten mounting bolts.
13-74!"

12 General 1. Filter A) Install bypass filter (4). B) Install fuel filter (3), oil filter (2), and corrosion resistor (1). Install each filter as follows. Coat seal portion and thread portion of filter cartridge thinly with engine oil (SAE #30). Tighten until packing surface contacts seal surface of filter holder, then tighten further by hand as follows: Bypass filter: 3/4 1 turn Oil filter: 3/4 1 turn Fuel filter: 1/2 3/4 turn Corrosion resistor: 2/3 turn
ASSEMBLY
assembly
2. Alternator assembly A) Install alternator assembly (4), tighten lock bolt (2) and adjustment bolt (1) temporarily, then install belt (3). B) Set so that locknut of adjustment bolt (1) faces in direction of extension of belt (3), then adjust so that deflection is approx. 15 mm when belt (3) is pressed at midpoint with a force of approx. 6kg. After adjusting, tighten lock bolt (2) and locknut of adjustment bolt.
3. Starting motor assembly Fit gasket and install starting motor (1)
13-75 "

12
ASSEMBLY
13-76!"
14
MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 VALVE, VALVE SPRING AND VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4 ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6 CROSSHEAD AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13 CAM FOLLOWER AND PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14 TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 PISTON, PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17 CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19 FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24 OIL COOLER BY-PASS VALVE, REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
14-1

TURBOCHARGER
No Check item 1 End play (Play in axial direction) 2 3 4 5 6 Radial play (Play in radial direction) at compressor wheel Radial play (Play in radial direction) at turbine wheel Tightening torque of blower impeller locknut Tightening torque of turbocharger mounting bolt Tightening torque of V band locknut
Criteria Standard 0.03 [0.001] 0.15 [0.006] Repair limit 0.10 [0.004] 0.46 [0.018]
Unit: mm [in] Remedy Replace thrust parts Replace bearing parts Tighten
0.20 [0.008] 0.53 [0.021] 41 Nm [362 in-lb] 61 Nm [540 in-lb] 8 Nm [70 in-lb]
14-2
ENGINE BODY
ENGINE BODY
CYLINDER HEAD
Tightening order of cylinder head mounting bolts
No 1
Check item Distortion of cylinder head mounting surface Protrusion of nozzle
Criteria Standard 0 - 0.06 [0 - 0.023] Repair limit 0.09 [0.0035]
Standard: 4.65 5.65 [0.183 0.222]
Tightening torque of cylinder head mounting bolt (Coat the thread areas and bearing surface with molybdenum disulfide)
Bolt no.
Order 1st step0
2nd step
3rd step -
4 5 6 7 Tightening torque of nozzle holder mounting bolt Tightening torque of fuel inlet connector Tightening torque of connector pipe locknut Tightening torque of cylinder head cover mounting bolt Target 6.8 kgm [49.2 ft.lb] 3.8 kgm [27.5 ft.lb] 4.0 kgm [28.9 ft.lb] 0.5 kgm [3.6 ft.lb]
Range 4 -16 kgm [101.3 - 115.7 ft.lb] 22 kgm 21.5 - 22.5 kgm [159.1 ft.lb] [155.5 - 162.7 ft.lb] Retighten with 90 120 90 7 kgm 6 7.5 kgm [50.6 ft.lb] [43.4 54.2 ft.lb] Range Retighten 6 7.5 kgm [43.4 54.2 ft.lb] 3.5 4.1 kgm [25.4 29.6 ft.lb] 3.5 4.5 kgm [25.4 32.5 ft.lb] 0.4 0.6 kgm [2.9 4.3 ft.lb]
Target 15 kgm [108.5 ft.lb]
Unit: mm [in] Remedy Repair by grinding or replace Replace nozzle or cylinder head Tighten bolts in accordance with bolt No.
14-3
ENGINE BODY
VALVE, VALVE SPRING AND VALVE GUIDE
14-4
No 1 Check item Amount of valve sinking Criteria Valve Standard size Tolerance Intake valve 0 0.10 [ 0.0039] Exhaust valve 0 0.10 [ 0.0039] Valve Standard size Intake valve 2.4 [0.094] Exhaust valve 2.15 [0.085] Valve Standard size Intake valve 60 Exhaust valve 45 Intake valve 10 [0.394]
ENGINE BODY
Unit mm[in] Remedy Replace valve or valve seat
Thickness of valve lip
Valve seat angle H
Repair limit 0.70 [0.0275] 0.70 [0.0275] Repair limits 1.9 [0.075] 1.6 [0.063] Repair limits 015 015
Replace valve Repair or replace valve and valve seat Replace valve
Outside diameter of valve stem
Inside diameter of valve guide
Clearance between valve guide and valve stem
Bend of valve stem 5 Protrusion of valve guide
-0.045[-0.0017] -0.060[-0.0023] Exhaust valve 10 [0.394] -0.074[-0.0029] -0.089[-0.0035] Before inserting 10 [0.394] +0.011[+0.0004] -0.011[-0.0004] After inserting 10 [0.394] +0.011[+0.0004] -0.011[-0.0004] Valve Standard clearance Clearance limit Intake valve 0.034-0.071 0.22 [0.0013-0.0027] [0.0086] Exhaust valve 0.063-0.100 0.24 [0.0025-0.0039] [0.0094] Repair limit: 0.02 [0.0007] (total indicated runout for 100 [3.937]
Replace valve guide
Replace valve or valve guide
Standard size Tolerance 23 [0.906] 0.2 [ 0.0078] 6 Valve spring Valve Standard size Repair limit Replace spring Free Installed Installed Free Installed valve spring length length load length load Outer 81.7 51.0 43.32.2 38.7 kg (Large) [3.22] [2.01] kg [85.3 lb] [95.45 9.7 lb] Inner 72.0 46.0 22.01.5 19.7 kg (Small) [2.84] [1.81] kg [43.4 lb] [48.56.6 lb] Squarence of valve spring Repair limit: 2 (for both ends) H The intake valve cannot be reground. It must be replaced with a new part. H If the exhaust valve has been used for more than 10,000 hours, replace with a new part.
Replace valve Repair
14-5
ENGINE BODY
ROCKER ARM AND SHAFT
No. Check item 1 Outside diameter of rocker arm shaft Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm bushing 2 Valve clearance (When engine cold) Tightening torque of rocker arm adjustment screw locknut
Criteria Standard size 32.0 [1.26] 32.0 [1.26] Standard clearance 0.0285 0.0935 [0.0012 0.0036] Tolerance 0.0065 [ 0.0002] + 0.087 [+0.0034] + 0.035 [+0.0013] Clearance limit 0.13 [0.0051]
Valve Standard size Tolerance Intake 0.43 [0.0169] 0.02 [0.0007] Exhaust 0.80 [0.0315] 0.02 [0.0007] Target Range Tighten 6 kgm [43.4 ft.lb] 5.4 6.6 kgm [39.1 47.7 ft.lb]
Unit: mm [in] Remedy Replace rocker arm shaft Replace rocker arm Replace rocker arm or rocker arm shaft Adjust
14-6
ENGINE BODY
CROSSHEAD AND GUIDE
No 1
Check item Depth of crosshead stem
Standard size 6.2 [0.244] 11 [0.433] 11 [0.433] 49.0 [1.929]
3 4
Inside diameter of crosshead Outside diameter of crosshead guide Protrusion of crosshead guide Tightening torque of crosshead locknut
Criteria Tolerance +0.3 [+0.0118] 0 [0] +0.06 [+0.0023] +0.02 [+0.0007] +0.11 [+0.0043] 0 [0] 0.25 [ 0.0098] 6 0.6 kgm [43.4 4.3 ft-lb]
Repair limit 6.71 [0.264] 11.17 [0.440] 10.95 [0.431] -
Unit: mm [in] Remedy Replace
Repair Tighten
14-7
ENGINE BODY
CYLINDER BLOCK
14-8
No. Check item 1 Distortion of cylinder head mounting surface 2 Inside diameter of main bearing hole Surface roughness of main bearing mount hole Out-of-roundness of mount hole Thickness of No.4 main bearing only Except No.4 Inside diame- Journal ter of main No.4 bearing only Except No.4 Inside diameter of camshaft bushing hole Inside diameter of camshaft bushing Tightening torque of main bearing cap bolt (Coat thread area with engine oil) Criteria Standard size 0 0.09 [0 0.0035] Standard size 157 [6.18] Within 10 S Service limit: 0.005 [0.0002] Repair limit 0.135 [0.0053] Tolerance + 0.025 [+ 0.001] 0.010 [ 0.0004]
ENGINE BODY
Unit: mm [in] Remedy Repair by grinding or replace Replace or repair main bearing cap Correct
0.050 [ 0.0019] 0.060 [ 0.0023] 4.5 [0.177] 0.065 [ 0.0026] 0.075 [ 0.0030] Standard size Tolerance Repair limit 148 [5.827] + 0.175 [+ 0.0068] 148.23 [5.835] + 0.130 [+ 0.0051] 148 [5.827] + 0.145 [+ 0.0057] 148.20 [5.834] + 0.100 [+ 0.0039] 69 [2.717] + 0.025 [+ 0.0009] 0 [0] 65 [2.559] + 0.040 [+ 0.0016] 0 [0] Target 29 kgm [209.8 ft.lb] 65.15 [2.565]
4.5 [0.177]
Replace main bearing
Tightening torque of oil pan mounting bolt Difference of face between cylinder block and front cover
Range 27.5 30.5 kgm [198.9 220.6 ft.lb] 2nd step 58 kgm [419.5 ft.lb] 57.0 59.0 kgm [412.3 426.7 ft.lb] 3rd step Retighten with 90 90 120 Target Range 6.7 kgm [48.5 ft.lb] 6 7.5 kgm [43.4 54.2 ft.lb] Repair limit: 0.14 [0.0055] Replace by reassembling
Order 1st step
Repair or replace cylinder block Replace camshaft bushing Retighten
The main cap bolt can be tightened a maximum of 12 times. Make a punch mark on the bolt head each time it is tightened.
14-9
ENGINE BODY
CYLINDER LINER
No. Check item 1 Protrusion of cylinder liner
Criteria Permissible range: 0.08 0.185 [.0031 .0073]
Inside diameter of cylinder liner
Outside diameter of cylinder liner (Counter bore) Clearance between cylinder liner and block (Counter bore)
Outside diameter of cylinder liner (Counter bore bottom) Interference between cylinder liner and block (Counter bore bottom)
Outside diameter of cylinder liner (O-ring part) Clearance between cylinder liner and block (O-ring part)
Tolerance +0.020 [+0.0008] 0 [0 ] L 140 [5.512] +0.040 140.14 [5.517] [+0.0015] +0.021 [+0.0008] Standard size Tolerance 170.2 [6.692] 0 [0 ] 0.10 [0.0039] Standard: 0 0.163 [0 0.0064] Replace cylinder liner or cylinder block Standard size Tolerance Replace cylinder liner 161.2 [6.346] +0.090 [+0.0035] +0.050 [+0.0019] Standard interference Interference limit Repair cylin0.02 0.12 [0.0008 0.0047] 0.02 0.12 [0.0008 0.0047] der liner or repair or replace cylinder block Standard size Tolerance Replace cylinder liner 158 [6.22] 0.024 [0.0009] 0.049 [0.0019] 0.024 0.094 [0.001 0.0037] Replace cylinder liner or cylinder block
Rank S
Standard size 140 [5.512]
Unit: mm [in] Remedy Repair cylinder liner or repair or replace cylinder block Repair limit Replace cyl140.12 [5.516] inder liner (Only L is supplied)
14-10
ENGINE BODY
CRANKSHAFT
No. Check item 1 End play
Criteria Standard size 0.140 0.315 [0.0056 0.0124]
Outside diameter of main journal
STD 0.25 U.S. [0.0098] 0.50 U.S. [0.0197] 0.75 U.S. [0.0295] 1.00 U.S. [0.0394]
Standard size 148.00 [5.827] 147.75 [5.817] 147.50 [5.807] 147.25 [5.797] 147.00 [5.787]
Unit: mm [in] Remedy Repair limit Repair by using over 0.50 [0.0196] size thrust bearing or replace Tolerance Repair limit Repair by 0 147.98 [5.825] using over 0.020 147.73 [5.816] size bearing or replace [0] [0.0008] 147.48 [5.787] 147.23 [5.796] 146.98 [5.786]
Roundness of main journal Clearance of main journal Journal No. 4 only Except No.4 Surface roughness of main journal
Repair limit 0 0.010 [0 0.0003] Standard clearance Clearance limit 0.130 0.195 0.25 [0.0099] [0.0051 0.0076] 0.100 0.165 [0.004 0.0064] 0.22 [0.0087] 0.8 S (Surface roughness at R portion: 3.2 S)
Correct by using under size bearing or replace main bearing Correct surface roughness of crankshaft journal
14-11
3 Outside diameter of crank pin journal Standard size 100.00 [3.937] 99.75 [3.927] 99.50 [3.917] 99.25 [3.907] 99.00 [3.897] Tolerance 0 0.020 [0] [0.0008]
ENGINE BODY
Repair limit Repair by 99.88 [3.932] using over 99.63 [3.922] size bearing or replace 99.38 [3.913] 99.13 [3.903] 98.88 [3.893]
STD 0.25 U.S. [0.0098] 0.50 U.S. [0.0197] 0.75 U.S. [0.0295] 1.00 U.S. [0.0394]
Roundness of crank pin journal Clearance of crank pin journal Surface roughness of crankshaft pin journal
Repair limit 0 0.010 [0 0.0003] Standard clearance Clearance limit 0.046 0.116 0.17 [0.0067] [0.0019 0.0045] 0.8 S (Surface roughness at R portion: 3.2 S)
Replace connecting rod bearing Correct surface roughness of crankshaft journal Replace
Straightness of all main journal Straightness of two main journal Crank pulley mounting bolt
Standard size within 0 0.09 [0 0.0035] within 0 0.05 [0 0.0019]
Repair limit 0.09 [0.0035] 0.05 [0.0019]
1st step 2nd step 3rd step 6 Tightening torque of vibration damper mounting bolts
Target Range 7.5 kgm 5.5 9.5 kgm [39.8 68.7 ft.lb] [54.2 ft.lb] 25.0 kgm 23.0 27.0 kgm [180.8 ft.lb] [166.4 195.2 ft.lb] 76.0 kgm 74.0 78.0 kgm [549.7 ft.lb] [535.3 564.1 ft.lb] 11 1.0 kgm [79.6 7.2 ft.lb]
Tighten bolts in accordance with bolt No.
Judgement standards for judging if crankshaft can be used again If it is impossible to measure all the items in the MAINTENANCE STANDARD (including roughness), use the following conditions to judge if the crankshaft can be used again. 1. If more than 60% of the overlay of the pin bearing has been lost after about 4000 hours of operation due to the entry of dust, the crankshaft journal surface has probably become rough, so grind again or replace. 2. On engines where the oil filter may have be-come clogged because of deterioration of the oil or entry of water into the oil pan, there are probably scratches or increased roughness on the journal surface caused by dirt, so grind again or replace. 3. If the main journal or pin journal has seized, the crankshaft hardness will have been lost because of the high temperature and the strength may have dropped, so do not use such parts again. (There is danger that the crankshaft may break.)
14-12
ENGINE BODY
CAMSHAFT
No. Check item 1 End play 2 Outside diameter of camshaft journal Clearance of camshaft journal 3 4 Bend of camshaft Cam height
Criteria Standard size 0.1 0.25 [0.0039 0.0098] Standard size 65 [2.559] Repair limit 0.36 [0.0142] Tolerance 0.016 [0.0006] 0.036 [0.0014] Clearance limit 0.15 [0.0059]
Unit: mm [in] Remedy Replace thrust plate Replace camshaft Replace camshaft bushing Replace camshaft
Standard clearance 0.016 0.096 [0.0007 0.0037] Repair limit: 0.04 [0.0016] (Total indicated runout) Cam Standard size Tolerance Repair limit Intake 55.48 [2.184] 0.1 55.08 [2.168] [ 0.0039] Exhaust 55.75 [2.195] 0.1 55.35 [2.179] [ 0.0039]
14-13
ENGINE BODY
CAM FOLLOWER AND PUSH ROD
No. Check item 1 Outside diameter of cam follower shaft Inside diameter of cam follower shaft Outside diameter of cam roller Inside diameter of cam roller Outside diameter of cam roller pin Radius of push rod ball end
Standard size 22 [0.866] 22 [0.866] 31.7 [1.248] 12.7 [0.500] 12.63 [0.497] Standard size 12.7 [0.500]
2 3
Criteria Tolerance 0.021 [0.0008] 0.034 [0.0013] +0.021 [+0.0008] 0[0] +0.05 [+0.0019] +0.02 [+0.0007] +0.038 [+0.0015] +0.013 [+0.0005] 0.006 [ 0.0002]
Repair limit 21.92 [0.864] 22.07 [0.870] 31.5 [1.240] 12.78 [0.503] 12.56 [0.494]
Unit: mm [in] Remedy Replace
5 6 7
Radius of push rod socket end Bend of push rod Tightening torque of cam follower mounting bolt
Tolerance 0[0] 0.20 [0.0078] 13.4 [0.528] 0[0] 0.20 [0.0078] Repair limit: 0.3 [0.0118] (Total indicated runout) 4.5 6.0 kgm [32.6 43.3 ft.lb]
Tighten
14-14
ENGINE BODY
TIMING GEAR
14-15
No. Check item Measuring point a Gears Criteria Standard size 0.141-0.425 [0.0056-0.0167] 0.130-0.390 [0.0052-0.0153] 0.125-0.363 [0.0049-0.0143] 0.129-0.391 [0.0051-0.0153] 0.125-0.363 [0.0049-0.0143] 0.085-0.492 [0.0034-0.0193] 0.138-0.354 [0.0054-0.0139] 0.051-0.469 [0.0021-0.0184] 0.125-0.363 [0.0049-0.0143] 0.052-0.481 [0.0021-0.0189] 0.137-0.421 [0.0054-0.0165] 0.141-0.425 [0.0056-0.0167] 0.129-0.391 [0.0051-0.0153] 0.125-0.363 [0.0049-0.0143] 0.051-0.469 [0.0021-0.0184] 0.125-0.363 [0.0049-0.0143] 0.106-0.381 [0.0042-0.015] 0.138-0.354 [0.0054-0.0139] Standard clearance 0.016 - 0.084 [0.0006 - 0.0032] 0.016 - 0.084 [0.0006 - 0.0032] Repair limit 0.4 [0.0157] 0.4 [0.0157] 0.63 [0.024] 0.4 [0.0157] 0.4 [0.0157]
ENGINE BODY
Unit: mm [in] Remedy Repair limit 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] Replace 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] 0.6 [0.0236] Clearance limit 0.20 [0.0078] 0.20 [0.0078] Replace bushing
Backlash of each gear (* : Between spur gears)
Clearance between main idler gear bushing and shaft (R and L bank) Clearance between sub idler gear bushing and shaft End play of main idler gear End play of sub ider gear End play of injection pump drive gear End play of oil pump drive gear End play of accessory drive gear
2 3 4 5 6 7
Crankshaft gear and R-main idler gear (Large) R-main idler gear (Small) and b R-sub idler gear R-main idler gear (Small) and *b R-sub idler gear R-main idler gear (Small) and c R-camshaft gear R-main idler gear (Small) and *c R-camshaft gear R-camshaft gear and accesd sory drive gear R-camshaft gear and acces*d sory drive gear R-main idler gear (Small) and e R-injection pump drive gear R-main idler gear (Small) and *e R-injection pump drive gear R-main idler gear (Small) and f water pump drive gear R-main idler gear (Small) and g oil pump drive gear Crankshaft gear and L-main h idler gear (Large) L-main idler gear (Small) and i L-camshaft gear L-main idler gear (Small) and *i L-camshaft gear L-main idler gear (Small) and j L-injection pump drive gear L-main idler gear (Small) and *j L-injection pump drive gear L-injection pump drive gear k and air compressor drive gear L-injection pump drive gear *k and air compressor drive gear Tolerance Standard size Shaft Bushing +0.055 -0.016 [-0.0006] 56 [2.205] [+0.0021] -0.029 [-0.0011] 0[0] +0.055 -0.016 [-0.0006] 56 [2.205] [+0.0021] -0.029 [-0.0011] 0[0] Standard size 0.07 0.18 [0.0028 0.0071] 0.06 0.14 [0.0024 0.0055] 0.09 0.51 [0.003 0.020] 0.03 0.088 [0.0012 0.0034] 0.10 0.40 [0.004 0.0157]
Replace thrust bearing
14-16
ENGINE BODY
PISTON, PISTON RING AND PISTON PIN
14-17
ENGINE BODY
Unit: mm [in] Remedy Replace piston (only S is supplied)
No 1
Check item Outside diameter of piston (at right angles to boss)
Rank S L
Standard size 140 [5.512] 140 [5.512] Measurement location Top ring Second ring Oil ring
Measurement location Standard size
2-4 Clearance at piston ring end gap
No. 2 3 4
Clearance between piston ring groove and piston ring
No.
Criteria Tolerance 0.070 [0.0027] 0.085 [0.0033] 0.070 [0.0027] 0.085 [0.0033] Standard clearance 0.42-0.57 [0.0166-0.0224] 0.42-0.57 [0.0166-0.0224] 0.37-0.52 [0.0146-0.0204] Tolerance Ring Piston
Repair limit 139.85 [5.510] 139.85 [5.510] Clearance limit 1.0 [0.0394] 1.0 [0.0394] 1.0 [0.0394]
Replace piston ring
Top ring 2nd ring Oil ring
2.4 [0.0945]
0.015 [-0.0005] 0.035 [0.0013] 0.010 [0.0003] 0.035 [0.0013]
StanCleardard ance clearlimit ance Judge with groove wear gauge Judge with groove wear gauge
0.14 [0.0055]
Replace piston ring or piston
2.4 [0.0949]
4 [0.157]
0.02-0.06 +0.030 0.010 [0.0004] [+0.0012] [0.00080.0024] +0.010 0.030 [0.0012] [+0.0004]
Clearance between piston and piston pin
Standard size
Shaft
0 [0 ] 0.006 [0.0023]
Tolerance Hole
Standard clearance
Clearance limit
0.10 [0.0039]
Replace piston ring or piston pin
52 [2.047] Piston portion B
+0.045 [+0.0017] 0.035-0.051 +0.035 [+0.0013] [0.0014-0.0020]
Carbon deposit (Thickness: 1mm [0.0394] or more)
Replace piston (if thickness is less than 1 mm [0.0394], it is possible to clean off carbon at A and B and use again
14-18
ENGINE BODY
CONNECTING ROD
14-19
ENGINE BODY
Unit: mm [in] Remedy Replace bushing (supplied as semi-finished product) Replace bushing or piston pin Replace connecting rod (not permitted to correct) Replace bearing
No 1
Check item Inside diameter of connecting rod small end bushing
Criteria Tolerance +0.049 [+0.0019] +0.030 [+0.0011]
Repair limit 52.09 [2.051]
Clearance between connecting rod small end bushing and piston pin 2 Inside diameter of mounting hole of connecting rod small end bushing
Standard clearance 0.030 0.055 [0.0012 0.0021] Standard size 57.4 [2.260]
Clearance limit 0.11 [0.0043] Tolerance +0.030 [+0.0011] 0[0]
Inside diameter of connecting rod big end bearing (crankshaft pin journal) Inside diameter of connecting rod big end hole (no bearing, X, Y, Z directions)
Tolerance Repair limit +0.096 [+0.0037] 100.15 [3.946] +0.046 [+0.0018] 106 [4.173] +0.026 [+0.0010] 0.004 [0.0002] Tighten connecting rod cap to specified torque, then measure
5 6
Thickness of connecting rod bearing Parallelism, twisting of connecting rod
3.0 [0.118]
Tightening torque for connecting rod cap mounting bolt (coat nut seat face at bolt head with engine oil) Inside diame- Roughter of connect- ness ing rod big end Wave
Procedure 1st 2nd
Replace connecting rod (not permitted to correct) 0.025 [0.0009] Replace 0.035 [0.0013] bearing Standard Repair Replace limit connecting rod bushing 0-0.10 Parallel0.15 [00.0039] ism [0.0059] or connecting rod 0-0.25 Twisting 0.30 [0- 0.0098] [0.0118] Target Range Tighten in order shown 7.5 kgm [54.2 ft.lb] 7 8 kgm [50.7 57.8 ft.lb] in diagram Tighten 90 3.2 S 90 + 30 0 Replace
0.004 [0.00015] (Whole width)
The connecting rod bolt can be tightened a maximum of 5 times. Make a punch mark on the bolt head each time it is tightened.
14-20
ENGINE BODY
FLYWHEEL AND FLYWHEEL HOUSING
No 1 2 3 4 5
Check item Face runout of flywheel housing Radial runout of flywheel housing Face runout of flywheel Radial runout of flywheel Tightening torque of flywheel housing mounting bolts (Coat thread areas and bearing surface with engine oil) Tightening torque of flywheel mounting bolts (Coat thread areas and bearing surface with engine oil)
Criteria Repair limit: 0.25 [0.0098] Repair limit: 0.25 [0.0098] Repair limit: 0.30 [0.0118] Repair limit: 0.13 [0.0051] Target 35 kgm [253 ft.lb] 42 kgm [304 ft.lb] Target 10 kgm [72 ft.lb] 30 kgm [217 ft.lb] 55 kgm [398 ft.lb]
Unit: mm [in] Remedy Repair
Order 1st step 2nd step Order 1st step 2nd step 3rd step
Range 30 40 [217 289 ft.lb] 40 44 [289 318 ft.lb] Range 8 12 [58 86 ft.lb] 28 32 [203 231 ft.lb] 53 57 [384 412 ft.lb]
Tighten bolts in accordance with bolt No.
14-21
LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PUMP
No 1
Check item Axial clearance of pump gear
Criteria Tolerance Gear Housing thickness width

0[0] -0.030 [-0.0012] +0.067 [+0.0026] +0.040 [+0.0015]
Standard clearance
0.040-0.097 [0.00160.0038]
Unit: mm [in] Remedy Clearance Replace limit gear

0.040-0.097 [0.00160.0038]
Radial clearance of pump gear
Standard size 54.99 [2.167]
Tolerance Gear O.D. Housing I.D.

-0.15 [-0.0059] -0.21 [-0.0082] +0.06 [+0.0023] 0[0]
Standard clearance
0.15-0.27 [0.00590.0106]
Clearance limit
0.15-0.27 [0.00590.0106]
Interference between driven shaft and pump cover
Standard size 18 [0.709] 21 [0.827]
Tolerance Shaft Hole

+0.090 [+0.0035] +0.070 [+0.0027] +0.090 [+0.0035] +0.070 [+0.0027] +0.040 [+0.0015] +0.022 [+0.0008] +0.035 [+0.0013] 0[0]
Standard interference
0.030-0.068 [0.00120.0027] 0.030-0.090 [0.00120.0035]
Interference Replace limit
Interference between driven shaft and driven gear bushing
14-22
No 5 Check item Clearance between driven shaft and driven gear bushing Criteria Tolerance Shaft Hole
+0.090 [+0.0035] +0.070 [+0.0027] +0.090 [+0.0035] +0.070 [+0.0027] +0.106 [+0.0041] +0.088 [+0.0034] +0.147 [+0.0057] +0.122 [+0.0048] +0.129 [+0.005] +0.102 [+0.004] +0.173 [+0.0068] +0.146 [+0.0057]
LUBRICATION SYSTEM
Remedy Clearance Replace limit bushing
0.032-0.077 [0.00130.0030] 0.012-0.059 [0.00050.0023] 0.040-0.085 [0.00160.0033]
Standard size 18 [0.709] 18 [0.709] 18 [0.709] Standard size 18 [0.709]
Standard clearance
0.032-0.077 [0.00130.0030] 0.012-0.059 [0.00050.0023] 0.040-0.085 [0.00160.0033]
Clearance between driven shaft and body Clearance between drive shaft and pump body bushing Interference between drive gear and drive shaft
Tolerance Shaft Hole

+0.106 [+0.0041] +0.088 [+0.0034] +0.090 [+0.0035] +0.065 [+0.0025] +0.106 [+0.0041] +0.088 [+0.0034] +0.063 [+0.0024] +0.028 [+0.0011] +0.021 [+0.0008] 0[0] +0.065 [+0.0025] +0.047 [+0.0018]
Standard interference
0.025-0.078 [0.001-0.003]
Interference Replace limit
Interference between drive shaft bushing and pump cover Interference between drive shaft and oil pump drive gear Tightening torque of pump cover mounting bolt
21 [0.827] 18 [0.709]
0.044-0.090 [0.00170.0035] 0.023-0.059 [0.00090.0023]
10
11
3.15 0.35 kgm [20.3 25.3 ft.lb]
14-23
LUBRICATION SYSTEM
MAIN RELIEF VALVE
No. 1
Check item Clearance between main relief valve and body
Criteria Tolerance Valve O.D. Body I.D.

0.020 [0.0008] 0.053 [0.0021] +0.033 [+0.0012] 0[0]
Unit: mm [in] Remedy Standard Replace clearance valve or body 0.020 0.086
[0.0008 0.0033]
Main relief valve spring Free length 72.4 [2.8504]
Standard size Repair limit Replace Installed Installed load Installed load spring length 60.5 [2.3819] 40 kg [88.1 lb] 36 kg [79.2 lb] 8.5 0.5 kg/cm2 [113.8 127.9 psi] Adjust or replace spring
Main relief valve set pressure
14-24
LUBRICATION SYSTEM
OIL COOLER BY-PASS VALVE, REGULATOR VALVE
No 1
Check item Clearance between regula- Standard size tor valve and body 22 [0.8661]
Criteria Tolerance Valve O.D. Body I.D.

0.020 [0.0008] 0.041 [0.0017] +0.033 [+0.0012] 0[0]
Standard clearance
0.020-0.074 [0.0008-0.0029]
Unit: mm [in] Remedy Replace valve or body
Regulator valve spring Free length 111.5 [4.3898]
Standard size Installed length 75 [2.9528]
Installed load 13.87 kg [30.6 lb]
Repair limit Replace Installed load spring 24.4 kg [53.8 lb] Adjust or replace spring Replace valve or body
Regulator valve set pressure Clearance between oil cooler by-pass valve and body Oil cooler by-pass valve spring Standard size 28 [1.1024]
4.1 0.5 kg/cm2 [51.2 65.4 psi]
Tolerance Valve O.D. Body I.D.

0.020 [0.0008] 0.053 [0.0021] +0.033 [+0.0012] 0[0]
Standard clearance
0.020-0.086 [0.0008-0.0033]
Free length 125.8 [4.921]
Standard size Installed length 89.8 [3.5381]
Installed load 19 kg [41.9 lb]
Repair limit Replace Installed load spring Adjust or replace spring
Oil cooler by-pass valve set pressure
4.0 0.2 kg/cm2 [56.9 2.8 psi]
14-25
COOLING SYSTEM
COOLING SYSTEM
WATER PUMP
No 1
Check item Interference between impeller and shaft
Interference between drive gear and shaft
3 4
Clearance between impeller and body Abrasion of 4a. seal seal ring in ring water seal 4b. water seal
Unit: mm [in] Remedy Standard size Standard Replace. interference Usually, Shaft Hole replace +0.018 0.025 [-0.001] 0.031-0.068 19.0 [0.748] [+0.0007] 0.050 [-0.002] [0.0012-0.0027] impeller (there is +0.006 almost no [+0.0002] change in outside diameter of shaft) +0.021 0.012 [0.005] 0.020-0.060 30 [1.181] Replace 0.039 [0.015] [0.0008-0.0024] (usually, [+0.0008] +0.008 replace [+0.0003] gear) Standard clearance: 0.25 1.02 (Including end play) Replace (0.0099 0.0401) Surface roughness: Max. 0.8 S Criteria Tolerance Surface roughness: Max. 1.2 S
14-26
COOLING SYSTEM
THERMOSTAT
No 1 2
Check item Lift of thermostat valve Opening and closing of valve in thermostat
Criteria Min. 10 mm [0.394] (Check after immersion in a hot water bath of 90C [194F] for 4 or 5 minutes.) Valve must be closed fully when immersed in a hot water bath (71C) [159.8F] for 4 or 5 minutes after being immersed in a hot water bath (90) [194F] to fully open the valve.
Unit: mm [in] Remedy
14-27
15
REPAIR AND REPLACEMENT OF PARTS
TABLE OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 CYLINDER AND MOUNTING FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 REPLACING VALVE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7 PRESSURE TEST OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11 REPLACING VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12 REPLACING CROSSHEAD GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12 GRINDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14 METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17 CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE . . . . . . . . . . . . . . . . . . . 15-18 REPLACING MAIN BEARING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25 REPLACING CAM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29 CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION . . . . . . . . . 15-31 GRINDING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35 CORRECTING FRONT SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-42 CORRECTING REAR SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-44 CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-46 REPLACING CONNECTING ROD SMALL END BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-48 REPLACING CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-49 REPLACING CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50 REPLACING FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50
15-1 !
TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS

Operation Tool description Puller adapter, Intake valve Replacing valve seat Puller adapter, Exhaust valve Valve seat grinder, 110 volt Valve seat grinder, 220 volt Replacing valve guide Valve guide puller Valve guide installer Cross head guide puller Cross head guide installer Tool kit Fuel injector puller Alignment bar Tool kit Protrusion gauge Tool kit Standard piece Indicator gauge Gauge mandrel kit Sleeve installer Seal installer Sleeve installer Seal installer Use ReCon rod Bearing puller Push puller Cup plug driver, 30 mm Cup plug driver, 40 mm Barring device 790-101-2800 790-101-2300 3376796 3824895 3201740 Part Number 3377396 3376617 ST685A ST685C 3824919 3824918 ST1134 3824920 Commercially available 3825190 Commercially available Commercially available 3823495 Commercially available 790-101-8110 3823495 3825185 795-502-2220 795-502-2210 795-502-2120 795-502-2110
Replacing cross head guide Grinding valve Fuel injector removal Checking ID of main bearing bores Machining counterbore Measure liner protrusion Replacing cam bushing Correcting surface roughness of crank journal Measure crankshaft thrust Connecting rod bend/twist Mount front seal
Mount rear seal Replacing connecting rod small end bushing Replacing crankshaft gear
Install cup plug Engine revolution
15-2 !
CYLINDER HEAD
CYLINDER HEAD
1. 2. 3. 4. 5. 6. 7.
Cylinder head Cross head guide Valve guide O-ring Push rod tube Valve seat (intake side) Valve seat (exhaust side)
15-3 !

Symbol Inspection item Cracks, leakage from cylinder head Judgement standards
CYLINDER HEAD
Unit: mm Remedy
Correct by welding or replace
Check for cracks (external color check) Check for water leakage with air pressure test (3.0 3.5 kg/cm2, 30 sec.) Water pressure test (3.5 4.0 kg/cm2, 10 minutes)
Distortion of top, bottom surface of cylinder head
Tolerance 0 0.06
Repair limit 0.09
Grind to correct
Protrusion of injection nozzle
Permissible range: 4.65 5.65
Damage to valve contact surface of valve seat, loosening of valve seat
Pitting of valve contact surface Check contact of valve contact surface Airtightness test Tap cylinder head and check for looseness
Do not grind intake valve. Correct valve contact surface of valve seat or replace valve seat
Sinking of valve (both intake and exhaust)
Standard value 0 0.1
Repair limit 0.7
Replace valve or valve seat
Thickness of valve head Repair limit 1.9 1.6 Replace
Standard value Intake value 2.4 Exhaust value 2.15
Thickness of valve head
Angle of valve seat contact surface Intake valve: 30 Exhaust valve: 45
15-4 !

Symbol Inspection item Judgement standards
CYLINDER HEAD
Unit: mm Remedy
Check if head has become concave Check for cracks or pitting of valve seat contact surface Airtightness test Check for play in cotter pin when new cotter pin is inserted in cotter groove. Check for uneven wear or curvature of valve stem Check for hollow in tip of valve stem Outside diameter Valve Standard size Standard value Repair limit 10 10 9.940 9.955 9.911 9.926
Replace
Correct
Outside diameter of valve Intake valve stem Exhaust valve
Replace
Value E Sinking of valve (both intake and exhaust) Intake valve Exhaust valve
Standard size Standard value Repair limit 10 10 9.989 10.011 9.989 10.011
Protrusion of valve guide
Permissible range: 23 0.2
Replace
Outside diameter of cross head guide
Standard size Standard value Repair limit 11 11.000 11.011 10.95
Protrusion of cross head guide
Permissible range: 49 0.25
Correct
15-5 !
CYLINDER HEAD
CYLINDER AND MOUNTING FACE

WARNING! Wear protective eye wear to prevent fluid from possible contact with the eyes.
1. Grinding A. Remove valve seat. For details, see "REPLACING VALVE SEAT" on page 15-7. B. Grind cylinder head to remove deformation or rust. Do not exceed repair limit of cylinder head height "a". Stamp [R] on left side of cylinder head. # Standard dimension for height of cylinder head "a": 105 0.05 mm # Repair limit after grinding: 0.10 0.15 mm # Surface roughness of grinding surface: Within 6S # Flatness (deformation): Within 0.05 mm # Grinding limit: 0.3 mm # Difference in head height per unit: Within 0.15 mm C. Press fit one size larger over size valve seat. For details, see "REPLACING VALVE SEAT" on page 15-7. 2. Checking after completion of grinding Check that sinking of valve is within standard value. Carry out adjustment and modification if necessary. # Sinking of valve: Standard: 0 0.1 mm
15-6 !
CYLINDER HEAD
REPLACING VALVE SEAT

WARNING! Wear protective eye wear to prevent fluid from possible contact with the eyes. 1. Removal of seat A. When removing with a valve seat puller 1) Install grindstone (5) to grinder (1). 2) Align the groove of sleeve (3) with holder (2), and insert. # Adjust the position of the grinder with set screw (4). 3) Adjust the position of the grinder so that the center of grindstone (5) is at the center of valve seat (1), then tighten the set screw to fix the grinder in place. 4) Rotate the grindstone and move it slowly until it contacts valve seat (1). 5) Press the grindstone lightly against the inside face of the valve seat and make a groove around the whole circumference of the inside face of the valve seat. # Depth of groove: Approx. 1 mm
6) Push the three claws (6a) of puller head (6) of tool A inwards by hand, and fit into valve seat (1). 7) Tighten screw (8) to push the three claws into the groove on the inside face of the valve seat. # When the claws are completely in contact with the groove, stop tightening. 8) Insert bridge (9) on the outside of the puller head, set plates (10) and (11) on top of the bridge and tighten nut (12) to pull out the valve seat.
15-7 !

B. When welding a bar to the valve seat to remove 1) Weld bar (2) (length: 0.1 0.5 mm shorter that inside diameter of valve seat, diameter: approx. 10 mm) to inside of valve seat (1). # Be careful not to deposit any of the welding metal on the head itself. 2) When the temperature of the weld has dropped to around room temperature, insert a used valve (3) in the opposite direction, and hit the face of the valve with a small hammer to remove the valve seat. # Be careful not to hit too hard, as any excessive shock may cause the weld to break off. 2. Press fitting valve seat A. When not grinding and correcting press-fitting surface of valve seat 1) Using tools B1 and B2, or tools B1 and B3, press fit standard valve seat (1) with a press. # Do not use a hammer to press fit. # Press-fitting force for valve seat; Intake side: Approx. 1.5 ton Exhaust side: Approx. 1.5 ton
CYLINDER HEAD
2) Check the insertion depth a of valve seat from the bottom surface of cylinder head. # Insertion depth a of valve seat; Intake side: 2.2 mm Exhaust side: 2.4 mm
3. Over size machining of mounting hole for valve seat insert. A. Using tools C1 and C2, grind the hole to one level larger over size. # Machine within an over size range of 1.0 mm (0.0394 in). If it is more than 1.0 mm (0.0394 in), replace the cylinder head.
15-8 !

Method of machining valve seat and mounting hole Valve seat Valve seat Valve size d1 c1 S.T.D. Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust 55.0 52.0 55.25 52.25 55.5 52.5 55.75 52.75 56.0 53.0
+0.100 +0.090 +0.080 +0.070 +0.100 +0.090 +0.080 +0.070 +0.100 +0.090 +0.080 +0.070 +0.100 +0.090 +0.080 +0.070 +0.100 +0.090 +0.080 +0.070
CYLINDER HEAD
Unit: mm Valve seat mounting hole d2 55.0 52.0 55.25 52.25 55.5 52.5 55.75 52.75 56.0 53.0
+0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0 +0.019 0
d3 58.00 0.2 55.00 0.2 58.25 0.2 55.25 0.2 58.50 0.2 55.50 0.2 58.75 0.2 55.75 0.2 59.00 0.2 56.00 0.2 11 11 11 11 11.12 11.12 11.25 11.25 11.38 11.38
c2
0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1
8.8 8.6 8.8 8.6 8.92 8.72 9.05 8.85 9.18 8.98
0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1
0.25 O.S.
0.50 O.S.
0.75 O.S.
1.00 O.S.
# Roughness of inside surface: Within 6.3S # Roughness at bottom of mounting hole: Within 12.5 S # Concentricity with valve guide inside surface: Within 0.03 mm (0.0012 in) (TIR)
15-9 !

4. Finishing valve seat contact surface A. Using tools C1, C3, and C4, finish surface of the valve contact surface of valve seat to dimensions shown in diagram on the right. # When selecting tool C5 to insert into the valve guide, choose one that gives no clearance.
CYLINDER HEAD
B. Rub the valve seat contact surface with compound. C. Concentricity of valve guide and valve seat: Within 0.05 mm (TIR) D. Width of finished surface of valve seat at exhaust side, and width of contact with valve.
Exhaust 6210-11-1320 (S.T.D.) 6210-19-1320 (0.25 O.S.) 6210-18-1320 (0.50 O.S.) 6210-17-1320 (0.75 O.S.) 6210-16-1320 (1.00 O.S.) e: 47.1 f: 1.5
Intake 6210-11-1321 (S.T.D.) 6210-19-1321 (0.25 O.S.) 6210-18-1321 (0.50 O.S.) 6210-17-1321 (0.75 O.S.) 6210-16-1321 (1.00 O.S.) e: 45.7 f: 2.5
Part No.
Width of finished surface Width of contact with valve (when using master valve)
g: 1.5 0.2
g: 2.5 0.2
5. Final inspection A. Coat valve seat contact surface of the new valve thinly with red lead (minimum), insert it in the valve guide, push lightly against valve seat surface, and rotate 10. Check valve seat contact surface, and confirm that the contact is uniform without any breaks. or
15-10 !

B. Make marks with a pencil on valve seat contact surface of the new valve as shown in diagram on the right, insert it in the valve guide, push lightly against valve seat surface, and rotate 10. Check that pencil marks have been erased uniformly around the whole circumference.
CYLINDER HEAD
PRESSURE TEST OF CYLINDER HEAD

When corrections have been made around the cylinder head, test pressure as follows.
1. Water pressure test A. Assemble tool E and tool F, and connect the hose to flange (1). B. Apply water pressure at 3.5 4.0 kg/cm2 (50 57 psi) for approx. 10 minutes. Check that there is no leakage from around cylinder head. # When carrying out this test, heat the whole cylinder head and carry out test with hot water 82 93C (180 - 200oF). 2. Air pressure test A. Connect the air compressor hose to flange (1). B. Put cylinder head in a container of water, apply air pressure 3.0 3.5 kg/cm2 (43 50 psi) for approx. 30 seconds. Check that there is no air leakage into the water. # If the above test shows any cracks around the plate plugs of the cylinder head, replace cylinder head.
15-11 !
CYLINDER HEAD
REPLACING VALVE GUIDE

1. Removal of valve guide Using tool G1, remove the valve guide.
2. Press fitting valve guide A. Press fit the valve guide until tip of tool G2 contacts the cylinder head. B. Measure protrusion of the valve guide and check that it is within standard range. # Protrusion of valve guide Tolerance: 23 0.2 mm (0.9 0.007 in)
REPLACING CROSSHEAD GUIDE

1. Removal of cross head guide Using tool H1, remove the cross head guide. A. As shown in the diagram grip cross head guide with collet (5) of puller. B. Tighten collet with bolt (1), and lock sleeve (2). C. Turn nut (3), and pull out cross head guide. D. Remove any burrs or flashes from the cross head guide mount.
2. Press fitting cross head guide A. Using tool H2, insert the cross head guide into cylinder head, and use a copper bar or plastic hammer to press fit until protrusion is within the permitted tolerance. # Protrusion of cross head guide Tolerance: 49 0.25 mm (1.9 0.01 in)
15-12 !
CYLINDER HEAD
GRINDING VALVE
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. 1. Grinding valve seat contact surface Using tool I (valve refacer), grind the valve seat contact surface. # Valve seat contact surface angle () Intake valve: 60 015 (DO NOT GRIND) Exhaust valve: 45 015 2. Checking after grinding Check thickness of the valve head, amount of sinking of the valve, and contact of the valve seat contact surface, and confirm that it is within the standard value. # Repair limit for thickness a of valve head Intake valve: Min. 1.9 mm (standard dimension: 2.15 mm) Exhaust valve: Min. 1.6 mm (standard dimension: 2.15 mm) # Sinking of valve Standard: 0 0.1 mm Repair limit: 0.7 mm # Use dial gauge (1) to measure face run out (TIR) of valve seat contact surface. Intake valve: 0.045 mm Exhaust valve: 0.030 mm # Use one of the following methods to check contact of the valve seat contact surface. Coat the valve seat contact surface of ground valve thinly with red lead (minimum), insert it into valve guide, push lightly against the valve seat, and rotate 10. Check the valve seat contact surface, and confirm that contact is uniform without any breaks. Make marks with a pencil on valve seat contact surface of the ground valve as shown in diagram, insert it into the valve guide, push lightly against valve seat, and rotate 10. Check that pencil marks have been erased uniformly around the entire circumference.
15-13 !
CYLINDER BLOCK
CYLINDER BLOCK
1. 2. 3. 4. 5. 6.
Cylinder liner Clevis seal Cylinder liner O-ring Cylinder block Main bearing cap bolt Main bearing cap (No. 1, 2, 3, 5, 6 are common) 7. Camshaft bushing
15-14 !
CYLINDER BLOCK
Unit: mm
Symbol A
Inspection item Cracks
Judgement standards Check for cracks (external collar check) Cylinder head bolt hole portion, etc.
Remedy Replace
Correction of contact at packing portion
Replace
Clearance from cylinder liner
Replace cylinder liner or cylinder block
Inside diameter of camshaft bushing
Replace bushing
Protrusion of liner
Replace cylinder liner or correct cylinder block Repair by machining, add shim
Depth of counterbore and corrosion of bottom surface
Distortion, wear of cylinder head mounting surface
Repair by machining
15-15 !

Symbol Inspection item Judgement standards
CYLINDER BLOCK
Remedy
Inside diameter of main bearing mounting hole Tighten main bearing cap bolt to specified torque Measure main bearing cap mating surface within up-and-down range of 10
Replace
Fitting of main bearing cap and cylinder block
Replace cylinder liner J Inside diameter of counterbore, outside diameter of cylinder liner flange
Correct cylinder block sleeve
15-16 !
CYLINDER BLOCK
METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR
When checking inside diameter of the main bearing mounting hole using an alignment bar, do as follows. Unit: mm Tool J (alignment bar) Diameter Roundness Straightness Length 1. 2. 3. 4. 5. 6. Standard dimension 1570.039 0.005 0.010 Min. 1300
0.014
Set cylinder block on a stand with main bearing cap mount at the top. Coat inside surface of main bearing hole of the cylinder block with engine oil. Remove main bearing cap. Set tool J (alignment bar) in main bearing hole of the cylinder block. Install the main bearing cap, then tighten mounting bolts to specified torque. Check that tool J moves smoothly.
15-17 !

Flow for correction procedure
CYLINDER BLOCK
CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE
# When removing, installing, disassembling, or assembling the engine, see "DISASSEMBLY AND ASSEMBLY" section for details. # If judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).
15-18 !
CYLINDER BLOCK
15-19 !
CYLINDER BLOCK
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. Grinding If there is strain or corrosion of top surface of the cylinder block, grind the top surface. If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in front-torear direction), or there is speckled wear, and these portions extend over more than half of the contact surface, or if grinding has been carried out on the top surface, correct the counterpower. 1. Grinding top surface of cylinder block A. Measure wear and strain of top surface of the cylinder block, and if it is over the repair limit, grind top surface of the cylinder block within the repair limit for height "d" of the cylinder block. # Guideline for grinding to surface of cylinder block When wear and corrosion on top surface of cylinder block are the same shape as mark left by the head gasket When wear amount "a" is more than 0.15 mm
Table 1 Standard dimension Flatness of cylinder block (for one cylinder) Height of cylinder block "d" Roughness of top surface of cylinder block 0.05 471.5 0.04
Unit: mm Repair limit 0.10 471.0
Within 12.5 S
When grinding with grindstone (reference) Grindstone speed: 1650 1950 m/min Table speed: 15 30 m/min Amount of grinding for one pass: 0.025 mm Cross feed for one pass: 1 2 mm Grindstone: A461V Grinding fluid: Water soluble grinding fluid 2. Grinding counterbore After grinding top surface of the cylinder block, measure depth of the counterbore. If necessary, correct the counterbore depth "f" within the repair limit. # Guideline for correcting counterbore If it is not within standard dimension. If there are blackened portions on cylinder liner contact surface of counterbore (particularly in front-to-rear direction), or there is speckled wear, and these portions extend over more than half of the contact surface.
15-20 !

After correcting, if the counterbore depth is within 14.05 15.525 mm, combine with shims and adjust so that liner protrusion is 0.07 0.15 mm. Table 2 Unit: mm Standard dimension counterbore depth f Cylinder liner protrusion e Roughness of counterbore Machined shape 11 +0.05 --Repair limit 12.52 S 0.080 - 0.185 Within 12.5 S In accordance with diagram on right (detail diagram for portion b)
CYLINDER BLOCK
For the machining amount for counterbore depth "f", decide an amount that will bring protrusion "e" of cylinder liner within the standard value. When grinding within repair limit in cases where counterbore depth "f" exceeds standard dimension, set machining amount so that one shim can be used for each cylinder as shown in the table below.
Table 3 Adjustment shims for counterbore depth Part No. 6210-29-2260 6210-29-2250 6210-29-2240 6210-29-2230 6210-29-2220 6210-29-2210 T 1.50 0.08 0.50 0.26 0.20 0.16 t 0.025 0.025 0.025 0.025 0.020 0.016 0.023 0.012 0.008 0.004 0.003 0.002
Unit: mm
Weight (kg) Remarks
15-21 !

Use tool K when grinding the counterbore.
CYLINDER BLOCK
3. Checking and distinguishing after grinding and correcting After grinding and correcting, check for scratches on the flat surface around the water and oil holes in the cylinder block top surface. Remove all burrs and flashes completely. After grinding the top surface, if cylinder block height "d" exceeds the standard dimension, but it within repair limit (471.0 471.4 mm), always use an over size head gasket.
Table 4 Head gasket S.T.D. Over size Part No. 6210-11-1812 6210-19-1813
Unit: mm Plate thickness 2.0 2.4
# To distinguish, the letters [OS] are stamped on the plate. Table 5 Over size head gasket Parts used for correction X X Shim X X Stamp Not needed OS SH WS (Size of letters: 5 - 10 mm) After correcting, stamp top surface of cylinder block (rear of left bank) according to the nature of correction as shown in table below.
15-22 !

4. Procedure for coating cylinder block top surface deck with gasket sealant When pulling out the cylinder liner and press fitting it again, coat cylinder block top surface deck (cylinder liner flange contact surface of the cylinder block) with gasket sealant (LG-6) as follows. # Use the same procedure when using a shim for the deck.
CYLINDER BLOCK
A. Use a cloth to wipe off all dirt and oil from cylinder block top surface deck and cylinder liner flange contact surface. B. Coat position marked in the diagram with LG-6. Diameter of line of gasket sealant: 2 3 mm Overlap of beginning and end of sealant: 6 6 mm # When using shims for deck After coating bottom of the shim thinly with LG-6, install it to left portion of the cylinder block. Next, coat with LG-6 in same way as when not using shims. C. Press fit liner into the cylinder block. When doing this, coat the cylinder block contact surface of seal and O-ring with a small amount of engine oil (SAE30) immediately before press fitting the liner. # Do not coat with engine oil until immediately before press fitting the cylinder liner.
D. After setting the cylinder liner into the cylinder block, assemble a used head gasket and temporarily tighten the cylinder head. When doing this, tighten in the tightening order shown in diagram on the right. 137 - 157 Nm (101 115 lbf ft)
15-23 !

E. Loosen cylinder head mounting bolts, remove cylinder head, then wipe off excess gasket sealant that has come out from the counterbore. # The gasket sealant that comes out may cause deformation of head gasket grommet, so always carry out Steps 4) and 5) without fail. # After carrying out Steps 4) and 5), use a new head gasket to install the cylinder head.
CYLINDER BLOCK
5. Standard for rebuilding cylinder liner O-ring portion of cylinder block If the bushing of cylinder liner O-ring of the cylinder block has been corrected, make the finishing dimensions as follows. # Concentricity of (6) in relation to standard (A): Max. 0.05 mm
Table 6 No. (1) (2) (3) (4) (5) (6) (7) Finishing dimensions
Unit: mm 167 see "REPLACING MAIN BEARING CAP" on page 15-25. 161.45 0.25 160.67 0.064 176 0.25 184.94 0.18 158 +0.040 0
159.03 (Gauge diameter)
15-24 !
CYLINDER BLOCK
REPLACING MAIN BEARING CAP

When replacing the main bearing cap, machine semi-finished product to the following dimensions, then install. Correction parts Part Number 6215-29-1210 6215-29-1230 6215-29-1250 Part Name Main bearing caps other than No. 4, 7 Main bearing cap No. 4 Main bearing cap No. 7
1. Machining inside diameter of main bearing cap A. Remove the cylinder liner. B. Install replacement main bearing cap to the cylinder block, and tighten to specified torque.
Main bearing cap mounting bolt:Coat seat face of threaded potion with engine oil.
Main bearing cap mounting bolt:
Order 1st step 2nd step 3rd step
Target 2.9 kgf m (21 lbf ft) 5.9 kgf m (43 lbf ft) Tighten 90 further
Range 2.8 - 3.1 kgf m (20 - 23 lbf ft) 5.8 - 6.0 kgf m (42 - 44 lbf ft) 90+30 0
# Align cylinder block and main bearing cap notch. C. Set a cylinder block mounting jig on table of a horizontal boring machine, fit cylinder liner mounting hole of the cylinder block to standard line on the jig, and install the cylinder block. D. Of the main bearing caps to be used again, take one with longest pitch and put a dial gauge in contact with inside diameter at two places to align center of the boring machine arbor.
15-25 !
CYLINDER BLOCK
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. E. Check machined inside diameter of bearing cap (1) and grind a little at a time. # Grind until the bit touches inside surface of cylinder block (2). # Inside diameter of cap main bearing cap 1) Machining dimension Tolerance: 157 +0.025 mm 0 2) Inside diameter of cap when main bearing cap is tightened to specified torque after machining mm Tolerance: 157 +0.025 -0.010 (Up-down range of 10 at mating surface of main bearing cap) # Finishing roughness: Within 10 S # Do not grind inside face of cylinder block. 2. Machining width of main bearing cap (Only when machining No. 7 main bearing cap) A. Insert cast iron bushing (1), then pass arbor (2) through. B. Install facing bit (3) to arbor. C. Grind cap (4) until bit touches cylinder block face. D. Grind opposite side in the same way. # Roughness of thrust bearing mounting surface: Within 12.5 S # Do not grind cylinder block # Width of main bearing cap 0 Tolerance: 52 -0.030 mm
15-26 !
CYLINDER BLOCK
REPLACING CAM BUSHING

# When replacing the cam bushing, first remove blind plug at rear of cylinder block. 1. Removal of No. 1, 7 bushings A. As shown in diagram, assemble push tool L2, collar L3, and push bar L1 of push tool L, then hit the push bar to knock bushing (2) out from cylinder block (1).
2. Removal of No. 2, 6 bushings A. Assemble push bar L1, push tool L2, collar L3, and guide L4 of push tool L, then hit the push bar to knock bushing (3) out from cylinder block (1).
3. Removal of No. 3, 4, 5 bushings A. Assemble push bar L1, push tool L2, collar L3, and guide L4 of push tool L, then hit the push bar to knock bushing (4) out from cylinder block(1).
B. After removing bushing, remove any burrs or dirt, and clean mounting hole of the bushing.
15-27 !

4. Press fitting No. 3, 4, 5 bushings A. Assemble bushing (4) to tool L, and press fit the bushing until oil hole of cylinder block (1) matches oil hole of the bushing.
CYLINDER BLOCK
5. Press fitting No. 2, 6 bushings A. Assemble bushing (3) to tool L, and press fit the bushing until oil hole of cylinder block (1) matches oil hole of the bushing.
6. Press fitting No. 1, 7 bushings A. Assemble bushing (2) to tool L, and press fit the bushing until oil hole of cylinder block (1) matches oil hole of the bushing.
7. Measuring after press fitting bushing A. Using inside gauge (1), measure inside diameter of bushing. B. Check clearance between bushing and shaft, and if the clearance is not within specified range, or shaft does not move smoothly, correct inside diameter of bushing with a reamer. When inside diameter of bushing has been corrected with a reamer, clean all metal particles from the oil hole and oil groove. # Inside diameter of cam bushing: 65 +0.06 mm 0 # Clearance of camshaft journal: 0.016 0.096 mm
15-28 !
CRANKSHAFT
CRANKSHAFT
1. Crankshaft. 2. Main bearing (upper) (common except for No. 4). 3. Main bearing (lower) (common except for No. 4). 4. Thrust bearing (Top x 1, bottom x 2, all common). Unit: mm
Symbol
Inspection item Cracks
Judgement standards Use a magnetic flaw detector to check for cracks Scratches, Check for damage to journal portion: Seizure, Discoloration Damage to threaded hole at front and rear end of crankshaft
Remedy Replace
If damage is slight, correct with an oilstone or correct by lapping. Replace if there is seizure.
A.
B.
Damage
C.
Clogging of oil hole
Check for clogging of oil hole Standard value Repair limit 0.50
Correct Replace thrust bearing or correct with over size
D.
End play of crankshaft
0.140 0.320
15-29 !

Symbol
CRANKSHAFT
Unit: mm Remedy Repair limit 3.79 3.92 0.07 0.12 4.04 4.17 4.29 Tolerance Repair limit 99.88 99.63 0 0.020 99.38 99.13 98.88 Repair limit 0.010 0.260 Tolerance Repair limit 147.98 147.73 0 0.020 147.48 147.23 146.98 Repair limit 0.010 0.250 0.220 Repair limit 0.09 Replace Within 0.05 0.05 Correct with under size or replace main bearing Correct with under size or replace
Correct with under size or replace connecting rod bearing
Inspection item Size STD
Judgement standards Standard size 4.000 4.125 4.250 4.375 4.500 Standard size 100.00 99.75 99.50 99.25 99.00 Tolerance
E.
Thickness of thrust bearing
0.25 OS 0.50 OS 0.75 OS 1.00 OS Size STD
Replace thrust bearing or correct crankshaft with over size
F.
Outside diameter of crankshaft pin journal
0.25 US 0.50 US 0.75 US 1.00 US
Correct with under size or replace
G.
Roundness of crankshaft pin journal Clearance of crankshaft pin journal
Standard 0 0.010 0.046 0.116 Size STD Standard size 148.00 147.75 147.50 147.25 147.00
H.
I.
Outside diameter of main journal
0.25 US 0.50 US 0.75 US 1.00 US
J.
Roundness of main journal Clearance of main journal
Standard 0 0.010 No. 4 only 0.130 0.195 0.100 0.165 Standard
K.
Other than No. 4
L.
Curvature of crankshaft (total run out of indicator)
Total coaxially of main journal Coaxially of neighboring journals
Within 0.09
15-30 !
CRANKSHAFT
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION

If roughness of crankshaft journal portion does not fulfill standard, and there are scratches or dents on outside diameter which it is possible to correct, then correct the surface roughness A. Cleaning and blowing with air Before polishing, brush oil holes and blow with air. B. Correcting surface roughness of journal portion.
1. When correcting with special polishing machine Use a special polishing machine as shown in diagram on the right. A. Set rotating speed for polishing machine at 40 50 rpm. When correcting, use sandpaper (belt type), and move sandpaper once up and down entire journal width for each journal. # Use #320 sandpaper (belt type). # Move sandpaper smoothly and do not stop at any point. # Do not use honing oil. B. Next, replace with #500 sandpaper, coat journal surface with honing oil, and move handle of machine to the left and right by amount of play to give fine movement. Use this movement to move once up and down entire width of the journal. # Move sandpaper smoothly and do not stop at any point C. Using tool M (standard gauge), check surface roughness. # When measuring surface roughness, compare surface roughness of journal portion with tool M (standard piece). Standard value for surface roughness (pin journal, main journal): Journal portion: Max. 0.8 S R portion: Max. 3.2 S
D. Check surface roughness, and if it is not within standard, polish again once up and down the width of journal with #500 sandpaper. # Check that there are no scratches or dents in journal portion or fillet portion. If there are any scratches or dents, polish again and follow procedure from Step 1).
15-31 !

2. When a special polishing machine is not available, use a polishing jig such as shown in diagram to right. A. Use a crankshaft grinding machine and rotate crankshaft to polish. # Sandpaper: #800 # Machining oil: Honing oil (or diesel oil) # Work speed: 40 rpm B. Move polishing jig the amount of play of journal width (approx. 5 mm), and move up and down journal in axial direction to carry out polishing. # Polishing time for one journal is approx. 6 minutes. After completing honing of one journal, replace sandpaper with new. # When honing the pin journal, carry out work with pin journal at rotation center. 3. Assembly of polishing jig and method of use A. Assemble polishing jig for pin journal and main journal as shown in diagram to the right.
CRANKSHAFT
B. Cut out a piece of #800 sandpaper with shape shown in diagram to the right.
C. Take 2 pieces of sandpaper, align with slit of jig plate (1), then insert and fix in position with tape. D. Fit journal in jig plate (1), and fix ends of jig lever (2) with a rubber band.
15-32 !

Polishing jig Make a polishing jig according to diagram below. Polishing jig (for pin journal) Plate (1) [2 are used for each jig]
CRANKSHAFT
Lever (2) [2 are used for each jig]
15-33 !

Polishing jig (for main journal) Plate (1) [2 are used for each jig]
CRANKSHAFT
Lever (2) [2 are used for each jig]
15-34 !
CRANKSHAFT
GRINDING CRANKSHAFT
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. When grinding crankshaft to correct wear, light seizure or damage, grind to any of the following under size dimensions. Under size: 0.25, 0.50, 0.75, 1.00 mm If there is curvature or uneven wear of the crankshaft, it is preferable to replace crankshaft and not repair it. (A high level of skill is required.) Be particularly careful when finishing the fillet portion R, shoulder r, and R around the hole. Unit: mm Finishing dimension Pin journal R1 r1 Main journal R2 r2 4+0.4 0 5 0.5
0 3.50.5
Finishing dimension for fillet:
Surface roughness 3.2 S 12.5 S 3.2 S 12.5 S
6 0.5
Finishing dimensions for oil holes in main journal and pin journal are as shown in diagram to the right. Main journal portion
15-35 !

Pin journal portion
CRANKSHAFT
Surface roughness for outside diameter of the pin journal and main journal shall be 0.8 S or less. # Necessary equipment and jigs for grinding 1. Magnet flaw detector 2. Shore hardness gauge 3. Etching kit 4. Crankshaft mill 5. Crankshaft polisher 6. Roughness gauge 7. Fillet R measurement ball gauge
1. Inspecting before grinding A. Visual inspection Check for cracks, damage, discoloration caused by seizure, and wear, and judge if it is possible to correct by grinding. B. Inspecting hardness of journal surface Standard value: 63 69 Hs If it is below repair limit, discard the part.
15-36 !

2. Inspection during grinding and after grinding A. Inspecting fillet R. Check that fillet R is connected smoothly to shoulder of the journal. Use a fillet R measurement ball gauge to check that R dimension is between the dimension for minimum value gauge and the dimension for maximum value gauge Unit: mm Fillet R Main journal Pin journal Min. radius 4.0 3.0 Max. radius 4.4 3.5
CRANKSHAFT
B. Checking for traces of seizure using etching After grinding, carry out an etching test to confirm that there is no grinding seizure. If any traces of seizure are found, grind approx. 0.02 mm and correct again to the next under size dimension. After inspection, neutralize and wash inspection surface, then coat with rust prevention oil. C. Magnetic flaw detection Carry out a magnetic flaw detection of the corrected crankshaft before use and check that there are no cracks. Be particularly careful to check journal fillet portion entering watch danger zone of the crankshaft. After carrying out magnetic flaw detection, always carry out demagnetization.
C. Measuring curvature (measuring alignment) Measure the curvature of crankshaft after grinding and check that it is within standard value. Check curvature (alignment) at the following four places: 1) Total length of alignment Tolerance: Max. 0.09 mm 2) Neighboring alignment Tolerance: Max. 0.05 mm 3) Tip alignment Tolerance: Max. 0.03 mm 4) Rear end alignment Tolerance: Max. 0.03 mm
15-37 !
CRANKSHAFT
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. 3. Grinding main journal Grind each main journal to same under size dimension. When grinding, leave a tolerance of 0.007 0.008 mm for finishing. Mark under size dimension on the ground crankshaft as shown in the diagram to prevent any mistake in the size when assembling the bearing.
Main journal under size dimension Size S.T.D. 0.25 US 0.50 US 0.75 US 1.00 US Standard size 100.000 99.750 99.500 99.250 99.000 Tolerance
Unit: mm
0 0.020
Roundness, cylindricity (TIR), surface roughness of main journal. Tolerance: Max. 0.010 mm Repair limit: 0.010 mm Surface roughness: Max. 0.8 m
4. Grinding thrust surface There is no particular need to grind front and rear thrust surface to same under size dimension. Mark under size dimension on ground crankshaft as shown in diagram to prevent any mistake in the size when assembling thrust bearing. If thrust surface has been ground, check that end play of crankshaft is within the permitted range. (For details, see overall assembly in "DISASSEMBLY AND ASSEMBLY" section.)
15-38 !

Thrust surface over size dimension Rear thrust surface STD. STD. Front thrust surface Standard size Repair limit 0.25 O.S. 0.50 O.S. Standard size Repair limit Standard size Repair limit 59
+0.050 0
CRANKSHAFT
Unit: mm
0.25 O.S. 59.25

+0.050 0
0.50 O.S. 59.5

+0.050 0
59.060 59.25
+0.050 0
59.310 59.5
+0.050 0
59.560 59.75
+0.050 0
59.310 59.50
+0.050 0
59.560 59.75
+0.050 0
59.810 60
+0.050 0
59.560
59.810
60.050
Squareness of thrust surface (TIR) Tolerance: 0.02 mm Repair limit: 0.02 mm
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. 5. Grinding pin journal Grind each pin journal to same under size dimension. When grinding, leave a tolerance of 0.007 0.008 mm for finishing. Mark under size dimension on ground crankshaft as shown in diagram to prevent any mistake in size when assembling bearing.
Pin journal under size dimension Size S.T.D. 0.25 US 0.50 US 0.75 US 1.00 US Standard size 100.000 99.750 99.500 99.250 99.000 Tolerance
Unit: mm
0 0.020
Roundness, cylindricity (TIR), surface roughness of main journal. Tolerance: Max. 0.010 mm Repair limit: 0.010 mm Surface roughness: Max. 0.8 m
15-39 !

6. Grinding main journal width and pin journal width When correcting wear surface of main journal and pin journal, correct using minimum amount of grinding. Crankshaft pin journal width # When grinding one side only Standard: 92 +0.054 mm 0 # Squareness (TIR) of thrust surface Repair limit: 0.02 mm
CRANKSHAFT
7. Correcting grindstone Carry out dressing for grindstone for each journal Adjust grindstone correction device and correct grindstone to a dimension matching arc of the fillet. When checking and correcting grindstone edge, grind a wooden test piece and check with a ball gauge. 8. Prevention of grinding seizure Use plunge grind method when grinding. Use whole width of grindstone # Avoid grinding boss surface as far as possible. Direct an ample supply of cooling oil When crankshaft speed is 40 rpm, make standard grinding speed at circumference of grindstone 2000 m/min. 9. Finishing surface See section on "Surface Roughness". Surface roughness standard (pin journal, main journal) Journal face: Max. 0.8 S Thrust surface: Max. 1.6 S Tip taper portion, pin, journal boss portion, fillet portion: Max. 3.2S Allowance for polish finishing: 0.007 0.008 mm 10. Action after grinding Check again that each dimension is as specified. Wash each part thoroughly and coat it with rust prevention oil. When storing for a long period, support at three points or fit a lifting tool and stand upright. 11. Balancing (reference) As far as possible, do not carry out repairs that will affect balance of the crankshaft. Service limit for imbalance: 10 gcm Limitations for accurate reading of balance Crankshaft curvature: 0.05 mm (TIR) Crankshaft rotation speed: Max. 325 rpm To correct balance, make a drill hole in the counterweight or carry our grinding. Direction of drill hole: Radial direction Hole diameter: Max. 13 mm Hole depth: Max. 50 mm No. of holes: Max. total of 6 for one counterweight Center of hole: Align with center of counterweight (deviation shall not exceed 0.5 mm) Distance between holes: Min. 5 mm
15-40 !

12. Procedure for measuring curvature of crankshaft and outside diameter of journal A. Support center of both ends of crankshaft with lathes. Put probe of a dial gauge perpendicularly in contact with the center journal (No. 4) and set dial to 0 at the peak. Then rotate one turn and read minimum and maximum values. If no lathes are available, support No. 1 and No. 7 journals on a V block.
CRANKSHAFT
B. Measure outside diameter of the main journal and outside diameter of the pin journal with a micrometer or air micrometer.
Locations for measuring journal Pin journal: X and Y directions, 5 places Main journal: X and Y directions, 3 places
15-41 !
CRANKSHAFT
CORRECTING FRONT SEAL CONTACT SURFACE

Correction parts Komatsu Part No. 6215-29-4320 6215-29-4340 6215-29-4330 Part Name Sleeve, front seal assembly Sleeve Front seal
If there is wear or damage to the front seal contact surface of crankshaft (1), use correction oil seal (2) and sleeve (3) to correct. Remove crankshaft pulley and damper. Remove front seal (2). # Be careful not to damage surface of the crankshaft.
1. Press fitting sleeve A. Use sandpaper to remove any dust or mud from the sleeve press-fitting portion of crankshaft (1), then clean the part. 60 mm range (hatched portion) from end face of the crankshaft. B. Coat the whole inside of the sleeve thinly with sealant (LG-7). C. Using a plastic hammer or wooden hammer, tap edge of sleeve (3) around the circumference to install sleeve (3) uniformly to end face of crankshaft (1). Do not use a metal hammer. If a metal hammer is used, burrs or flashes will be made at end face of the sleeve, and this will damage the lip surface of oil seal. The sleeve is symmetrical, so it can be installed in either direction.
D. Using sleeve press-fitting tool N1, press fit until inside of the press-fitting tool is in contact with end face of the crankshaft. Tighten mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.) Press fit sleeve to a position 5 mm from front face of the crankshaft.
E. After press fitting the sleeve, wipe off all sealant that is squeezed out. If sealant sticks to lip of the oil seal, it will cause leakage of oil.
15-42 !

If a sleeve is already being used F. Using a puller, remove sleeve (3).
CRANKSHAFT
If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holding the sleeve, then remove sleeve.
G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth. The remaining procedure is same as for Steps A thru E above.
2. Press fitting front seal A. Use plastic sleeve to install seal over end of crankshaft B. Using sleeve press-fitting tool N2, press fit until the inside of press-fitting tool is in contact with end face of the crankshaft. Tighten mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.) Press fit front seal to a position 13 mm from front face of the crankshaft.
C. Install damper and crankshaft pulley.
15-43 !
CRANKSHAFT
CORRECTING REAR SEAL CONTACT SURFACE

Correction parts Komatsu Part No. 6215-29-4220 6215-29-4240 6215-29-4230 Part Name Sleeve, rear seal assembly Sleeve Rear seal
If there is wear or damage to rear seal contact surface of crankshaft (1), use correction oil seal (2) and sleeve (3) to correct. Remove flywheel. Remove rear seal (2). # Be careful not to damage surface of crankshaft.
1. Press fitting sleeve A. Use sandpaper to remove any dust or mud from sleeve press-fitting portion of crankshaft (1), then clean the part. 60 mm range (hatched portion) from end face of the crankshaft. B. Coat entire inside of sleeve thinly with sealant (LG-7). C. Using a plastic hammer or wooden hammer, tap edge of sleeve (3) around circumference to install sleeve (3) uniformly to the end face of crankshaft (1). Do not use a metal hammer. If a metal hammer is used, burrs or flashes will be made at end face of the sleeve, and this will damage lip surface of the oil seal. The sleeve is symmetrical, so it can be installed in either direction.
D. Using sleeve press-fitting tool O1, press fit until inside of the press-fitting tool is in contact with end face of the crankshaft. Tighten mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.) Press fit sleeve to a position 14 mm from front face of the crankshaft.
E. After press fitting the sleeve, wipe off all sealant that is squeezed out. If sealant sticks to lip of the oil seal, it will cause leakage of oil.
15-44 !

If a sleeve is already being used F. Using a puller, remove sleeve (3).
CRANKSHAFT
If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holding the sleeve, then remove sleeve.
G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth. The remaining procedure is same as for Steps A thru E above.
2. Press fitting rear seal A. Use plastic sleeve to install seal over end of crankshaft B. Using sleeve press-fitting tool O2, press fit until inside of the press-fitting tool is in contact with end face of the crankshaft. Tighten the mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.) Press fit front seal to a position 21 mm from front face of the crankshaft.
C. Install flywheel.
15-45 !
CONNECTING ROD
CONNECTING ROD
1. 2. 3. 4. 5. 6. 7. 8. Connecting rod bolt Washer Cap Dowel pin Bearing (lower) Bearing (upper) Rod Bushing
Unit: mm
Symbol A Inspection item Cracks Judgement standards Check for cracks with a color check or magnetic flaw detector Remedy
Curvature, twisting
Replace
Clearance between connecting rod bushing and piston pin Inside diameter of hole at big end of connecting rod
Standard size 52
Tolerance Shaft 0 0.006 Hole +0.049 +0.030
Standard clearance 0.030 0.055 Standard size 106 Standard clearance 0.046 0.116
Clearance limit 0.11 Tolerance +0.026 +0.006 Clearance limit 0.26
Replace bushing, roughness of inside surface of bushing: Max. 3.2 S
Inside diameter of hole at big end Without bearing Roughness of inside surface of hole at big end: Max. 3.2 S Clearance from crankshaft pin journal (with bearing) Localized wear of big end internal circumference: Max. 0.004 (whole width)
Replace
Even if each part is within repair limit, if it is above the clearance limit, replace the part (bearing etc.) Size STD. E Thickness of bearing 0.125 US 0.250 US 0.375 US 0.500 US Standard size 3.000 3.125 3.250 3.375 3.500 0.025 0.035 Tolerance Repair limit 2.91 3.04 3.16 3.29 3.40 Replace
15-46 !

Symbol Inspection item Scratches on inside surface of bearing, seizure Distance between holes at big end and small end Scratches at I shape portion of connecting rod H Dents Judgement standards
CONNECTING ROD
Remedy Replace bearing (replace connecting rod also) Tolerance 0 0.05 Check for scratches in horizontal direction in area A Replace
Check for scratches or seizure
Standard size 305
Replace Replace if there are any dents, regardless of size. Replace if fingernail catches in fretting Correct with oilstone Replace bolt Replace washer Replace Replace bolt
Check for grinder grain in horizontal direction in area A
Fretting of mating surface of cap
Check for fretting of mating surface Roughness of mating surface: Max. 6.3 S Back contact of mating surface: Min. 70% Scuffing of cap bolt seat surface
Scuffing of bolt surface
Scuffing of bolt seat surface Scuffing of washer surface
K L
Deformation of dowel pin Damage to bolt
Check for deformation of dowel pin Check for deformation of dowel pin hole Check for cracks, damage to bolt thread Check for curvature of bolt
# It is impossible to measure all items in this judgement standard (in particular, the localized wear of big internal circumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding. The reason for this is that it is impossible to confirm the precision after machining and rebuilding the hole at connecting rod big end. # When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on hole surface at big end, measurement of big end hole surface toughness and wave is unnecessary.
15-47 !
CONNECTING ROD
REPLACING CONNECTING ROD SMALL END BUSHING

1. Removal of connecting rod bushing A. Set connecting rod on tool P3. B. Using tools P1 and P4, remove connecting rod bushing with a press. After removing bushing, remove any burrs or dirt, and clean mounting hole of the bushing.
2. Press fitting connecting rod bushing A. Set the connecting rod on tool P3. B. Assemble connecting rod bushing to tool P1, then set tool P2 and secure with tool P4 so that it does not move. Align connecting rod bushing oil hole and connecting rod oil hole.
C. Push tool P1 with a press and press fit connecting rod bearing. Bushing is a semi-finished product, and inside diameter is small, so piston pin will not fit. After press fitting the bushing, machine inside diameter of bushing with a reamer or honing machine in accordance with the MAINTENANCE STANDARD. # After machining, remove all metal particles from the oil hole and oil groove. # Surface roughness of inside diameter after machining bushing: Within 3.2 S
15-48 !
CONNECTING ROD
REPLACING CRANKSHAFT GEAR

1. Removal of gear Make a scratch in surface at root of teeth with a grinder, then assemble tools Q1 and Q2 and turn nut (1) to remove gear. # If gear cannot be removed in this way, make a scratch in surface at root of teeth with a grinder, then heat gear with a gas burner and knock gear out with a copper rod. # Be careful not to damage crankshaft.
2. Press fitting gear A. Check gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. B. Knock a new key into key groove of the shaft.
C. Heat gear for specified time at the specified shrink-fitting temperature. Gear shrink-fitting temperature: 200C Heating time: Min. 30 minutes D. Put timing mark of gear on outside, then use a hitting tool to press fit until the side face of gear is in close contact with crankshaft flange. Knock in quickly before gear becomes cool.
15-49 !
CONNECTING ROD
REPLACING CAMSHAFT GEAR

WARNING! Use care when placing camshaft assembly to prevent injury to fingers.
1. Removal of gear Set camshaft assembly on press stand, then push camshaft to remove gear. 2. Press fitting gear A. Check gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. B. Knock a new key into groove of the shaft. C. Assemble the thrust plate. D. Heat gear for the specified time at specified shrink-fitting temperature. Gear shrink-fitting temperature: 200 240C (392 - 464oF) Heating time: Min. 30 minutes E. Put timing mark of gear on the outside, then use a hitting tool to press fit until side face of gear is in close contact with the camshaft flange. Knock in quickly before gear becomes cool.
REPLACING FLYWHEEL RING GEAR

WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material. 1. Removal of gear Make a scratch in surface at root of the gear teeth with a grinder, then split with a chisel to remove. 2. Press fitting gear A. Check gear mounting surface, and if there are any scratches, correct them with an oilstone. B. Heat gear for specified time at the specified shrink-fitting temperature. Gear shrink-fitting temperature: Max. 200C Heating time: Min. 50 minutes C. Set chamfered face of gear facing the flywheel, and press fit until side face of gear is in close contact with the flywheel.
15-50 !
DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186
DATE: P NAME OF COMPANY: R O P O DEPARTMENT: S E NAME: R MANUAL DESCRIPTION: MANUAL OR CSS CD NO: MANUAL OR CSS CD ISSUE DATE: BOOK DESCRIPTION MACHINE MODEL & S/N:
PROPOSAL FOR MANUAL OR CSS REVISION

FOR INTERNAL USE ONLY -- No. PMR CITY: STATE OR PROVINCE:: COUNTRY: FAX NO: CSS PROGRAM - e.g: Lookup, Parts or Service CSS PROGRAM RELEASE VERSION: CSS BOOK PUBLISHER:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS: PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet. FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PROPFREV.WPD 012100

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Shop Manual

SA12V140Z-1 SERIES DIESEL ENGINE

Copyright 2000 Komatsu DataKom Publishing Corporation

PRODUCT PUBLICATIONS INFORMATION

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM AND RETURN TO

ATTN. STREET ADDRESS

PURCHASE ORDER NO.

TYPE or PRINT ONLY

CITY, STATE, ZIP CODE COUNTRY

CURRENT PRICES WILL BE CHARGED

PREPARATIONS FOR WORK

PRECAUTIONS DURING WORK

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

DISTRIBUTION AND UPDATING

REVISED EDITION MARK

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g

Used as adhesive or sealant for metal, glass or plastic.

LT-4 Holtz MH 705 Three bond 1735

Polyethylene container Tube

Gasket sealant LG-3 790-129-9070 1 kg Can

Three bond 1211 LM-G Molybdenum disulphide lubricant

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI

General purpose type

SYG2-400CA SYG2-350CA SYG2-400CA-A G2-CA SYG2-160CA SYG2160CNCA Molybdenum disulphide lubricant

400 g (10 per case)

Used for places with heavy load.

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Thread diameter of bolt mm 6 8 10 12

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF HOSE NUTS

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

TIGHTENING TORQUE FOR FLARED NUTS

Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6

Tightening torque kgm 2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5

137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05