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TECHNICAL INFORMATION

MODEL

2TE67L-BV on SV08-1

CONTENTS

1. Technical Data ..........................................................................................................................................................................1-1

2. Servicing Standards ..................................................................................................................................................................2-1

3. Measurement, Inspection and Adjustment ................................................................................................................................3-1

3-1 Measuring the Compression Pressure ..............................................................................................................................3-1

3-2 Adjusting the Valve Clearance ..........................................................................................................................................3-2

3-3 Checking the V-belt Tension .............................................................................................................................................3-3

3-4 Checking the Fuel Injection Valve .....................................................................................................................................3-3

3-5 Checking and Adjusting the Fuel Injection Timing (FID) ...................................................................................................3-6

3-6 Adjusting the Maximum (or Minimum) Idling Speed ..........................................................................................................3-7

3-7 Checking the Cooling Water System and Radiator for Water Leakage.............................................................................3-7

3-8 Checking the Sensors .......................................................................................................................................................3-8

4. Measurement Procedure, Service Data and Corrective Action .................................................................................................4-1

4-1 Cylinder Head....................................................................................................................................................................4-1

4-2 Cylinder Block....................................................................................................................................................................4-6

4-3 Valve Rocker Arm..............................................................................................................................................................4-8

4-4 Piston and Piston Rings ..................................................................................................................................................4-10

4-5 Connecting Rod...............................................................................................................................................................4-13

4-6 Camshaft .........................................................................................................................................................................4-16

4-7 Crankshaft .......................................................................................................................................................................4-17

4-8 Gears...............................................................................................................................................................................4-20

4-9 Trochoid Pump ................................................................................................................................................................4-21

5. Precautions for Reassembly......................................................................................................................................................5-1

6. Fuel Injection System ................................................................................................................................................................6-1

6-1 Fuel Oil Injection Pump .....................................................................................................................................................6-1

6-2 Disassembling Procedures................................................................................................................................................6-2

6-3 Reassembling Procedures ................................................................................................................................................6-3

7. Electrical Equipment..................................................................................................................................................................7-1

7-1 Starter Motor......................................................................................................................................................................7-1

7-2 Alternator ...........................................................................................................................................................................7-6

7-3 Glow Plug ..........................................................................................................................................................................7-8

7-4 Stop Solenoid ....................................................................................................................................................................7-9

1. TECHNICAL DATA

1. Technical DataItem Unit SV08-1

Engine

Main specifications

Engine model 2TE67L-BV

Type Vertical type series water-cooled4 cycle diesel engine

Combustion system Swirl pre-combustion chamber

Number of cylinders - Bore Stroke pcs.-mm mm 2 - 67 72

Total displacement cc 507

Rated output / engine speed kW (PS)/rpm 7.7 (10.5)/2400

Maximum torque / engine speed N•m (kg•m)/rpm 31.5 (3.21)/2000

Specific fuel consumption g/kW(PS)•h 280 (22.8 or less)

Maximum idling speed min-1 (rpm) 2575 to 2625

Minimum idling speed min-1 (rpm) 1175 to 1225

Engine dry mass (excluding air cleaner and silencer) kg 60(Exclude the air cleaner and the silencer)

Lubricating method Forced lubrication by trochoid pump

Specific lubricating oil consumption g/kW(PS)•h 0.1 to 0.8 (0.2 to 0.5)

Compression pressure MPa (kgf/cm²) 2.9 (30) at 300 min-1 (rpm)

Cylinder head

Intake valveOpen bTDC degrees 13

Close aBDC degrees 43

Exhaust valveOpen bBDC degrees 43

Close aTDC degrees 13

Intake valve clearance (Cold engine) mm 0.2

Exhaust valve clearance (Cold engine) mm 0.2

Intake valve seat angle degrees 90

Exhaust valve seat angle degrees 90

Piston

First compression ringRing shape Barrel face

Ring quantity pcs. 2

Second compression ringRing shape Taper face


Oil-ringRing shape I type (with coil expander)


Governor

Name Mechanical all speed type

Type Centrifugal type

Fuel feed system

Fuel filter Filter paper with automaticair release device

Fuel filter filtration area cm² 432

Oil/water separator Mesh filter screen

Feed pump Mechanical, diaphragm

1-1

1. TECHNICAL DATA

Item Unit SV08-1

Engine

Lubrication system

Lubrication pump Trochoid pump

LO pressure regulating valve opening pressure kPa (kgf/cm²) 353 to 451 (3.0 to 4.0)

LO filter Full flow filter

LO filter filtration area cm² 75

Filter valve opening pressure kPa (kgf/cm²) 80 to 120 (0.8 to 1.22)

Operating pressure of alarm switch kPa (kgf/cm²) 39.2 to 58.8 (0.4 to 0.6)

Cooling device

Cooling system Forced circulation radiator cooling system

Fan belt size HM28

Thermostat opening temperature ºC 73 to 77

Thermostat full-open temperature ºC 87 or more

Radiator cap pressure kPa (kgf/cm²) 88.2 (0.9)

Radiator fan pcs. Ømm 7 Ø230

Operating temperature of water temperature alarm switch ºC 107 to 113

Air cleaner

Type Cyclone type

Filtration area m² 0.44

Fuel injection pump

Injection pump type ND-PFR 2NC50A 2ND 828

Injection pump plunger diameter mm Ø4.5

Injection pump cam lifting height mm 6.5

Fuel injection timing (FID) degrees 15 to 17

Firing order 1 2

Nozzle

Type ND10PD41

Nozzle hole diameter Number of holes Ømm pcs. Ø1.0 1

Spray angle degrees 10

Fuel injection pressure MPa (kgf/cm²) 11.9 to 12.7 (125 to 135)

Turbocharger

Type -

Revolution speed min-1 (rpm) -

Turbocharging pressure mmHg -

Starting device

Cold starting aids Ceramic glow plug

Starting aids capacity V-W 11-93.5

Battery type 44B-19L

Battery voltage - 5 hrs rate capacity V-Ah 12-30

Electrical equipment

Alternator

Type GP8146

Nominal output V-A 12-14

Rated speed min-1 (rpm) 5200

1-2

1. TECHNICAL DATA

Item Unit SV08-1

Electrical equipment

Current limiterType RS5161

Regulation voltage V 14 to 15

Starter motor

Type Direct current type

Nominal output V-kW 12-1.2

Engagement Magnet shift

Stop motorType - -

Nominal output V-A -

Stop solenoidRegular V-A 12-0.566

Moment V-A 12-3.75

Hour meter V-W 12-0.18

Horn V-W 12-30

Fuse A pcs. 10 2

Monitor lamps

Battery charge alarm lamp V-W 12-3

Engine oil pressure alarm lamp V-W 12-3

Water temperature alarm lamp V-W 12-3

Headlight V-W -

Boom light V-W 12-27

Room lamp (for cabin) V-W -

Wiper motor (for cabin) V-W -

Cabin heater (for cabin) V-W -

1-3

2. SERVICING STANDARDS

2. Servicing Standards

1) Nominal and Allowable Values

Applicable model 2TE67L-BV

Item Unit Standard Wear limit

Cylinder head

Cylinder head distortion mm 0.05 or less 0.12

Valve seat angleIntake degrees

( ° )90

Exhaust 90

Valve seat widthIntake

mm1.59 to 1.8 2.5

Exhaust 1.59 to 1.8 2.5

Intake valve

Stem outside dia.

mm

Ø5.960 to 5.975 Ø5.9

Guide inside dia. Ø6.000 to 6.012 Ø6.08

Oil clearance Ø0.025 to 0.052 Ø0.2

Exhaust valve

Stem outside dia.

mm

Ø5.940 to 5.955 Ø5.9

Guide inside dia. Ø6.000 to 6.012 Ø6.08

Oil clearance Ø0.045 to 0.072 Ø0.2

Valve sinkageIntake

mm0.7 to 0.9

1.8Exhaust 0.7 to 0.9

Valve headthickness

Intakemm

0.775 to 1.0750.5

Exhaust 0.775 to 1.075

Intake valveoperating timing

Open b. TDC degrees ( ° )

13

Close a. BDC 43

Exhaust valveoperating timing

Open b. BDC degrees ( ° )

43

Close a. TDC 13

Valve spring

Free length mm 33

Inclination mm 1.0 1.2

Tension [28.3 mm compressed] kg 6.9 6.5

Intake / exhaust valve clearance mm 0.2 0.5

Cylinder block

Cylinder bore dia.

mm

67.000 to 67.019 67.2

Cylinder bore dia. 67.250 to 67.265 Over size 0.25

Roundness of cylinder 0.00 to 0.01 0.03

Cylindricity of cylinder 0.00 to 0.01 0.03

Upper surface distortion 0.05 or less 0.12

Valve rocker arm

Rocker arm for Intake / exhaust valve

Shaft outside dia.

mm

9.950 to 9.968 Ø11.57

Bush inside dia. 10.000 to 10.015 Ø10.09

Oil clearance 0.032 to 0.065 0.2

Push rod bend 0.03 or less

Tappet

Stem outside dia. Ø17.965 to 17.980 Ø17.93

Guide hole inside dia. Ø18.000 to 18.018 Ø18.05


2-1




Piston

Piston outside dia.

mm

66.938 to 66.953 67.90

Piston outside dia. 67.188 to 67.203 Over size 0.25Minimum clearance between piston and cylinder 0.047 to 0.081

Projection of piston from the upper surface of cylinder block0.5 to 0.6 Thickness of gasket 1.20.6 to 0.7 Thickness of gasket 1.3

Piston pin

Outside dia. Ø18.996 to 19.002 Ø18.98

Bush hole inside dia. Ø18.998 to 19.004


Piston ring

Top ring

Ring groove width

mm

1.550 to 1.570

Ring width (B) 1.470 to 1.490

Clearance between groove and ring 0.060 to 0.100 0.25

End gap 0.130 to 0.280 1.0

Second ring

Ring groove width 1.540 to 1.560



End gap 0.100 to 0.250 1.0

Oil ring

Ring groove width 3.010 to 3.030



End gap 0.100 to 0.300 1.0

Connecting rod

Crank pin side

Crank pin metal inside dia.

mm

Ø38.000 to 38.011

Crank pin metal thickness 1.484 to 1.503

Crank pin outside dia. Ø34.964 to 34.975 Ø34.90


Piston pin side

Bush hole inside dia. Ø19.015 to 19.026 Ø20.10

Piston pin outside dia. Ø18.996 to 19.002 Ø18.98

Oil clearance 0.017 to 0.030 0.2Twist and parallelism 0.08 or less for 100 mm 0.2

Oil clearance 0.040 to 0.085

Cam

Cam shaft bend

mm

0.02 or less 0.05

Cam heightIntake / Exhaust 26.565 to 26.620 26.1

Injection pump 34.480 to 34.520 34.3

Fuel pump 27.90 to 28.00 27.0

Crank shaft

#1, 2Journal

Crank shaft

mm

42.964 to 42.975 39.90

Oil clearance 0.039 to 0.092

#3Journal

Crank shaft 45.948 to 45.959


Bend 0.03 or less 0.06

2-2




Side gap

Crank shaft

mm

0.1 to 0.3

Oil pump 0.1 to 0.15

Connecting rod 0.1 to 0.3

Backlash

Crank gear

mm 0.04 to 0.12Cam gear

Idle gear

Others

Lube oil pumpdischarge volume

High speedL / min

13.7 at 3000 min-1 (rpm)

Low speed 4.6 at 1000 min-1 (rpm)

Oil pressure regulating valve opening pressurekPa

(kgf/cm²)382.4 to 422.2

(3.9 to 4.1)

Oil pressure switch operating pressurekPa

(kgf/cm²)39.2 to 58.8(0.4 to 0.6)

Cooling water pump discharge volume L / min 26.5 at 3000 min-1 (rpm)

Thermostat valve openingtemperature

Temperature °C 73 to 77

Lift at opening mm 6.0 or more at87°C or higher

Thermo-switch operatingtemperature

ON°C

107 to 113

OFF 103 or more

2-3


2) Tightening torque for major bolts and nuts

3) Tightening Torque for General Bolts and Nuts

No. Item Thread size × Pitch Tightening torque [Unit : N•m (kgf•m)] Lubricating oil

1 Cylinder head bolt M8 × 1.25 34.3 to 41.2 (3.5 to 4.0) Yes

2 Connecting rod nut M7 × 1.0 22.6 to 27.5 (2.1 to 2.6) Yes

3 Flywheel mounting bolt M10 × 1.25 80.4 to 86.3 (7.0 to 8.0) Yes

4 Bearing holder upper and lower tightening M9 × 1.25 52.0 to 55.9 (2.0 to 2.5) Yes

5 Crankshaft pulley tightening nut M12 × 1.5 84 to 93 (9.0 to 10.0) Yes

6 Fuel injection nozzle tightening M20 × 1.5 49.0 to 53.0 (6.0 to 7.0) No

7 Glow plug M10 × 1.25 14.7 to 19.6 (1.5 to 2.0) No

Item Thread size × Pitch Tightening torque[Unit : N•m (kgf•m)] Remarks

Hexagon head bolt (7T)Nut

Coarsethread

M6 × 1 9.8 to 11.8 (1.0 to 1.2)

1) Apply 80% of tightening torque when tightened to aluminum.

2) Apply 60% of tightening torque for 4T bolts and lock nuts.

3) Use fine screw threads for engine only.

M8 × 1.25 22.6 to 28.4 (2.3 to 2.9)

M10 × 1.5 44.1 to 58.9 (4.5 to 6.0)

M12 × 1.75 78.5 to 98.1 (8.0 to 10.0)

M14 × 2 112.8 to 142.2 (12.0 to 15.0)

M16 × 2 166.8 to 206.0 (17.0 to 21.0)

M18 × 2.5 235.5 to 284.5 (24.0 to 29.0)

M20 × 2.5 323.8 to 402.2 (33.0 to 41.0)

Fine thread

M14 × 1.5 127.5 to 147.1 (13.0 to 15.0)

M16 × 1.5 210.9 to 240.3 (21.5 to 24.5)

R (PT) plug

1/8 9.8 (1.0)1/4 19.6 (2.0)3/8 29.4 (3.0)1/2 58.9 (6.0)

Pipe joint bolt

M8 12.7 to 16.7 (1.3 to 1.7)M12 24.5 to 34.3 (2.5 to 3.5)M14 39.2 to 49.0 (4.0 to 5.0)M16 49.1 to 58.9 (5.0 to 6.0)

2-4

3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3. Measurement, Inspection and Adjustment

3-1 Measuring the Compression Pressure

1) Measurement Procedure(1) Warm up the engine. Remove the fuel injection pipe

and the fuel injection valve from the cylinder to bemeasured.

(2) Crank the engine before attaching the compressiongauge adapter.

Note :Crank the engine when the regulator handle has beenturned to "STOP" position (no injection state).(3) Attach the compression gauge adapter and the

compression gauge to the cylinder to be measured.Note :Never fail to attach the gasket to the tip of the adapter.(4) Crank the engine with the starter motor until the

reading of the compression gauge is stabilized,according to the above step (2) and Note.

2) Trouble Diagnosis Through Measurement of Compression PressureReduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas(which causes contamination and increased consumption of lubricating oil, and other trouble) and the engine start-ing failure. The compression pressure is influenced by the following factors :(1) Degree of the clearance between the piston and the cylinder ;(2) Degree of the clearance around the intake / exhaust valve seats ; and(3) Gas leak through the nozzle gasket or the cylinder head gasket.This means that the compression pressure decreases as the engine parts are worn and lose durability through theuse of the engine over a long period of time.In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are causedby dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage ofany piston rings. Therefore, the condition of the engine should be diagnosed by measuring the compression pres-sure.

[Engine compression pressure (Reference values)]

Compression pressure at 200 rpm MPa (kgf/cm2) Variations of compressionpressure among cylinders

MPa (kgf/cm2)Standard Allowable limit

2.94 (30) 2.45 (25) 0.2 to 0.3 (2 to 3)

Measuring the compression pressure002184-00E

3-1


Causes and countermeasures to be taken when the compression pressure is less than the limit value.

3-2 Adjusting the Valve Clearance

(1) Inspect and adjust the intake / exhaust valve clear-ance while the engine is in the cold state.

(2) Set the piston in the cylinder to be measured to thetop dead center (TDC) of compression.

(3) Loosen the lock nut and the adjust screw. Checkthat the valve cap is free from inclination or foreignmatter.

(4) Insert a thickness gauge between the rocker armand the valve cap. Tighten the adjust screw until theclearance listed below is attained.

Notes :1. If the valve cap is worn or otherwise damaged in the

head, replace it with a new one.2. Check that the valve cap is fitted on the head of

intake/exhaust valve.

No. Item Causes Countermeasures

1• Filter element of air cleaner • Clogged filter element

• Broken filter element• Defective filter element seal portion

• Clean the filter element.• Replace the filter element.

2 • Valve clearance • Excessive or no valve clearance • Adjust the valve clearance. (Refer to Section 3-2.)

3

• Valve timing • Improper valve timing• Improper valve clearance

• Adjust the valve clearance. (Refer to Section 3-2.)

• Inspect and adjust the valve rocker arm. (Refer to Sections 4-3, 4-6 and 4-8.)

4

• Cylinder head gasket• Nozzle gasket

• Gas leak through the gasket • Replace the gasket.• Re-tighten the cylinder head and the nozzle at the

specified torque. (Refer to Section 2 2) of Chapter 2.)

5• Intake/exhaust valve• Valve seat

• Gas leak due to worn valve seats or trapped foreign matters

• Sticking of valves

• Lap the valve seats. (Refer to Section 4-1 2).)

• Replace the intake/exhaust valves.

6• Piston• Piston ring• Cylinder

• Gas leak due to scratches or wear of the piston, piston ring or cylinder

• Do the honing and use oversize parts. (Refer to Sections 4-2 3) and 4-4 8).)

Intake / exhaust valveclearance

Refer to Section "2 1) Nominal and Allowable Values".

002185-00X

Adjust screw

(Adjusting the valve clearance)

Valve clearance

Lock nut

003337-00E

Valve cap

Good No good003338-00E

3-2


3-3 Checking the V-belt Tension

Press the center of the V-belt between the alternator andthe cooling water pump with a finger by 49 N (5 kgf). Ifthe slack is about 4 mm, the V-belt tension is proper. Ifnot, adjust the V-belt tension using adjusting plate of thealternator.Loosen the alternator holding cap screw and the nut onthe adjusting plate in order to adjust the V-belt tension bymoving the cap screw to arrowed direction.

3-4 Checking the Fuel Injection Valve

1) Measuring the Fuel Injection Pressure

Note :Thoroughly remove carbon deposits from the injectionnozzle hole before the measurement.

(1) Connect the fuel injection valve to the high pressurepipe of the nozzle tester.

(2) While pumping the lever of the nozzle tester slowly,read the pressure gauge on the nozzle tester themoment the nozzle starts fuel injection.(For the fuel injection pressure, refer to Section "1.Technical Data").

(3) If the measured fuel injection pressure is lower thanthe specified value, replace the pressure adjustingshim with a thicker one.

Types of pressure adjusting shim thicknessmm Fuel injection pressure adjustment

0.9 to 1.45 (every 0.025 mm)Thicker adjusting shim by 0.1 mm increases the fuel injection pressure for 0.78 MPa (8 kgf/cm2).

Crank pulley

Fan pulleyAdjusting plate

Alternator

Alternator holding cap screw003340-00E

(Adjusting the V-belt tension)003339-00E

Injection nozzle

Nozzle tester

003341-00E

( )Measuring the fuel injection pressure with a nozzle tester

3-3


[Reference : Structure of fuel injection valve]

2) Checking the Spray PatternWhile pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Referto Section "1. Technical Data"), check the spray pattern. If the spray pattern is not normal, clean or replace the noz-zle.

(1) Check that the pattern is neither like a stream nor slivered.(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 4 degrees.

(3) Spray fuel on a sheet of white paper placed about 30 cm below the nozzle. The injection spray should form aperfect circle.

(4) No fuel should drip from the nozzle after injection.(5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower

than the specified value : 2.0 MPa (20 kgf/cm2).(6) Test the injection with a nozzle tester ; retighten the nozzle holder and test it again if there is excessive fuel leak

from the overflow coupling. Replace the nozzle as a set if the fuel leak is still excessive.

Nozzle holder

Nozzle spring

Nozzle spring seat

Pressure adjusting shim

Valve stop spacer

Nozzle valve

Nozzle case nut

Nozzle body

Nut

Gasket

003342-00E

[Normal spray pattern] [Abnormal spray pattern]

4 degrees

003343-00E

3-4


3) Nozzle Valve Sliding TestThoroughly wash the nozzle valve using clean fuel. Hold the nozzlebody vertical, and put the nozzle valve approx. 1 / 3 of its length intothe body.Check if the nozzle valve falls smoothly by self-weight whenreleased. If so, the nozzle valve is good.

4) Nozzle Body Identification Number

(Nozzle valve sliding test by self-weight)003344-00E

Size : Size P (or S)

Spray angle

Design code

: Throttle typeCode D: Pintle typeNo code

Type :�Pintle typeBosch automotive type

NP 117DP- 4DN

003345-00E

3-5


3-5 Checking and Adjusting the Fuel Injection Timing (FID)

(1) Using the crankshaft pulley, turn the engine in the specifieddirection. Check the injection timing with the delivery valvespring holder of the fuel injection pump for the cylinderNo.1. (Cylinder are numbered from No.1 sequentially fromthe flywheel side).

(2) When the crankshaft is turned in the specified direction, thefuel level rises at the tip of the delivery valve spring holder.At that time, stop turning the crankshaft.

(3) Check the timing marks imprinted on the timing gear caseand the crankshaft pulley.(For the fuel injection timing, refer to Section "1. TechnicalData".

(4) When the cylinder head is removed, set the dial gauge onthe top of piston to confirm fuel oil injection timing by thepiston movement.

(5) If the present injection timing differs from the specified tim-ing, remove the fuel injection pump, and adjust the timing byincreasing or decreasing the adjusting shim thicknessbetween the fuel injection pump and gear case.

• Increase the shim thickness by 0.3 mm to delay the injectiontiming by approximate 2°.

• Decrease the shim thickness by 0.3 mm to advance the injec-tion timing by approximate 2°. Every 0.1 mm of thickness between 0.2 to 0.5 mm, adjustingshims are established.

Injection timing (BTDC) Piston movement (mm)

15.0 to 17.0 1.656 to 2.116

Cylinder No.1003346-00E

Timing mark

Crankshaft pulley

003347-00E

Adjustment shim

003348-00E

3-6


3-6 Adjusting the Maximum (or Minimum) Idling Speed

(1) First warm up the engine. Then, gradually increase theengine speed up to the high idling speed. (Refer to Section"1. Technical Data".)

(2) If the high idling speed differs from the specified one,adjust it by the cap screw on the timing gear case.

(3) Set the low idling speed to the specified value, (Refer toSection "1. Technical Data") by turning the low idlingspeed set bolt.

3-7 Checking the Cooling Water System and Radiator for Water Leakage

1) Checking the Cooling Water System for Water LeakageNote :The cooling water system can be checked effectively while theengine is warm.

(1) Supply cooling water up to the normal water level in theradiator. Attach the cap tester body to the radiator.

(2) Start operating the cooling water pump, and set the pres-

sure of the tester to 88.3 ± 14.7 kPa (0.9 ± 0.15 kgf/cm2).Any lower reading of the pressure gauge on the cap testerindicates water leakage from the cooling water system.Then, find out the portion of the cooling water system fromwhich cooling water leaks.

2) Checking the Radiator CapAttach the radiator cap to a cap tester. Set the pressure of the

tester to 88.3 ± 14.7 kPa (0.9 ± 0.15 kgf/cm2). Check if the capis opened at the set pressure. If not, replace the cap, becauseit is defective.

High idling�speed adjusting bolt Low idling speed

adjusting bolt

Timing gear case

Stop lever

003349-00E

Checking the cooling water systemfor water leakage( )

Cap tester

003350-00E

(Checking the radiator cap)Radiator cap

003351-00E

3-7


3-8 Checking the Sensors

1) Checking the Thermostat and the Thermoswitch(1) ThermostatPut the thermostat into the water in a container. Whilemeasuring the water temperature, heat the water. Checkthat the thermostat begins to work at 73.0 to 77.0 °C andfully opens at 90 °C.

(2) ThermoswitchPut the thermoswitch into the antifreeze or oil in a con-tainer. While measuring the liquid temperature, heat theliquid. If the tester shows continuity at a temperature of107 to 113 °C, the thermoswitch is normal.

2) Oil Pressure SwitchRemove the connector from the switch. While runningthe engine, bring the tester probes into contact with theswitch terminal and the cylinder block. If the testershows continuity, the hydraulic switch is defective.

Thermometer

Thermostat

003352-00E

Thermometer

Tester probes

003353-00E

Tester probes

(Continuity test)003354-00E

3-8

4. MEASUREMENT PROCEDURE, SERVICE DATAAND CORRECTIVE ACTION

4. Measurement Procedure, Service Data and Corrective Action

For the maintenance of all parts, make measurements according to the following measurement procedure. If anypart is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it isexpected that any part within the allowable value will exceed the value before the next maintenance based on therecord of its use, be sure to replace such a part beforehand.

4-1 Cylinder Head

1) Checking the Combustion Surface for Distortion(1) Remove the intake / exhaust valves and the fuel

injection valve from the engine. Clean the surface ofthe cylinder head.

(2) Place a straight-edge along each of the four sidesand each diagonal of the cylinder head. Measurethe clearance between the straight-edge and thecombustion surface with a thickness gauge.

(3) Visually check if the combustion surface is free fromdiscoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.

2) Intake / Exhaust Valve Seat(1) Valve sinkageOver long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth andreplace the valve and valve seat if the valve sinking depth exceeds the standard value.

Cylinder headcombustionsurface distortion

Standard Wear limit


Standard Wear limit

Valvesinkage

Intakevalve Refer to Section "2 1) Nominal and

Allowable Values".Exhaustvalve

Straight-edge

Thickness gauge

Measuring the combustionsurface distortion( )

003355-00E

Depth micrometer

(Measuring the valve sinkage)003356-00E

Valve sinkage

003357-00E

4-1


(2) Width and angle of the valve seatRemove carbon deposits from the seat surface. Mea-sure the seat width and angle using vernier calipers andan angle gauge respectively.

[Valve seat correction procedure](1) If the seat surface is worn or roughened slightly, lap

the seat surface to a smooth state with a valve com-pound mixed with oil.

(2) If the seat surface is worn or roughened exces-sively, correct the seat surface using a seat grinderor a seat cutter, and finish it according to the abovestep (1).

[Procedure for using seat grinder and seat cutter](1) Correct the roughened seat surface with a seat

grinder or a seat cutter.

(2) When the seat width is enlarged from the initialvalue, correct it by grinding the seat surface with a70 degrees seat grinder or a seat cutter. Then, grindthe seat surface with a 15 degrees grinder so thatthe seat width should be the standard value.

Note :When using a seat cutter, apply pressure evenly takingcare not to cut the seat surface unevenly.(3) Knead a valve compound with oil and finish the valve seat by lapping with the compound.Note :If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and thevalve guide inside dia. If the oil clearance exceeds the wear limit, replace the valve or the valve guide before correct-ing the valve seat surface. (For the oil clearance between the valve and the valve guide, refer to the subsection 3 inthis section.)

Standard Wear limit

Valveseatwidth

Intake


Exhaust

Valveseatangle

Intake

Exhaust

Seat grindstone Angle (degrees)

Intake valve 45

Exhaust valve 45

(Measuring the valve seat width)003358-00E

Seat grinder

Grindstone

003359-00E

(Valve seat correction angle)

Valve seat

Seat width

70

15

003360-00E

4-2


(4) Last, lap the valve using only oil.Notes :1. After correcting the valve seat, thoroughly clean the valve and the cylinder head using light oil or the like. Thor-

oughly remove the valve compound or the grindstone powder.2. For slightly poor contact, take the steps (3) and (4) only.

3) Intake / Exhaust Valve(1) Wear and bend of the valve stemReplace the valve stem if bent or worn excessively. In this case, replace the valve guide together with the valvestem.(2) Valve stem and valve guideOil clearance is the difference between the valve guide inside diameter measured with a three-point micrometer or acylinder gauge and the stem outside diameter measured with a micrometer. If the oil clearance is near the wear limit,replace both the intake / exhaust valve and the valve guide with new ones. Note :Three-point micrometer : Used for an inside diameter of 0.157 to 0.315 in. (4 to 8 mm).Cylinder gauge : Used for an inside diameter of 0.236 in. (6 mm) or more.

(3) Thickness of valve headMeasure the thickness of the valve head with a micrometer.If the measured value is near the wear limit, replace thevalve with a new one.

Standard Wear limit

Intakevalve

Stemoutside dia.


Guideinside dia.

Oil clearance

Exhaust valve

Stemoutside dia.

Guideinside dia.

Oil clearance

Standard Wear limit

Thicknessof valvehead

Intakevalve Refer to Section "2 1) Nominal and

Allowable Values".Exhaustvalve

Seat widthThickness

Valve diameter

Seat angle003362-00E

(Measuring the valve stem outside diameter)

003361-00E

4-3


4) Valve Stem Seal[Time of replacement](1) When oil loss is found excessive.(2) When the valve stem seal is removed.(3) When the intake / exhaust valve is removed.

[Precautions on installation]Before reinstalling the intake / exhaust valve, thoroughlyremove the burrs on the valve stem surface and then applysufficient lubricating oil to the valve stem.

Valve stem seal

Valve guide

Cylinder head

003363-00E

Hatched portion indicateswhere to apply lubricating oil.( )

003364-00E

4-4


5) Checking the Valve Spring(1) Visually check if the valve spring is free from flaws

and corrosion.(2) Measure the free length (length of the spring) and

inclination (squareness of the side of the coil).

6) Checking Valve Spring Holder and CotterCheck the contact of the inner surface of the valve springholder with the outer surface of the cotter as well as thecontact of the inner surface of the cotter with the notch inthe head of the valve stem. If such contact is uneven or ifthe cotter has sunk due to wear, replace the cotter with anew one.

Standard Wear limit

Valve spring

Free length


Inclination

Tension[lbs. (kg)][0.0394 in.(1 mm)compressed]

(Measuring the free length)

003365-00E

(Measuring the inclination of valve spring)

Inclination

Square

Free length

Surface plate

003366-00E

4-5


4-2 Cylinder Block

1) Checking the Cylinder Block(1) Visually check if the cylinder block is free from water

leak, oil leak and cracks. If any portion of the cylinderblock might be cracked, check the portion by colorcheck.

(2) Replace the cylinder block if badly damaged andunreparable.

(3) Thoroughly clean each oil hole. Make sure that it isnot clogged.

2) Measuring the Cylinder Bore and the Distortion of the CylinderMeasure each cylinder bore with a cylinder gauge. Mea-sure the cylinder bore diameters at the point a, approx.0.79 in. (20 mm) below the crest of the liner, and at thepoints b and c at equal intervals.Obtain the distortion of the cylinder (the roundness andcylindricity of each cylinder) from the following measuredvalues :• Roundness :

Difference between the max. and min. bore values onthe same cross section of each liner.

• Cylindricity :Difference between the max. and min. bore values inthe same direction of each liner.

Apply honing (honing and boring) if any measured valueexceeds the allowable limit.Note :For oversized pistons and piston rings, refer to Section "4-4 Piston and Piston Rings".

Standard Wear limit

Cylinder bore dia.Refer to Section "2 1) Nominal and

Allowable Values".Roundness of cylinderCylindricity of cylinder

(Measuring the cylinder bore diameter)

Cylinder gauge

003367-00E

20a

b

c

Measurement should be made at the points a, b and c in the directions of A and B

Cylinder bore measuringpoints( )

Note :

A

B

003368-00E

4-6


3) Honing(1) Application of honingApply honing or boring to the cylinder if it is partiallyworn, flawed, or otherwise damaged. If the partial wear,flaw or other damage is minor, it can be repaired only byhoning with a Flex-Hone. However, if it is not minor,apply honing after boring. In this case, taking the maxi-mum wear into consideration, it is important to examinewhether the cylinder can attain perfect roundness afterhoning and / or boring, and whether prepared oversizedpistons and piston rings can be used. (For the oversizedpistons and piston rings, refer to Section "4-4 Piston andPiston Rings".)(2) Procedure for using the Flex-HoneIt is common practice to use the Flex-Hone for honing.The procedure for using it is described below. Any mate-rial needs a honing allowance of approx. 0.00004 in. (1 /1000 mm) for honing with the Flex-Hone.[1] Items to be preparedFlex-Hone, power drill, and honing liquid

[2] Handling procedureSoak the Flex-Hone in the honing liquid. Insert the Flex-Hone into the cylinder and move it up and down for about30 seconds while turning it at a cross hatch angle of about30 to 40 degrees. Then, extract the Flex-Hone while turn-ing it.Notes :1. Use the Flex-Hone at a speed of 300 to 1200 rpm. Use

of the Flex-Hone at a higher speed may be hazardous.2. Never insert into or extract from the cylinder the Flex-

Hone, with the power drill stopped.

Flex-HoneYanmar code No.

Applicable bore dia.(mm)

129400-92400 63 to 70

(Flex-Hone)003369-00E

Light oilEngine oil50%50%

Honing liquid

Power drill

Flex-Hone

003370-00E

30 to 40 degrees

003371-00E

4-7


4) Overhaul of Cylinder (Reference)

4-3 Valve Rocker Arm

1) Measuring the Rocker Arm Shaft Outside Diameter and the Rocker Arm Bush Inside DiameterOil clearance is the difference between the rocker arm bush inside diameter measured with a cylinder gauge and therocker arm shaft outside diameter measured with a micrometer. If the oil clearance is near the wear limit, replace therocker arm shaft and the rocker arm with new ones.

Standard Wear limit

Intake /exhaustvalve rocker arm

Shaftoutside dia.

Refer to Section "2 1) Nomi-nal and Allowable Values".Bush inside

dia.

Oil clearance

Service life of cylinder block (H3)

and blow-by and blow-by and blow-by and blow-by

Examine the applicabilityof oversizedpistons and piston rings.

*L.O.C = lubricating oil consumption

Increase in L.O.C*

(H3 = 3H1)

Time for boring and honing (H2)

Time for honing (H1)

(H2 = 1.5H1)

Increase in L.O.C Increase in L.O.C Increase in L.O.C

Honing Boring

( )003372-00E

Measuring the rocker arm shaftoutside diameter( )

003373-00E

Measuring the rocker armbusu inside diameter( )

003374-00E

4-8


2) Checking the Push Rod Bend, Measuring the TappetStem Outside Diameter and Checking the TappetContact Surface

Put the push rod on the surface plate to check that there is noclearance between the push rod and the surface plate. Mea-sure the tappet stem outside diameter with a micrometer.

3) Other Inspections(1) Valve rocker arm shaft spring

Check if the rocker arm shaft spring is free from corro-sion and wear. If not, replace it with a new one.

(2) Wear of intake/exhaust valve rocker arm and valve capCheck the intake / exhaust valve rocker arm for the con-tact surface with the valve cap. If any of them is exces-sively worn or partially flaked, replace it.

(3) Check the portion where the valve clearance adjustscrew is in contact with the push rod. If the portion isworn or flaked, replace the push rod or the adjust screw.

Standard Wear limit

Push rod bend

Refer to Section "2 1) Nomi-nal and Allowable Values".Tappet

Stem outsidediameter

Guide holeinsidediameter

Oil clearance (Measuring the push rod bend)

Thickness gauge

003375-00E

(Measuring the tappet stem outside diameter)003376-00E

Adjust screw

Check of contact surface

Push rod

Check of contactsurface of rocker arm

003377-00E

4-9


4-4 Piston and Piston Rings

1) Checking the Piston(1) Remove carbon deposits from the head and com-

bustion surface of the piston while taking care not todamage the piston. Check if there are any cracks ordamage.

(2) Check the outer surface and ring grooves of the pis-ton, and replace it if worn or damaged.

2) Measuring the Piston Outside DiameterTo measure the piston outside diameter, measure thelong diameter of the oval hole in the vertical direction tothe piston pin bush hole at a position which is 15 to 17mm above from the lower end of the piston.

3) Shapes of Piston Rings

Standard Wear limit

Piston outside dia.Refer to Section "2 1) Nominal and

Allowable Values".Minimum clearancebetween pistonand cylinder

Measuringposition

15 to 17 mm

003378-00E

Measuring the rocker armbusu inside diameter( )

003374-00E

Second ring

Oil ring

Top ring

003380-00E

4-10


4) Measuring the Ring Groove Width, the Ring Width (B), and the End GapTo measure the piston ring groove width, first measurethe width (B) of the piston ring. Then, fit the piston ringinto the ring groove after cleaning the groove carefully.Insert a thickness gauge between the piston ring and thegroove to measure the clearance between them. Obtainthe ring groove width by adding the ring width to the mea-sured clearance.

To measure the end gap, push the piston ring into thesleeve using the piston head, insert a thickness gaugebetween both ends of the piston ring. If the sleeve is worn,measure the end gap after pushing the piston ring into thesleeve to the portion which is less worn (approx. 30 mmfrom the lower end of the sleeve).

Standard Wear limit

Topring

Ring groovewidth


Ring width (B)

Clearancebetweengroove and ring

End gap

Secondring

Ring groovewidth

Ring width (B)


End gap

Oil ring

Ring groovewidth

Ring width (B)


End gap

(Measuring the ring groove width)003382-00E

(B)Width

Thickness 003381-00E

End gap

Measuring the end gapof piston ring( )

Approx. 30 mm

Piston ring

Cylinder block

003383-00E

4-11


5) Installation of Piston Rings(1) Using a piston ring replacer, fit the piston ring into

the ring groove, with the manufacturer's mark nearthe end of the piston ring facing upward (to the com-bustion chamber side). After fitting the piston ring,check that the piston ring moves smoothly.

(2) After fitting all the piston rings, shift the end gaps ofthem at 120 degrees intervals, so that they are notaligned along the piston. Apply lubricating oil to thepiston pin before inserting it into the piston.

6) Measuring the Outside Diameter and Bush HoleInside Diameter of the Piston Pin

Measure the outside diameter and bush hole insidediameter of the piston pin. Replace the piston pin if oneor both of the measured values exceed the wear limit.Apply lubricating oil to the piston pin before inserting it

into the piston.

Standard Wear limit

Pistonpin

Outside dia.


Bush holeinside dia.

Oil clearance

003385-00X

(Inserting piston pin)003387-00E

Measuring points of the piston pin outside diameter( )

003384-00E

(Measuring the piston pin outside diameter)003386-00E

4-12


7) Top Clearance (Reference)

8) Oversized Piston and Piston Ring

4-5 Connecting Rod

1) Visual InspectionInspect the following portions for cracks, distortion and discoloration :(1) Portions close to the boundaries between the chamfered parts of the large and small ends, and the I-beam sec-

tion of the connecting rod.(2) Portion around the oil hole in the bush at the small end.

2) Measuring the Twist and ParallelismMeasure the twist and parallelism of the connecting rod with a connecting rod aligner.

Top clearance


[0.250S : Oversized by 0.25 mm]

Size classification Piston assembly code(including piston ring assembly) Piston ring assembly code

0.250S 165000-47550 165000-47560

Twist and parallelism


Reference axis

Parallelism

Twist

100 mm

100 mm

(Measuring the twist and parallelism)003388-00E

4-13


3) Measuring the Clearance Between the Crank Pin and BushTo measure the oil clearance between the crank pin andthe crank pin metal, measure the inside diameter of thecrank pin metal and the outside diameter of the crankpin, and calculate the difference between them.If the measured oil clearance exceeds or near the wearlimit, replace the crank pin metal. If the crank pin isexcessively or partially worn, grind the crank pin, anduse an oversized crank pin metal.Note :To measure the inside diameter of the crank pin metal,install the metal into the large end of the connecting rodand tighten the rod bolts at a specified tightening torque,making sure that each half of the metal is set in the cor-rect way.

4) Measuring the Oil Clearance Between the PistonPin Bush and the Piston Pin

To measure the oil clearance between the piston pinbush and the piston pin, measure the inside diameter ofthe piston pin bush and the outside diameter of the pis-ton pin, and calculate the difference between them.

Rod bolt tightening torque(Apply lubricating oil tothe rod bolt)

Refer to Section "2 2) Engine Tightening torque for major

bolts and nuts"

Standard Wear limit

Crankpin side

Crankpin metalinside dia.


Crankpin metalthicknessCrankpin outsidedia.

Standard Wear limit

Pistonpin side.

Bushinside dia.

Refer to Section "2 1) Nominal and Allowable Values".Piston pin

outside dia

Oil clearance

Cylinder gauge

Measuring the inside diameter ofthe crank pin metal( )

003389-00E

Cylinder gauge

Measuring the inside diameter ofthe piston pin bush( )

003390-00E

4-14


5) Checking the Contact of the Crank Pin MetalApply a blue ink or a minium to the inside surface of thecrank pin metal. Instal the crank pin metal to the crank-shaft, and tighten the rod bolts at a specified tighteningtorque (refer to the above 3 of this section) to check thecontact of the metal. If the contacted surface of the metaloccupies 75 % or more of the total surface, the crank pinmetal is good in terms of contact.

6) Installing the Piston and the Connecting RodInstall the piston with the connecting rod, with the marksat the large end of the connecting rod facing the fuelinjection pump. Also, install the piston so that the recessof the combustion chamber is on the fuel injection pumpside as seen from the top.

7) Side Gap of the Connecting RodAfter installing the connecting rod to the crankshaft,tighten the rod bolts at a specified tightening torque(refer to the above 3 of this section). Measure the sidegap by inserting a thickness gauge between the con-necting rod and the crank arm. If the measured valueexceeds the wear limit, replace the crank pin metal orthe connecting rod.

8) Undersized Crank Pin Metal

Side gap Refer to Section "2 1) Nomi-nal and Allowable Values".

Undersized by 0.25 mm

Crank pin metal

Part code No.Metal thickness [in. (mm)]

Standard

165000-15870 1.625

003391-00X

4-15


4-6 Camshaft

1) Removing the CamshaftRemove the tappets and fuel oil injection pump, andloosen two cap screws (M6) inside of the camshaft gearto remove the camshaft.

2) Checking the Camshaft AppearanceCheck the camshaft for the contact surface of the camwith the tappet, seizure and wear of the bearing, anddamage of the cam gear.

3) Measuring the Bend of the CamshaftSupport the camshaft with V-blocks. Using a dial gauge,measure the runout of the journal at the center of thecamshaft while rotating the camshaft.Take 50 % of the measured runout as bend.

4) Measuring the Intake / Exhaust Cam Height

Standard Wear limit

Camshaft bend Refer to Section "2 1) Nominal and Allowable Values".

Standard Wear limit

Camheight

Intakecam Refer to Section "2 1) Nominal and

Allowable Values".Exhaustcam

003393-00X

Dial gauge

V-block

(Measuring the camshaft bend)003394-00E

Micrometer

(Measuring the cam height)003395-00E

Cam height

003392-00E

4-16


4-7 Crankshaft

1) Side Gap Around the CrankshaftBefore extracting the crankshaft and when installing it,contact a dial gauge with the end of the crankshaft.Press the crankshaft to each of the right and left sides inthe axial direction to measure the side gap. Alternatively,insert a thickness gauge directly into the clearancebetween the thrust metal in the reference part and thethrust face of crankshaft to measure the side gap. If themeasured value exceeds the wear limit, replace the rearend bearing holder (flywheel side) with a new one.

2) Removing the CrankshaftRemove the three cap screws shown below to pull outthe crankshaft to flywheel end. Remove the relief valvebeforehand.

3) Removing the Main BearingRemove two bearing holding cap screws to remove themain bearing.

Side gap Refer to Section "2 1) Nomi-nal and Allowable Values".

Crankshaft

Relief valve

Dial gauge

003396-00E

Allen head cap screws

Cap screw

003888-00E

Bearing holder

003889-00E

4-17


4) Color Check of CrankshaftClean the crankshaft and check it using a color check kitor a magnetic inspector. Replace the crankshaft if it iscracked or badly damaged. If the damage is minor, cor-rect it by re-grinding.

5) Checking the MetalsCheck the metals for flaking, melting, seizure, and thestate of the contact spur face. Replace any of the metalsif it is damaged.

6) Bend of the CrankshaftSupport the journals of the crankshaft with V-blocks atboth ends. Measure the runout at the center journal witha dial gauge while rotating the crankshaft to check thebend of the crankshaft.

7) Measuring the of Crank Pin and JournalMeasure the outside diameters, roundness, taper anglesof the crank pin and journal. If the partial wear or theroundness exceeds the wear limit but the measured out-side diameter is within the limit, correct it by regrinding.Replace the crankshaft with a new one, if it is unrepara-ble. An under sized crank pin metal by 0.0098 in. (0.25mm) is available. (Refer to Section 4-5, 4-8 in this chap-ter.)

Bend Refer to Section "2 1) Nomi-nal and Allowable Values". Runout

(Measuring the crankshaft bend)

Bend

Dial gauge

V-block V-block

003397-00E

003399-00X

Crank pinCrank journal

R

R

Measuring points of the crank pinand journal( )

003398-00E

4-18


8) Precautions for Installation of the Metal Caps(1) The lower half of the metal on the holder side has no oil groove.(2) The upper half of the metal on the cylinder block side has an oil groove.(3) The aluminum bearing holders are on the flywheel side.(4) Place the embossed mark "F" of the bearing holder to front (crankshaft pulley side).

Install the bearing holder without the embossed mark "F" facing its chamfered side to front (crankshaft pulleyside).

9) Undersized Main Metal by 0.25 mm and Bushings by 0.25 mm

Standard Wear limit

Crankpin

Crank pinoutside dia.

Refer to Section "2 1) Nominal and Allowable Values".Crank

journal

Outsidedia.

Main metalthickness

Oilclearance

No. Part code No. Metal thickness

#1 Bushing 165000-15850 2.125

#2 Metal 165000-15920 2.125

#3 Metal 165000-15900 2.125

Main metal (reference)

Metal cap (reference)Main metal

Metal capMetal cap

Thrust metal (flywheel side)

003400-00E

4-19


4-8 Gears

1) Checking the GearsCheck the teeth surfaces of each gear and replace the gear if the teeth are damaged, worn, or flaked.

2) Measuring the BacklashesApply a dial gauge onto the pitch circle of the gear, and measure the backlash.

3) Gear TrainAfter installing all the gears, check that the matchmarkes of idle gear and camshaft gear, idle gear and crankshaftgear are aligned as below.

Standard Wear limit

Backlash

Crank gear, cam gear, idle gear and fuel injection pump drive gear

Refer to Section "2 1) Nomi-nal and Allowable Values".

Cam gear

*P.T.O. (Option)Crank gear

Idle gear

003401-00E

4-20


4-9 Trochoid Pump

Lube oil pump is installed in the idle gear. Remove the E-ring to disassemble the trochoid pump.

1) Clearance Between Outer Rotor and Inner RotorInsert a thickness gauge between the top of the innerrotor tooth and the top of the outer rotor tooth to mea-sure the clearance.

Standard Wear limit

Clearance betweenouter rotor andinner rotor


Collar

Adjusting shim

E-ring

003402-00E

Outer rotor

Inner rotor

Thickness gauge

Measuring the clearance betweenouter rotor and inner rotor( )

003403-00E

4-21

5. PRECAUTIONS FOR REASSEMBLY

5. Precautions for Reassembly

Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautionsbelow particularly before and during the reassembly.

1) Cleaning the ComponentsClean the cylinder block, the cylinder head, the crankshaft, and the camshaft carefully so that they are free fromchips, dust, sand, and other foreign matter.

2) Parts to be Replaced in ReassemblyBe sure to replace the following parts with new ones in reassembly.(1) Valve guide seal(2) Head gasket packing(3) All of the copper packings, O-rings and gasket packings

3) Measuring the Side Gap Around the CrankshaftApply a dial gauge to the end of the crankshaft. Press thecrankshaft to each of the right and left sides in the axialdirection to measure the side gap. Alternatively, insert athickness gauge directly into the clearance between the ref-erence thrust metal and the thrust surface of the crankshaftto measure the side gap. If the measured value exceeds thewear limit, replace the thrust metal with a new one.

4) Gear TrainAfter installing all the gears, check that the match marksidle gear - crankshaft gear and idle gear - camshaft gear.

Side gap Refer to Section "2 1) Nomi-nal and Allowable Values". Crankshaft

Dial gauge

003404-00E

Cam gear

*P.T.O. (Option)Crank gear

Idle gear

(From the gear case side)

003405-00E

5-1


5) Applying Lubricating Oil to the Intake / ExhaustValve Stem

Apply lubricating oil to the valve guide so that the oilspreads over the lower surface (hatched portion in the fig-ure) of the valve guide, before reinstalling the valve guide.

6) Reinstalling the Piston Rings(1) Fit the piston ring into the ring groove, with the manu-

facturer's mark near the end of the piston ring facingupward (to the combustion chamber side), using apiston ring replacer. After fitting the piston ring, checkthat it moves smoothly.

(2) Install the piston their end gaps rings into theirrespective ring grooves so that their end gaps areshifted at 120 degrees intervals, making sure thatthey are not aligned along the piston. Apply lubricat-ing oil to the outside surface of the piston.

7) Applying Lubricating Oil to the Push Rod Adjust Screw Contact PortionApply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly.

8) Installation Direction of the Piston and the Connecting Rod

Install the piston so as for the apex of the triangle on the top of piston to face the front end of the engine. Assemblethe connecting rod so that the matchmarks of large end of the connecting rod face the fuel oil injection pump.

Valve guide

003406-00E

Apply lubricating oil

003407-00E

Matchmarks

Front end of the engine

003408-00E

5-2


9) Installation of the Cylinder Head GasketInstall the gasket with the part number stamp on it facingup. The thickness of it is determined by piston projectionfrom the top of cylinder block.

Piston projection and gasket thickness

10) Tightening Order and Tightening Torque of the Cylinder Head BoltsTighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below.

11) After Completing the Reassembly, Carry Out a Verification Run of the Engine to Check That There is NoWater or Oil Leakage.

Sink of piston (mm) Stamp No. Thickness (mm)

0.5 to 0.6 7600 1.2

0.6 to 0.7 7610 1.3

Tightening torqueRefer to Section "2 2) Engine Tightening torque for major

bolts and nuts".

008548-00E

No. stamp

008549-00X

008550-00E

Flywheel side Front end of the engine

5-3

6. FUEL INJECTION SYSTEM

6. Fuel Injection System

6-1 Fuel Oil Injection Pump

The injection pump is a PFR model of Bosch type. Thepump camshaft has pump drive cams and injection oilflow is controlled by a control lever in the gear case.

1) Injection Pump

Disassemble the pump at a specified service shop only.

2) GovernorThe governor is a mechanical all speed type andinstalled in the gear case. The fly weight assembly isinstalled on the camshaft and its movement is conveyedthrough slider-control lever-link to the control rack of thepump. The fly weight control spring is installed on thearm complete and tension bar so that the governor leverangle changes spring tension to control the enginespeed.

3) High Idling Speed Set ScrewThe arm complete movement is restricted by the highidling speed set screw and idling speed is limited. (Asshown to the right, caps 3 are installed by the factory notto be readjusted the preset.

Part Code No. 165000-15210

003412-00X

008552-00J

3

6-1


4) Smoke Set and Start SpringSmoke set 1 is installed on the cylinder block. It restrictsfuel oil injection in high speed range and the angleichspring is installed in it so as to increase fuel oil injectionto gain a big torque in mid speed range.The start spring is installed on gear case and governorlink to increase fuel oil injection when the engine isstarted.The smoke set is preset by the factory and sealed by acap 3 not to be readjusted locally.

5) Adjusting the High Idling Speed (Refer to 3-7)The set screw 2 is preset by the factory and sealed,however, the idling speed can be readjusted.(1) Screw in the left hand side screw of the governor

lever to decrease high idling speed.(2) Screw in and out the right hand side screw of the

governor lever to increase and decrease low idlingspeed respectively.

6-2 Disassembling Procedures

(1) Remove the engine stop solenoid.(2) Remove the fuel oil injection pump holding screws

and 4 nuts.(3) Pull up the injection pump a little and remove R-pin

that connects the control rack and governor link toremove the timing gear case.

Note :Remove the gear case after covering the key groove forcrankshaft pulley with a friction tape or something so asnot to damage the oil seal of the timing gear case.

008551-00X

1

2

008553-00E

Start spring

008554-00E

R-pin

6-2


6-3 Reassembling Procedures

(1) Install the slider after aligning it and the cam gearpin.

(2) Fix the control lever with the stopper lever and thenassemble the gear case.

Note : Make sure if the start spring is securely installed.

(3) Align the gear case pin and oil pump cover holewhen the gear case is reinstalled.

Note : Rotate the oil pump cover clockwise and counterclock-wise, fix the spring pin hole in the center of its movementand install the timing gear case.

(4) After reinstalling of the timing gear case, make sureif the link simultaneously moves when the stop leveris operated.

Note : Cover the key groove for crankshaft pulley with a frictiontape or something so as not to damage the oil seal of thetiming gear case.

Cam gear pin

Slider

003416-00E

Start spring

Control lever

003417-00E

Gear case pin

Oil pump cover hole

003418-00E

6-3

7. ELECTRICAL EQUIPMENT

7. Electrical Equipment

7-1 Starter Motor

To start the engine, the starter motor rotates the ring gear installed on the engine flywheel with the pinion gearengaged with the ring gear so that the force generated by the rotation exceeds the resistance including the enginecompression pressure and all frictional force. The starter motor consists of the following major parts : a motor whichgenerates torque ; a pinion which transmits the torque to the engine ring gear ; a clutch ; and a magnetic switchwhich pushes out the pinion and turns on and off the principal current.

1) Specifications and Service DataYanmar code 165000-47590Applicable model 2TE67L-BV

Starter motor model MITSUBISHIM000T84281

Nominal output / Weight kW / kg 1.2 / 2.65Rotation direction(viewed from pinion side) Clockwise

Engagement method Magnetic shift

No loadTerminal voltage / Current V / A Less than 11/90Speed rpm More than 2800

Loadcharacteris-tics

Terminal voltage / Current V / A Less than 4.0/650

Torque / speed N•m / (kgf•m) / rpm 15.7 (1.60)

Pinion DP or module/ Number of pinion teeth DP10 / 12

BrushStandard spring force N (kg) 20.5 to 22.6

(2.09 to 2.31)Standard height/ Wear limit mm 12.3 / 7.0

Commutator Outside diameter

Standard/ Wear limit mm Ø29.4 / Ø28.8

Gap between pinion and pinion stopper mm 0.5 to 2.0

7-1


1. StructureThe starter is 4-P direct drive type motor and the overrunning clutch is activated by the solenoid.

Lever

Internal gear

Gear shaft

Ball

Armature

Armature shaft

Planetary gearYoke

Overrunning clutch

Switch

Brush

Fig.1

7-2


2. DisassemblyNote : Put two matching marks on the switch and yoke before disassembling.(1) Remove the terminal nuts of the magnet switch to remove connector.

Remove switch holding screws to remove the switch and plunger.(2) Remove the brush holding screws and through screws.

Remove the rear bracket but do not remove the brush holders.(3) Slip in a socket (OD Ø29.4 mm) or something between the commutator and brush holder for inspection and

reassembly.(4) Remove the armature and the yoke.(5) Remove the planetary gear and packing.

Remove the gear shaft assembly and lever at the same time.Note : For easy reassembling, line up the lever, plate and packing according to disassembling order.(6) Remove the overrunning clutch[1] Drive a pipe that matches the snap ring with a hammer to remove the stop ring and snap ring.[2] Remove the overrunning clutch from the armature shaft. If the snap ring is damaged, replace it with a new one.

3. Inspection(1) Armature[1] Check the coil for short circuit. If any, replace the armature.[2] Check the coil for ground. If it grounds, replace the armature.[3] Check the commutator for wear. If it is too much, replace the armature.[4] Check the commutator for insulation depth. Repair if it is inadequate.(2) Gears

Check for excessive wear or damage.(3) Brush[1] Check brushes for wear. If it is too much, replace them with new ones.[2] Check if the brushes smoothly move in the holder to verify the springs work well.[3] Check the brush holder plate and brush holder insulated for connection. If any, replace the brush holder assem-

bly with a new one.(4) Overrunning Clutch and Pinion Gear

Rotate the pinion gear with holding the clutch housing. It should rotate one way only. If something is wrong, replace the overrunning clutch. If any wear and burrs in the pinion gear, replace the overrunning clutch.

Note : Never wash the overrunning clutch not to remove lubrication grease in it.(5) Front Bracket / Rear Bracket

Check metals of them for wear. If it is too much, replace metals with new ones.(6) Switch

Check the terminal M and body of the switch for connection. Unless they are connected, replace the switch witha new one.

7-3


4. Reassembly and AdjustmentReassemble in the reverse order of the disassembly procedures with observing the following instructions.(1) Fill or coat grease on the following parts.

Greasing points Grease

a Front sleeve bearing MULTEMP #6129

b Rear sleeve bearing MULTEMP #6129

c Reduction device (Armature shaft gear, Internal gear, Planetary gear) MULYKOTE RAG-650

d Overrunning clutch and lever friction part MULTEMP #6129

e Gear shaft spline and pinion friction part MULYKOTE RAG-650

f Ball MULYKOTE RAG-650

a

dfcb

e

Fig.2

7-4


5. Non Load Testing

(1) Arrange the test circuit with the voltmeter and ammeter as shown in Fig.5.Note : Use as bold wire as possible and securely connect all terminals.(2) Close the switch and compare RPM, ammeter and voltmeter readings with the service data.(3) If anything is not within the standard, repeat the inspection mentioned above.

Switch

Ammeter

VoltmeterS

B

A

+

-

V

Starter motor

Battery12V

Fig.5 003422-00E

7-5


6. Service Data

7-2 Alternator

The alternator is a revolving-field type three-phase AC generator. The AC electricity generated by the alternator isconverted to DC through the full-wave rectification by the diode and is stored in the battery.

Specification

(Disassembly procedures)(1) Remove the alternator from the engine.(2) Remove the cap and cap screw (M10).

Fix the shaft tip. Do not fix the flywheel 4.(3) Remove the flywheel 4. Drive lightly the tip of M10

screw of the shaft.

Standards or limit

Non load performanceVARPM

11.0Less than 902800

Commutator O.D.Limit

29.4 mm28.8 mm

Brush LengthLimit

12.3 mm7.0 mm

Brush spring PressureLimit

21.57±15% N5.88 N

Pinion gap 0.5 - 2.0 mm

Nominal output voltage(Full-wave rectification) V / A 14 / 8.5

Alternator model GP8146

Yanmar code 165000-15580

Working speed rpm 1600 to 5200

Maximum speed rpm 5600

Nominal output current A / V Less than 15 / 14 (5200 rpm)

Working ambient temperature °C -40 to 80

Pulley diameter / V-belt size mm Ø65, FM28

Ground polarity Negative

Applicable models 2TN67-BV

Connection diagram

Alternator Starter switch

Load

Bat

tery

Bat

tery

cha

rge

alar

m la

mpCurrent

limiter

003423-00E

1

3

3

2

4

1 Stater coil2 Roter3 Ball bearing4 Flywheel 003424-00E

7-6


(4) Lead wire clamp of the coil plate. Remove a M4 cap screw to remove the coupler.

(5) Loosen two screws to remove stater coil 1 from coil plate.

(Reassembly procedures)(1) Reassemble in the reverse order of disassembling.

(Inspection)1. Combination of the alternator and regulator

2. Alternator(1) Performance

(2) Rotation of flywheel

Tightening Torque 29.4 to 34.3 N•m (3.0 to 3.5 kgf•m)

Normal Not normal Cause

Charge current and battery voltage (5200 rpm at alternator)

1. More than 14 A at 14 V or less

2. 14 A to 0.5 A at 14 to 15 V

More than 14 A at 15 V or more

Mulfunction of regulator

Charge current : 0 A Alternator, regulator or wir-ing.

Charge current flows but battery voltage is low.

Battery (over discharging)


Non load voltage (between two sky blue wires) when running (about 5200 rpm) More than AC 28 V Less than AC 28 V

or nothingPoor magnetic force at flywheel.Cutting in coil or wires.

Connection Between two sky blue wires Connected Not connected Coil cutting

Insulation resistance (between a lead wire and coil plate) More than 3 M Less than 3 M Poor Insulation of coil.


Rotate flywheel by hand 12 times of resistance develop at 1 turn but it smoothly rotates

Noise while rotating BearingForeign material

No rotation resistance Poor magnetic force

7-7


7-3 Glow Plug

The glow plug installed on the cylinder head is a starting aid in cold weather, which serves to warm the air in thecombustion chamber to start the engine easily at low ambient temperature.The glow plug is operated to warm the air in the combustion chamber by setting the starter switch key to "GLOW"and supplying electricity for about 6 seconds.

(1) Specifications

The glow plug is ceramic glow. Be careful of its handling.(1) When removing

Loosen by a specified tool and remove by hand.No air tool is allowed.

(2) When installing[1] Screw in the plug for 2 - 3 threads by hand.[2] No air tool is allowed.[3] Tighten it to 8 to 15 N•m (0.8 to 1.5 kgf•m) by a torque wrench.(3) If a glow plug is dropped, never use it again.

Yanmar code 165000-15620

Rating DC11 V / 0.5

Rated operating time 6 sec.

Applicable models 2TE67L-BV

Tightening torque

Glow plug body 8.0 to 15 N•m(0.8 to 1.5 kgf•m)

Terminal mounting nut 1.0 to 1.5 N•m(0.1 to 0.15 kgf•m)

7-8


7-4 Stop Solenoid

Inspection(1) The solenoid is normal as long as the plunger is pulled into the body when the terminal A is connected to (+) of

the battery and body to (-).(2) The solenoid is normal as long as the plunger is kept holding in the body when the plunger is pushed in and

battery’s (+) and (-) terminals are connected to the terminal B and body respectively.Note : Complete the pulling test in a short time, or wiring may be cut.

B

A

Terminals of solenoid

B (for holding)

A (for pulling)

003425-00E

7-9

Published byEdited byFinished by

: Engineering & Development Dept.: Quality Assurance Dept.: Yanmar Technical Service Co., Ltd.

Copyright c 2006 YANMAR CONSTRUCTION EQUIPMENT CO., LTD. All Rights Reserved.This manual may not be reproduced or copied in whole or in part, without the written consent of YANMAR CONSTRUCTION EQUIPMENT CO., LTD.

2TE67L-BV on SV08-1

Technical Information

First Edition : Jan. 2006

TECHNICAL INFORMATION - ayr-extranet.com manuel... · 1.550 to 1.570 Ring width (B) 1.470 to 1.490...

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Transcript of TECHNICAL INFORMATION - ayr-extranet.com manuel... · 1.550 to 1.570 Ring width (B) 1.470 to 1.490...