Beruflich Dokumente
Kultur Dokumente
00-1
GENERAL
CONTENTS
1. GENERAL............................................................................................................ 1-1
9. ALTERNATOR..................................................................................................... 9-1
1. GENERAL
1-1 Specifications
Number of cylinders — 4
PS 46.5 60.0
*: Value when radiator, silencer, and air cleaner are not installed.
N·m
225
175 Torque kW
Torque
150 55
125 50
100 45
320 35
Output
300 30
Output
280 25
240 15
220 10
200 5
N·m
225
183 Nm/1,500 rpm
200 Torque
175 kW
Torque
150 55
100 45
75 40
g/kWh
320
Output 35
Output
Fuel consumption
300 30
280 25
260 20
Fuel consumption
240 15
220 10
200 5
Description Example
• Illustration
a The job contents are described in the disassembly procedure for Nos. not shown in the illustra-
(4) Abbreviations
Abbreviation Meaning
Ass’y assembly
Sub-Ass’y sub-assembly
STD Standard
IN Intake
EX Exhaust
OS oversize
US undersize
Note: Never apply lubricating oil to the bolt thread or seat surface.
2. TROUBLESHOOTING
3-3)
4-2 (6))
4-2 (2)-
4-2 (2)-
4-4 (5))
4-4 (4))
4-4 (5))
4-4 (5))
4-4 (4))
4-3 (4))
4-2 (5))
3-8)
3-3)
3-8 (1))
3-8 (1))
3-2)
3-2)
3-6 (1))
1-2 (2))
5-5)
1, 1-2)
3, 3-5)
3, 3-5)
1, 1-2)
3, 3-4)
3, 3-7)
4D94LE, 4D98E 2.84 – 3.04 {29 – 31} 2.35 {24} 0.2 – 0.3 {2 – 3}
3-1 Inspecting water leak from cooling water system and radiator ............................................................... 3-2
3-2 Fan belt tension inspection and adjustment ........................................................................................... 3-3
3-3 Adjusting the valve clearance ................................................................................................................. 3-4
3-4 Testing injection pressure and spraying condition of fuel injection nozzle ............................................. 3-5
3-5 Testing and adjusting of fuel injection timing .......................................................................................... 3-9
3-6 Sensor inspection ................................................................................................................................. 3-10
3-7 Battery inspection ................................................................................................................................. 3-11
3-8 Adjusting operation ............................................................................................................................... 3-13
3-9 Long storage......................................................................................................................................... 3-13
3-10 Periodic maintenance schedule............................................................................................................ 3-14
3-1 Inspecting water leak from cooling water system and radiator
(1) Water leak check in cooling water system Water leak check in cooling water system
1) Fill cooling water to the normal level in the
radiator, and install the cap tester on the
radiator.
2) Operate the manual pump to set the
pressure to 88.3 ± 14.7 kPa {0.9 ± 0.15 kgf/
cm 2 }. If the cap tester pressure gauge
reading drops then, water is leaking from
the cooling water system. Check the water
leaking point.
1
1) Cap tester YE0360
2) Radiator cap
2
YE0361
6
YE0363
1
3
YE0365
1) Valve clearance
2) Adjusting screw
3) Lock nut
4) Valve cap
3 Tightening torque:
order to disassembly.
(3) Point
1) Apply pads to the vice so that the body of YE1001
the nozzle holder will not be damaged.
2) Do not grip the retaining nut but grip the
body of the noz zle holder to pr ev ent
deformation.
k Never direct the spray at a human body. The pressure of the fuel injected through the nozzle is so
high that the fuel can break and injure the human skin.
k Do not direct the spray at a fire. The atomized fuel catches fire easily and can cause a fire and a
burn.
Examples of spraying conditions to judge performance of nozzle and nozzle holder assembly
Since the needle has flat cuts (F cuts), the fuel is sprayed in strings along the flat cuts. This does not indicate a
trouble.
Judgment
A B C D E
Item
Example of
form of spray
Movement of
pressure
gauge pointer
Vibrates continu- Same as A. Stops at about Rises to cracking Does not rise at
ously at about cracking pres- pressure but low- all when tester
cracking pres- sure and does not ers remarkably. handle is oper-
sure. vibrate. ated.
Fuel is atomized
but does not indi- Fuel spouts out in
Spray is almost Spray is extremely Fuel drips (spouts
Form of spray cate pulsation of line and drips
even. uneven. out in line).
needle (looks like remarkably.
burner).
1) Needle
2) Body
3) Throttle type (F cuts)
20
then stops. After rotating about 25°, rotate a
30
10
40
little clockwise and counterclockwise and
check that dial indicator pointer does not
50
move. (2)
90
60
80
70
(6) Set the dial indicator pointer to “0”.
YE0375
1) Thermometer
2) Thermostat
3) Cover
4) Gasket
5) Thermostat
6) Housing Continuity test
7) Tester probes
8) Cylinder block
7
(flywheel side)
8
YE0378-A
1) Battery case 4
2) Terminal
3) Cap
4) Cover 5
5) Cathode plate 6
6) Separator
1 7
7) Glass mat
8) Anode plate
8
YE0379
9) Upper limit
10) Lower limit 9
11) OK 10
12) Too low
13) Excessive
14) Electrolyte level 11 12 13
15) Battery tester
14
YE0380
Electrolyte temperature
at measurement
Hydrometer structure
Converted specific gravity at 20°C
2
Specific gravity and remaining
battery charge 3
Discharged
Specific Remaining
quantity of
gravity charge
electricity 4
(20°C) (%)
(%)
1.260 0 100
YE0383
1.210 25 75
1.160 50 50
1) Float 3) Glass tube
1.110 75 25
2) Rubber bulb 4) Float
1.060 100 0
How to read hydrometer
3) Terminals
Clean if corroded or soiled.
4) Mounting bracket
Repair or replace it if corroded.
Retighten if loosened.
5) Battery appearance
Replace the battery if cracked or deformed.
Clean with fresh water if contaminated.
YE0384
(1) Supply the fuel oil, lubricating oil and cooling water.
a Check the levels of the lubricating oil and cooling water again after test running (for about 5 minutes)
and add as required.
(2) Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.
(3) Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and
exhaust gas color.
(4) Adjust the no-load minimum and maximum revolutions according to the specifications.
(1) Always drain cooling water in a cold season or before a long storage. (This is unnecessary when antifreeze
is used.)
k Negligence of water draining will cause the cooling water remaining inside the engine to be frozen and
expanded to damage the engine parts.
Water draining procedure
1) Remove the radiator cap.
2) Loosen the water draining valve under the radiator to drain water from the inside.
3) Loosen the drain valve on the side surface of the cylinder to drain water from the inside.
4) After draining water, tighten the radiator cap and drain plug and valves.
(2) Remove the mud, dust and oil deposit and clean the outside.
(4) Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
(5) Disconnect the battery cable from the battery negative (–) terminal.
(6) Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing
or entrance.
(7) Select a well-ventilated location without moisture and dust for storage.
(8) Perform recharging once a month during storage to compensate for self-discharge.
Q: Test w: Replace
Maintenance period
Testing Every Every Every
Classification Item during Daily Every 250 Every 500
1000 2000 4000
operation hours or hours or
hours or hours or hours or
6 weeks 3 months
6 months one year two years
Checking and adding coolant Q
Testing coolant temperature
warning lamp Q
Cooling water Checking and cleaning radiator
system fins (*) Q
Adjusting cooling fan V-belt First testing at
tension 50 h Q
Draining coolant, cleaning cooling
system, adding new coolant w
Adjusting intake and exhaust
Cylinder head
valve clearances Q
Checking battery electrolyte
level and recharging Q
Electrical system
Testing battery warning lamp Q
Assurance of
Checking, cleaning, and testing
emission control
fuel injection valve (if necessary) Q
device
Checking engine oil level Q
Testing engine oil pressure
warning lamp Q
Engine oil
Replacing engine oil w
Replacing lubricating oil filter w
Acceleration Testing and adjusting governor
device relay and acceleration device Q
Checking fuel level and adding
fuel Q
Testing fuel filter warning lamp Q
Draining oil separator Q
Fuel
Testing oil separator Q
Cleaning oil separator (*) Q
Replacing fuel filter (*) w
Checking and replacing hoses,
Hose
fuel piping, and coolant piping Q Q
Intake and Cleaning and replacing air
exhaust systems cleaner element (*, **) Q w
*: If the engine is used in very dirty environment, check and clean every day.
**: If the engine is used in dirty or dusty environment, replace every 1000 h or as necessary.
4. ENGINE BODY
4-1 Introduction
Make preparation as follows before starting engine inspection and service:
k Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
(2) Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lubricating oil and fuel.
(3) Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so
as not to let any foreign matter enter the engine.
k Always wear glasses or other protectors when using compressed air or steam to prevent any foreign
matter from getting in the eyes.
a Any part which is found defective as a result of inspection or any part whose measured value does not
satisfy the standard or limit shall be replaced.
a Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state
of use should be replaced even when the measured value then satisfies the standard or limit.
Point 2
Reassemble:
• Check the thermostat function. (See 3-6 in Chapter 3 for the check procedure.)
Point 3
Reassemble:
• Replace the fuel filter element with a new one.
Disassemble:
• Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.
Point 4
Reassemble:
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it with a filter wrench (see 10-1-6 in Chapter 10) by 3/4
turn.
Point 5
Disassemble:
• Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of for-
eign matters.
Point 6
Disassemble:
• Keep the removed push rods by attaching tags showing corresponding cylinder Nos.
Reassemble:
• Always apply oil to the contact portions of the push rods and clearance adjusting screws.
3
First step: 49 – 58.8 Nm {5 – 6 kgf•m}
Second step:
103.0 – 112.8 Nm {10.5 – 11.5 kgf•m}
Point 8
Disassemble:
• Carefully remove the fuel injection nozzle so as not to leave the tip end protector from being left inside
the cylinder.
Reassemble:
• Replace the fuel injection nozzle protector with a new one.
Point 9
Disassemble:
• When removing each intake/exhaust valve
from the cylinder head, use a valve spring
compressor (1) (see 10-1-4 in Chapter 10)
and compress the valve spring and remove
the valve cotter.
• Keep each removed intake/exhaust valve
after attaching a tag showing the corre-
sponding cylinder No.
• If cotter burr is seen at the shaft of each in-
take/exhaust valve stem, remove it with an
oilstone and extract the valve from the cylin-
der head.
Reassemble:
• Replace the valve stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the valve stem seal.
• Different valve stem seals are provided for the intake and exhaust valves. Do not confuse them since
those for exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, valve stem seal, valve spring, seat, and cotter, tap the head
of the valve stem lightly for settling.
• Do not forget to install the valve cap.
Standard Limit
Standard Limit
Standard Limit
YE0395
YE0396
Valve guide
8.015 – 8.030 8.10
I.D.
Valve stem 2) Measuring positions
0.035 – 0.065 0.18
clearance
Valve stem
7.965 – 7.970 7.90
Exhaust valve
O.D.
Valve guide
8.015 – 8.030 8.10
I.D.
Valve stem
0.045 – 0.075 0.18
clearance
YE0397
3) Measuring positions
YE0398
4) Thickness 6) Stool
5) Length of valve
Standard Limit
Inclination — 1.2
YE0400
Valve spring
YE0401
YE0403
Intake Exhaust
Seat cutter angle
120° 90° 3
YE0405
1) Seat angle
2) Seat width
3) Cylinder head correction angle
Grinding wheel 1 2
5 YE0406
angle
40° 150°
4) Grinder
[A]: Lap the valve and seat with a mixture of 5) Grindstone
valve compound and engine oil.
[B]: Lap with engine oil only. Valve lapping
YE0407
k Do not touch the cooled valve guide with bare hands to avoid skin damage.
Point 2
Reassemble:
• When installing the gear case cover, do not forget to install the two reinforcing bolts at the center.
• Measure the backlash of each gear.
Gear train
(Unit: mm)
Standard Limit
Crankshaft gear,
camshaft gear,
Fuel injection 0.08 – 0.14 0.16
pump gear, Idle
gear, PTO gear
Lubricating oil
0.09 – 0.15 0.17
pump gear
Point 3
Disassemble:
1) Before loosening the mounting nuts of
the fuel injection pump, make marks (1)
on the rear part of the gear case
housing and fuel injection pump
mounting flange.
2) Using a wrench, hold the bolt of the
crankshaft pulley so that the engine will
not move and remove mounting nut (2)
and lock washer (3) of the pump drive
gear.
(1)
0000593
0000593A
Point 4
Reassemble:
• Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by align-
ing with idle gear A, B and C marks.
• Install the idle gear shaft with the oil hole facing upward.
Point 5
Reassemble:
• Install the PTO gear with its inner spline side facing the flywheel.
Point 6
Disassemble:
• Install a bolt as a handle in the hole at the
end face of the flywheel and remove careful-
ly so as not to damage the ring gear.
Disassemble:
• Since the camshaft gear is shrink-fit, heat it 3
to 180 – 200°C for extraction. YE0412
• For camshaft removal, raise the engine with
its mounting flange at the bottom. After re- 1) Camshaft gear
moving the thrust metal mounting bolt from 2) Thrust metal
the camshaft gear hole, extract the cam- 3) End play
shaft carefully so as not to damage the
bearing bushing.
• Rotate the camshaft a few turns before ex-
tracting it to prevent the tappet from being
caught by the cam.
• After removing the camshaft, set the engine
horizontal and fix it on the base.
k Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to
the horizontal position. Proceed carefully so as not to lose balance.
Point 8
Reassemble:
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.YM977770-1207F) and install the gear case by matching the two dowel pins.
Point 9
Reassemble:
• Replace the oil seal whenever disassembled.
• Apply lithium grease at the time of assembly.
Standard Limit
Cam height
Cam height 42.435 – 42.565 42.185
6
Block I.D. 50.000 – 50.025 50.100
1) Oil filter
Reassemble:
• Apply sealant (code No. YM977770-1207F)
before reassembly.
Point 2 1
Disassemble:
• Measure the connecting rod end play. 2
Reassemble:
• Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings.
• Use the piston insertion tool (See 10-1-9 in Chapter 10) to insert each piston w/rod in the cylinder block
3 Connecting rod metal cap mounting bolt: 53.9 – 58.8 Nm {5.5 – 6.0 kgf•m}, apply lube oil
and install the bearing metal cap.
Point 3
Disassemble:
• Place the engine on a stable base with the cylinder block upper surface facing down, and remove the
flywheel housing carefully so as not to damage the combustion surface.
Reassemble:
• Apply sealant (code No. YM977770-1207F) and install the flywheel housing by matching the two dowel
pins. After assembly, raise the engine with its mounting flange on the bottom side.
k Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.
Reassemble:
• If the end play exceeds the standard, re-
place
the thrust metal with an oversize one. YE0419
Disassemble: (7)
(3)
• Remove the main metal caps, cap side
bearings, and thrust metals. Place each
(6) (4)
thrust metal with identification of the position
and direction.
Reassemble:
• Carefully install each thrust metal so that the (5)
grooved one is positioned away from the
cap.
• Do not confuse the upper and lower main 0001717-A
bearing metals. The upper main bearing
metal (cylinder block side) has an oil hole, 1) Cylinder block 5) Shim gauge
and the lower one does not. The "wheel and 2) Crankshaft 6) Thrust
arrow" marks on the cap shall face the fly- 3) Thrust metal 7) Standard width
wheel.
4) Main metal cap
3 Main metal cap mounting bolt: Main bearing
107.9 – 117.7 Nm {11.0 – 12.0 kgf•m}
apply lubrication oil 2
1 3
Point 5
Disassemble: 4
• Remove the crankshaft. Remove each main
bearing metal upper (cylinder block side)
and pair it with the main metal cap side low-
er metal.
YE0420
YE0422
Reassemble:
• Install the piston in the cylinder block with 9
10
the punched mark on the big end of the con-
necting rod on the nozzle side. (The em-
bossed mark at the connecting rod I-beam 11
section shall be on the flywheel side.)
6) Camshaft side
12
7) Piston ID mark
8) Fuel injection nozzle side
9) Cylinder block size mark 13
10) Flywheel side
11) Piston ID mark
12) Embossed mark
(flywheel side) YE0423
13) Match mark
Point 7
Reassemble:
• Replace the oil seal with a new one whenever disassembled. Apply lithium grease at the time of assem-
bly.
2
3
4 5
YE0427
1) Bend
2) Deflection
3) Dial gauge
4) V-block
5) V-block
k If the oil clearance is excessive though the thicknesses of the main journal and crankpin metals are
normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
k If rust of surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then
assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface occupies 75% or more, the metal is normal. If the
contact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.
1) Measurement position
YE0431
3. Piston ring, ring groove and piston ring end Piston ring components
clearance measurement
• Except for the top ring, to measure the 1
piston ring groove width, first measure
the width of the piston ring. Then insert
the piston ring into the ring groove. In- 2
sert a thickness gauge in between the
piston ring and groove to measure the
gap between them. Obtain the ring 3
groove width by adding ring width to the
measured side clearance.
1) Top ring
YE0432
2) Second ring
3) Oil ring Measuring side clearance
4) Width
5) Thickness
5
YE0433
• To measure the piston ring end clear- Ring joint end clearance measurement
ance, push the piston ring into the
sleeve using the piston head, insert a 6
thickness gauge in end clearance to
measure. The ring shall be pushed in to
7
approx. 30 mm above the bottom end of
the cylinder. For the top ring, measure
only the piston ring joint end clearance
in normal state.
(Unit: mm) 10 8
Standard Limit 9 YE0434
Piston ring groove
2.040 – 2.060 — 6) Cylinder block head surface
width
Piston ring width 1.940 – 1.960 1.920 7) Joint end clearance
Top ring
Piston side
0.025 – 0.060 0.180
clearance
Piston end
0.250 – 0.450 0.550
clearance
2. 4D98E
YE0437
YE0439
3) Flex-hone
4) Electric drill
5) Honing fluid
6) Lube oil
7) Diesel oil
3. Apply the honing fluid to the Flex-Hone and Honing cross hatch
turn the electric drill at 300 to 1,200 rpm.
Then insert the Flex-Hone into the cylinder
bore while turning it, and move it up and
down for about 30 sec. to obtain a honing
mark with a cross hatch angle of 30 to 40°.
YE0441
k Avoid faster revolution than 1,200 rpm since it may cause breakdown.
k Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.
k Limit the honing depth to 1/1,000 mm each time.
Increase in
Increase in lubricating Increase in lubricating Increase in lubricating lubricating
oil consumption oil consumption oil consumption oil consumption
or blow-by or blow-by or blow-by or blow-by
5. LUBRICATION SYSTEM
1) Outer rotor 2
2) Gear case
3) Crankshaft
4) Punch mark 1
4
3
YE0444
Point 2
Disassemble-Reassemble:
• Only wash the pressure regulator valve. Disassembly is unnecessary unless any abnormality in opera-
tion is detected.
(Unit: mm) 2
Standard Limit 1
(Unit: mm)
1) Gear case
Standard Limit 2) Outer rotor
Shaft O.D. 12.925 – 12.970 12.915
Side clearance
Bearing I.D. 12.980 – 13.020 13.050
3
Clearance 0.010 – 0.065 0.105
0001615A-A
3) Depth micrometer
5 6
7
0000047A-A
4) Rotor shaft
5) Shaft O.D.
6) Bearing I.D.
7) Gear case
6. COOLING SYSTEM
Point 2
Disassemble:
• Check the thermostat function. See 3-6 (1) in Chapter 3 for the inspection method.
7-1 Specifications
Type — VM
Turning direction
— Right
(Seen from gear side)
Max. revolving speed (Pump) rpm 2,490
Plunger diameter mm 12
(1) Outline
• The fuel oil in the fuel tank (1) is sucked by
the feed pump (7) in the injection pump
through the sedimenter (2) and fuel filter (4)
to the fuel inlet of the injection pump.
• The fuel filter (4) filtrates the fuel oil. It may
have a sedimenter (2) to separate water in
its bottom.
• The fuel oil sucked to the fuel inlet is pres-
surized by the feed pump (7) and supplied
into the pump chamber.
• The pressure of the fuel oil in the pump
chamber is in proportion to the pump speed.
If it exceeds a certain level, however, the ex-
cessive oil is returned to the suction side by
the regulating valve (6).
• The fuel oil in the pump chamber is sent
through the fuel oil passage in the distributor
head to the plunger (8). Then, the fuel oil is
pressurized high by the plunger (8) and sent
through the injection pipe to the nozzle (13)
and nozzle holder.
• The overflow valve (11) on the injection
pump keeps the oil temperature in the pump
chamber constant and returns excessive
fuel oil to the fuel tank (1).
(1) Outline
1) Pump
• Drive shaft (1) receives the engine pow-
er directly through the timing belt (or
gear) and transmits it to cam disc (3)
through cross coupling (2).
• Since the positioning pin fitted to cam
disc (3) is fitted to the groove of the
plunger flange, plunger (4) revolves
similarly to cam disc (3).
• Cam disc (3) has a face cam and recip-
rocates by the specified cam lift on roller
(5) of the roller holder assembly.
• There are 2 plunger springs having set
forces on the outside of plunger (4),
which return down the plunger pushed
up by cam disc (3).
• In this way, the plunger is rotated by
drive shaft (1) and reciprocated by cam
disc (3).
• When the fuel oil pressurized high by
the plunger flows into outlet port (6), de-
livery valve (7) opens and the fuel oil is
injected through the nozzle and nozzle
holder into the combustion chamber of
the engine.
2) Governor
• The governor is installed above the
pump chamber and consists of flyweight
holder (1), governor lever assembly (2),
etc.
• Flyweight holder (1) holds 4 flyweights
(3) and governor sleeve (4) and is sup-
ported by the governor shaft. Drive
gear (5) is engaged with flyweight hold-
er gear (6) to increase the speed of
drive shaft (7) and rotate flyweight hold-
er assembly (1).
• Governor lever assembly (2) is support-
ed by the pivot bolt of the pump hous-
ing. Ball pin (8) at the lower part of the
governor lever assembly is inserted in
control sleeve (9) which rocks the out-
side of plunger (15).
• Governor spring (10) at the upper part is
connected to tension lever (12) by re-
taining pin (11) and its end is connected
to control lever (14) through control le-
ver shaft (13).
• Control lever (14) is connected to the
accelerator pedal through the link. It
changes the set force of governor
spring (10) according to the leaning an-
gle.
• The difference between the set force of
governor spring (10) and the centrifugal
force of flyweight (3) corresponds to the
moving distance of control sleeve (9), or
the injection rate.
3) Timer
• The timer is installed in the bottom of
the injection pump. Timer spring (2)
having a set force is installed to low-
pressure side A of timer piston (1).
• On the opposite side (high-pressure
side B), the fuel oil pressure in the
pump chamber is applied directly. Tim-
er piston (1) moves to rotate roller hold-
er (4) through roller holder pin (3),
according to the balance between the
fuel oil pressure and timer spring (2).
• When the piston moves to compress
timer spring (2), the injection timing is
advanced (roller holder (4) moves in the
reverse direction).
• In this way, the timer controls the injec-
tion timing according to the fuel oil pres-
sure in the pump chamber.
(1) Operation
• Drive shaft (1) drives feed pump (18), cam disc (16), and plunger (9) simultaneously. Plunger spring
(14) presses plunger (9) and cam disc (16) against roller (17).
• If drive shaft (1) rotates cam disc (16), face cam (3) moves on roller (17) to reciprocate plunger (9).
When inlet port (6) of plunger barrel (8) fitted to the distributor head comes to inlet slit (7) of the plunger
(9), plunger (9) sucks and pressurizes the fuel oil.
• When outlet port (13) of plunger barrel (8) is connected to outlet slit (11) of the plunger, the high-pres-
sure fuel oil opens delivery valve (12) and is injected into the combustion chamber of the engine
through the nozzle.
• When cut-off port (15) of the plunger moves out of control sleeve (4), feeding of the fuel oil from plunger
(9) finishes.
1) Suction stroke
• When inlet port (6) of the plunger barrel
comes to inlet slit (7) of plunger (9) in the
lowering stroke of plunger (9), the fuel oil in
the pump chamber is sucked in the plunger.
A. Pressurizing chamber
2) Injection stroke
• If the cam disc starts rising, plunger (9)
starts turning. When plunger (9) blocks inlet
port (6) of the plunger barrel, feeding of the
fuel oil starts.
• When outlet slit (11) of plunger (9) comes to
outlet port (13) of the plunger barrel, the
high-pressure fuel oil pushes up delivery
valve (12). Then, the fuel oil is injected into
the combustion chamber of the engine
through the nozzle and nozzle holder.
3) End of injection
• When the cam disc raises plunger (9) fur-
ther and cut-off port (15) of plunger (9)
moves out of control sleeve (4), the high-
pressure fuel oil returns to the pump cham-
ber through cut-off port (15).
• As a result, the pressure of the fuel oil in the
plunger lowers below the set force of deliv-
ery spring (10). Accordingly, delivery valve
(12) closes and feeding of the fuel oil finish-
es.
A. Pressurizing stroke
B. Start of back suction (End of feeding of oil)
C. End of back suction
(1) Operation
• The structure of the all speed governor is shown in the figure at left. Revolution of drive shaft (1) is
transmitted to the speed increasing gear of flyweight holder (6) through drive gear (21), and then used
to rotate flyweight holder (6).
• Flyweight holder (6) is supported on governor shaft (3) and has 4 flyweights (5) in it, which are opened
outward by the centrifugal force.
• Flyweights (5) push governor sleeve (19) to push governor lever assembly (15) to the right. Governor
lever assembly (15) consists of collector lever (10), tension lever (11) and start lever (14).
• Fulcrum M1 of collector lever (10) is fixed with the pivot bolt of the pump housing. Since collector lever
(10) is pressed by lower spring (17) and upper full load adjustment screw (12), it does not move.
• Tension lever (11) and start lever (14) move around shaft M2 fixed onto collector lever (10).
• When the engine is started, start spring (13)
presses start lever (14) against governor
sleeve (19). Then, start lever (14) is turned
to the left around fulcrum M2 to move con-
trol sleeve (18) to the start increasing posi-
tion. While the engine is running, start lever
(14) and tension lever (11) keep in contact
with each other and move as one unit.
• Governor spring (8) is installed above ten-
sion lever (11) and connected to control le-
ver (7) through control lever shaft (22). The
set force of governor spring (8) can be
changed by adjusting the movement of con-
trol lever (7). Idle spring (9) is installed up-
per back side of tension lever (11).
• Accordingly, the governor is controlled in the
all revolution speed range by start spring
(13), governor spring (8), and idle spring (9).
• An example of the injection rate control
characteristics of the all speed governor is
shown in the figure.
• When the engine is started, the fuel injection rate must be increased so that the engine starts easily.
While the engine is stopped, if the accelerator pedal is pressed, tension lever (8) is pulled to the left by
governor spring (4) until it reaches press fitted pin M3.
• At the same time, start lever (13) is separated from tension lever (8) by start spring (9) and pushes gov-
ernor sleeve (5) to the left. At this time, flyweight (14) is fully closed and start lever (13) turns around
M2 to move control sleeve (11) to start increasing position A (to the right).
• As a result, the engine can be started easily by pressing the accelerator pedal lightly.
• If the accelerator pedal is released after the engine is started, control lever (3) returns to the idling posi-
tion and the tension of the governor spring (4) is reduced to 0. Accordingly, flyweights (14) open out-
ward and push governor sleeve (5) to the right even if the engine is running at low speed.
• This movement turns start lever (13) to the right around M2 and moves control sleeve (11) in the fuel
reducing direction. When the centrifugal force of flyweight (14) is balanced with idle spring (6), idling
speed is stabilized.
• When the accelerator pedal is fully pressed and control lever (3) reaches maximum speed stopper bolt
(2), the tension of governor spring (4) becomes maximum and tension lever (8) is fixed to pin M3 press
fitted to the pump housing.
• At this time, idle spring (6) is fully compressed and start lever (13) and tension lever (8) become one at
point A and keep control sleeve (11) to the full load position.
• At this time, flyweight (14) is pressed and fully closed by governor sleeve (5).
• If the engine speed is increased and the centrifugal force of flyweights (14) exceeds the set force of
governor spring (4), governor sleeve (5) moves to the right and turns the governor lever assembly to the
right around M2.
• As a result, control sleeve (11) moves in the non-injection direction B (to the left) so that the engine
speed will not exceed the full-load maximum speed.
• If the accelerator pedal is not fully pressed, the set force of governor spring (4) changes freely. When
the engine is partially loaded, governor is controlled according to the set force of governor spring (4).
(1) Operation
• Magnet valve (1) is turned ON and OFF to open and close fuel oil passage A connected to inlet port B
of the plunger barrel, according to the operation of the ignition switch.
• If the ignition switch is turned ON, magnet valve (1) is turned ON and armature (3) is pulled up to open
fuel oil passage A.
• On the other hand, if the ignition switch is turned OFF, armature (3) is pushed down by spring (2) in it to
close fuel oil passage A.
• As a result, the fuel oil is not sent to the plunger and the engine is stopped immediately.
Outline
0001106A-02
• The CSD changes the oil pressure in the pump
chamber to control the injection timing of the in- 1) Cold spark device (CSD)
jection pump by being turned ON and OFF while
the engine is running.
• The CSD is a kind of actuator, which is turned 2 3
4 5
ON and OFF by a switch (coolant temperature
sensor) installed to the engine.
6
Structure
• The CSD consists of the magnet, spring, and
piston as shown in the figure at right. 11 10 9 8 7 023035-00J-A
CSD: ON
Operation
• As the switch to turn ON and OFF the CSD, a
coolant temperature sensor is used.
• When the engine is started, if the coolant tem-
perature is below the set temperature, thermo OFF
switch is turned ON to turn ON the CSD to in-
crease the pressure in the pump chamber quick-
ly to advance the injection timing. Engine coolant temperature
• On the contraly, if the coolant temperature is 023036-00E
023009-00X
CSD
023034-00E
ON
Preheater lamp
22
ON
Valve OFF
AEXO.85 (black)
(1)
7 2 0.5
6.5
Copper PK (YM124465-44950)
Function
25
DOWN
3. CSD
• When the key is turned to ON position, if the
38 coolant temperature is below set tempera-
59
ture, the CSD is turned ON.
LEFT RIGHT Arrangement of connector terminals
• However, if the coolant temperature in-
FRONT Connector A Connector B creases above set value, CSD is turned
OFF.
REAR
Relay characteristics
(Waterproof)
Standard
Connector B6185-0025 (SUMITOMO) or equivalent Type Remarks
Mating part: 6195-0021 (SUMITOMO)
value
Contact
Character-
Connection diagram
Starting switch
OFF ON
ST Preheater lamp
Battery
DC12V
8. STARTING MOTOR
8-1 Specifications
Weight kg 5.5
Brush Standard mm 15
Height
Limit mm 9
Standard mm 36.5
Outside diameter
Limit mm 35
Standard mm 0.03
Commutator Run-out
Limit mm 0.2
8-2 Components
(13)
(12) (14)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(23)
(3)
(2)
(1) (15)
(18)
(22)
(21)
(19)
(20)
(17)
(16) 0000103A
YES
Engine does not start? Inspect wiring up to magnetic switch
Is starter motor magnetic and repair if necessary.
NO • Key switch
8. STARTING MOTOR
YES
• Adjust / pinion projection length.
Troubleshooting
YES
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
0000102
4D94LE, 4D98E
8. STARTING MOTOR
Disassembly drawing
Disassembly procedure
1) Nut M8
Remove the magnetic switch nut M8 (12 mm),
and disconnect the connecting wire.
YE0478
a) Connecting wire
2) Screw M4 (2)
3) Through bolt M5 (2)
4) Rear cover
Remove the M4 screw fastening the brush
holder and remove through bolt M5 for rear
cover removal.
YE0479
5) Brush holder
Pull the brush spring up with the brush spring
puller. On the negative (–) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the posi-
tive (+) side, extract the brush from the brush
holder.
YE0480
6) Yoke assembly
7) Armature
Remove the brush holder. The armature and
yoke assembly can now be removed.
YE0481
8) Bolt M6 (2)
9) Magnetic switch
Remove bolt M6 (10 mm), and the magnetic
switch can be removed.
YE0482
YE0483
YE0484
YE0485
YE0486
36.5 35.0
YE0487
(Coil disconnection)
No continuity
Replace the armature.
YE0488
1) Multimeter
YE0489
1) Multimeter
Standard Limit
Armature 0.03 0.2
YE0490
1) Commutator 2) Armature
YE0491
7 9
YE0492
3) Hack-saw 7) Abnormal
4) Commutator 8) Chamfering
5) Commutator segment 9) Normal
6) Insulating material
(Coil disconnection)
No continuity
Replace the field coil.
YE0493
1) Multimeter
YE0494
1) Multimeter
(3) Brush
Measure the length of the brush. Replace with a
good one if the length is less than the limit.
(Unit: mm)
Standard Limit
15 9
YE0495
2) Brush
Insulation defect
Continuity exists
Replace the brush holder.
1
YE0496
1) Multimeter
YE0497
Coil disconnection
No continuity
Replace the magnetic switch.
YE0498
1) Multimeter
Coil disconnection
No continuity Replace the magnetic
switch. 1
1) Multimeter
YE0500
1) Multimeter
YE0501
YE0502
YE0503
8-6 Assembly
The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following
points:
(10)
(9)
0000268-A
0000131
(12)
0000269-A
0000106
0000104
Standard
l 0.3 – 1.5 mm
YE0506
YE0507
1. No-load test
Fix the starting motor on a test bench and connect wiring as shown in the following figure. When the switch
is closed, a current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and
rotation speed at this time, and check if they satisfy the specified characteristics.
1) Ammeter
2) Voltmeter
3) Battery
9. ALTERNATOR
12
11
10
9
6 8
5
7
2 3
23
1 27
19 22
20
21
13 25 26
24
18
17
16
15
14 0001671A
Turn key switch ON. NO Disconnect harness L terminal Ground drive machine side NO
Does battery indicator and IG terminal at alternator L terminal. Does battery Replace the battery indicator.
4D94LE, 4D98E
turn ON? indicator turn on?
YES
YES Inspect rotor assembly and
brushes.
Start Engine.
YES
Battery indicator
is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
Battery voltage NO
is between 13 With engine idling, Does battery indicator Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
YES
Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test 0001666E-A
9-3
9. ALTERNATOR
9. ALTERNATOR
Disassembly drawing
27
26
21
23
18 24
22
20
25
2 3
7
1 4
14 8
15
11
17 6 5
9
10
12
13
16
19 0001671A-A
Disassembly procedures
1) Remove nut (1) from the shaft of the rotor
assembly. Remove pulley (2).
(2)
(1)
0001673A
(8) (5)
(9)
0001674A-A
(16)
0001676A-A
(b)
0001773-A
(c) 0001774-A
(19)
(21)
(20)
0001677A-A
0001678A-A
(27)
(26)
0001679A-A
(1) 0001760
(2) Rotor
(a) Check of slip ring surface
When the slip ring surface is roughened or
dirty, polish it with sandpaper of #300 –
#500.
(3) 0001761
0001762
(3) Rectifier
Using tester (3) set in range K, check the conti-
nuity.
(1)
If normal, there is continuity in only one direc-
tion.
k Do not use a DC500V insulation resistance
tester to test the rectifier.
If it is used, the rectifier is broken.
k The condition of the rectifier cannot be
judged by only the resistance in the correct
direction. Judge by the difference in the re-
sistance.
(2)
1) Circuit
2) Testing
3) Tester (3)
0001763
(4) IC regulator
The following is the description of Model M1 IC regulator.
Wiring diagram
L1:
Power Supply
12V 3.4W
Variable DC
(Charge Light L2:
Substitute) 12V 3.4W
(Rotor Coil
Terminal E Substitute)
0001775E-A
L3: 12V 3.4W
(Reverse Side of the IC Regulator)
(Electrothermal Choke Substitute)
(5) Diode
Using tester (1), check continuity between termi-
nals B and F.
1) Disconnect the diode wiring between
terminals B and F.
0001765-A
9-5 Assembly
Carry out assembly in the reverse order to disassembly, observing the following.
(1) Assembly of brush holder
1) Insert tab (1) of brush holder (4) in groove (1) (2)
(2) of holder cover (3).
k Before assembling the brush holder, in- (3)
stall the IC regulator to the alternator.
(4) 0001766
(6)
(5) 0001768-A
(3)
0001770-A
(6)
0001769-A
(20)
0001677A-A
(17)
(16)
0001676A-A
(12)
(13)
0001675A-A
(8) (5)
(9)
0001674A-A
(2)
(1)
0001673A
L1
(CHG Light) S1 S2
rpm
L2
(Electrothermal Choke)
0001777E-A
L1
(CHG Light) S1 S2
rpm
0001778E-A
L1
(CHG Light) S1 S2
rpm
0001779E-A
L1
(CHG Light) S1 S2
0001780E-A
Regulated Voltage
4) Check that the voltage is within the standard
range.
k The output voltage has the tempera-
ture characteristics shown in the figure.
Perform measurement quickly.
Temperature of IC Regulator
0001781E-A
(Unit: mm)
L1 L2 d1 d2
Valve guide tool
1
(for extracting valve guide) 20 75 7.5 11
0000827
a Locally manufactured
(Unit: mm)
L1 L2 d1 d2
Valve guide tool
2
(for inserting valve guide) 15 65 14 20
a Locally manufactured
0000828
(Unit: mm)
Connecting rod bushing
L1 L2 d1 d2
replacer
3
(for removal/installation of 20 100 30 33
connecting rod bushing)
a Locally manufactured 0000829
(Unit: mm)
L1 L2 L3 d1 d2 d3
Valve stem seal inserter
5
(for inserting valve stem seal) 17 65 4 16.2 22 13.5
a Locally manufactured
0000820
Filter wrench
6 (for removal/installation of Available on the market
filter)
0000821
(Unit: mm)
Camshaft bushing tool L1 L2 d1 d2
7 (for extracting camshaft
bushing) 18 70 50 –0.3
–0.6 53 –0.3
–0.6
a Locally manufactured
0000822
Engine Applicable
name Part No. bore
Flex-Hone
8 (For re-honing of cylinder 4D94LE YM129400-92430 83 – 95 mm
liner)
4D98L YM129400-92440 89 – 101 mm
0000823
Part No.
Piston insertion tool
9 YM95550-002476
(for inserting piston)
a The above piston insertion tool is applicable 0000824
0000833
0000834
0000838
0000839
0000840
0000841
0000842
0000844
0000845
YE0560-A
0000848
YMTOL-97190080
0000849
18
Reference
No. Inspection item Unit Standard Limit page
1 Gap at intake/exhaust valve heads mm 0.15 – 0.25 — 3-4
Reference
Inspection item Unit Standard Limit
page
Combustion surface distortion mm Max. 0.05 0.15 4-6
Intake mm 0.5 – 0.7 1.0 4-6
Valve sink
Exhaust mm 0.6 – 0.8 1.1 4-6
Intake mm 1.3 2.0 4-6
Seat width
Valve seat Exhaust mm 2.2 3.0 4-6
Intake Deg. 120 — 4-10
Seat angle
Exhaust Deg. 90 — 4-10
Seat correction angle Deg. 1 40, 2 150 — 4-10
Reference
Inspection item Unit Standard Limit
page
Valve stem outside diameter mm 7.965 – 7.980 7.90 4-7
Intake Valve guide inside diameter mm 8.015 – 8.030 8.10 4-7
Valve clearance mm 0.035 – 0.065 0.18 4-7
Valve stem outside diameter mm 7.965 – 7.970 7.90 4-7
Exhaust Valve guide inside diameter mm 8.015 – 8.030 8.10 4-7
Valve clearance mm 0.045 – 0.075 0.18 4-7
Valve guide driving-in method — Cold-fitted — 4-11
Valve guide projection from cylinder head mm 14.7 – 15.0 — 4-11
Projection of valve stem seal from cylinder head mm 16.7 – 17.0 — 4-11
Replacement valve guide inside diameter after insert mm 8.015 – 8.030 — 4-7, 11
Reference
Inspection item Unit Standard Limit
Page
Free length mm 47.5 — 4-8
Inclination mm — 1.2 4-8
Load for compressing uneven pitch portion by 1 mm N {kgf} 22.1 {2.257} — —
Reference
Inspection item Unit Standard Limit page
Rocker arm shaft hole diameter mm 18.50 – 18.52 18.57 4-9
Rocker arm shaft outside diameter mm 18.47 – 18.49 18.42 4-9
Clearance mm 0.01 – 0.05 0.15 4-9
Reference
Inspection item Unit Standard Limit page
Crank gear, cam gear, idle gear, fuel injection pump
mm 0.08 – 0.14 0.16 4-13
gear and PTO gear
Lubricating pump gear mm 0.09 – 0.15 0.17 4-13
(3-2) Crankshaft
Reference
Inspection item Unit Standard Limit page
Bending (1/2 of the dial gauge reading) mm — 0.02 4-23
Pin outside diameter mm 57.952 – 57.962 57.902 4-24
Metal inner diameter mm 58.000 – 58.026 — 4-24
Crank pin Metal thickness mm 1.492 – 1.500 — 4-24
US 0.25 mm mm 1.617 – 1.625 — 4-24
Clearance mm 0.038 – 0.074 0.150 4-24
Journal outside diameter mm 64.952 – 64.962 64.902 4-24
Metal inner diameter mm 65.000 – 65.020 — 4-24
Crank journal Metal thickness mm 1.995 – 2.010 — 4-24
US 0.25 mm mm 2.125 – 2.130 — 4-24
Clearance mm 0.038 – 0.068 0.150 4-24
Reference
Inspection item Unit Standard Limit page
Crankshaft end play mm 0.11 – 0.21 0.28 4-20
mm 1.930 – 1.980 1.880 4-20
Thrust bearing thickness
OS 0.25 mm mm 2.055 – 2.105 — 4-20
(3-6) Tappet
Reference
Inspection item Unit Standard Limit page
Tappet stem outside diameter mm 11.975 – 11.990 11.955 4-30
Tappet hole (block) inside diameter mm 12.000 – 12.018 12.038 4-30
Clearance mm 0.010 – 0.043 0.083 4-30
Reference
Inspection item Unit Standard Limit
page
Clearance between outer rotor and gear case mm 0.100 – 0.155 0.25 5-4
Side clearance between outer rotor and gear case mm 0.05 – 0.10 0.15 5-4
Outer rotor to inner rotor tip clearance mm — 0.16 5-4
Shaft outer diameter mm 12.925 – 12.970 12.915 5-4
Rotor shaft and
gear case Bearing inside diameter mm 12.980 – 13.020 13.050 5-4
Clearance mm 0.010 – 0.065 0.105 5-4
Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Cooling water
Cooling fan M8 17.6 – 22.5 {1.8 – 2.3} 4-3
pump
Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
Delivery valve holder — 58.8 – 68.6 {6.0 – 7.0} 7-3
(*1) Drive gear M14 49 – 53 {5.0 – 5.4} 7-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel injection pump
Fuel pipe (return) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel feed pump M6 7.8 – 9.4 {0.8 – 0.96} 7-3
Oil inlet pipe M10 9.8 – 12.7 {1.0 – 1.3} 4-12
Rear stay M10 44.1 – 53.9 {4.5 – 5.5} 4-12
Fuel injection noz- Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
zle Nozzle holder — 39.2 – 44.1 {4.0 – 4.5} 3-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-9
Fuel pipe (outlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-9
Fuel feed pump
Priming pump M16 39.2 – 44.1 {4.0 – 4.5} 7-9
Plug M26 78.4 – 98.0 {8.0 – 10.0} 7-9
Fuel pipe M12 24.5 – 34.3 {2.5 – 3.5} 4-3
Fuel filter
Fuel return pipe M14 39.2 – 44.1 {4.0 – 4.5} 4-3
Alternator Stay M8 22.5 – 28.4 {2.3 – 2.9} 4-3