Gang Engine 13 P

T.O.
38G1-127-1
TM1-2815-262-1 3&P
TECHNICAL MANUAL
SERVICE AND OVERHAUL INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN
DIESEL ENGINE FOR SELF GENERATING NITROGEN SERVICING CART (SGNSC)

MODEL 4LE1PW14 NSN 2815-01-470-8023 F41608-98-D-0015
PACIFIC CONSOLIDATED INDUSTRIES 3430 WEST CARRIAGE DRIVE SANTA ANA, CALIFORNIA 92704 TELEPHONE 714-979-9200 TELEFAX 714-436-9150
DISTRIBUTION STATEMENT - Distribution authorized to U.S. Government agencies and their contractors for Administrative or Operational Use, 1 November 2000. Other requests for this document shall be referred to San Antonio ALC/LDEAM, 485 Quentin Roosevelt Ste 2, Kelly AFB, TX 78241-6421. WARNING: This document contains technical data whose export is restricted by the Arms Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act ot 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25. DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure or reconstruction of the contents.
PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE
1 NOVEMBER 2000
T.O. 38G1 -127-1 TMI-2815-262-1 3&P

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LIST OF EFFECTIVE PAGES
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NOTE The portion of text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.
Dates of issue for original and changed pages are: Original ... 0.... 1 November 2000
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38G1 -127-1 TM1-2815-262-1 3&P

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES NOTE Only those work packages and subordinate work packages assigned to this manual are listed in this index, therefore, WP/SWP numbers may not be sequential.
WP/SWP
Number 001 00 002 00 003 00 004 00 004 01 004 02 004 03 005 00 005 01 005 02 005 03
Change
Number 0 0 0 0 0 0 0 0 0 0 0
Title
Alphabetically Index Foreword Master List of Special tools and Consumables Engine Operation Periodic Inspection and Maintenance Engine Maintenance Schedule Engine Troubleshooting General repair Instructions Tightening Torque Specifications Engine Gaskets Engine Maintenance and Adjustments
WP/SWP Number 006 00 006 01 006 02 006 03 007 00 008 00 009 00 010 00 998 00 998 01 998 02
Change Number 0 0 0 0 0 0 0 0 0 0 0
Title
Engine Disassembly, Inspection and Repair, and Reassembly Engine Disassembly Procedures Engine Inspection and Repsir Procedures Engine Reassembly Procedures Engine Lubricating System Engine Cooling System Engine Fuel System Engine Troubleshooting Charts Illustrated Parts Breakdown Maintenance Parts List with Illustrations Numerical Index
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T.O. 38G1 -127-1 TM1-2815-262-1 3&P WP 001 00
WORK PACKAGE ALPHABETICAL INDEX
SERVICE AND OVERHAUL INSTRUCTIONS

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPW14
LIST OF EFFECTIVE WP PAGES

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ALPHABETICAL INDEX OF EFFECTIVE WORK PACKAGES

Only those work packages and subordinate work packages assigned to this manual are listed in this index.
Subject
Alphabetical Index ................ Engine Cooling System ....................... Engine Disassembly Procedures ...... I...........
WP1SWP
001 00 008 00 .......... 006 01
Snbject
Maintenance Parts List with Illustrations ........ Master List of Special Tools and Consumables .... Numerical Index ............................. Periodic Inspection and Maintenance .... Tightening Torque Specifications ....
WP/SW`P
998 01 003 00 998 02 ........ 00401 ........... 005 01
Engine Disassembly, Inspection and Repair, ........... 006 00 and Reassembly ........... Engine Fuel System .......................... Engine Gaskets ............................. Engine Inspection and Repair Procedures ......... Engine Lubricating System ....... Engine Maintenance Schedule ...... Engine Operation ............................ Engine Reassembly Procedures ................. Engine Troubleshooting ......... Engine Maintenance and Adjustments .... 009 00 005 02 006 02 ............. 007 00 ....... 005 03 ........... 004 02 004 00 006 03
............. 004 03 010 00 002 00 005 00 ............ 998 00
Engine Troubleshooting Charts ................. Foreword ............................... General Repair Instructions .................... Illustrated Parts Breakdown .......
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WORK PACKAGE FOREWORD


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TABLE OF CONTENTS
Paragph 1. 1.1 2. 2.1 2.2 General Information ..................... Engine Identification ..................... Engine Factory Support .................... Isuzu Engine After Sale Service .............. Isuzu Genuine Parts .....................
pap
2 2 4 4 4
Paragraph 3. 3.1 3.2 3.3 4. Fuel ................... Lubricant ................... Coolant ...................
Eag 4 4 5 6
Fuel, Lubricant and Coolant .................
Notes On the Format of These Work Packages . 6
LIST OF ILLUSTRATIONS
2igure Engine Details .2 2 3 Location of Engine Identification.2 Recommended Oil Viscosity Grades ..... Ew Figm 4 Ew Example of Major Components Order of Disassembly and Reassembly............... 6
5.....
T.O. 38G1 -127-1 TM1-2815-262-1 3&P WP 002 00 1. GENERAL INFORMATION

Figure 1 shows the shows the general arrangement of the engine.
1.1. ENGINE IDENTIFICATION

1.1.1 Location of Identification The engine serial number is stamped on the front upper right side of the cylinder body, and the engine model is cast on the rear lower right side of cylinder body, just above the oil filter (see Figure 2). Further, the engine model is also described on an ID label on the top of the cylinder head cover. 1.1.2 Confirmation of Engine Serial Number
IWARNING
CONDUCT CONFIRMATION OF THE ENGINE SERIAL NUMBER WITH THE ENGINE STOPPED. TO AVOID INJURY, DON'T CHECK IT WHILE THE ENGINE IS STILL HOT. It is advisable to check the engine serial number, engine model name, and type of machine together with the equipment manufacturer's name, as it is required when you contact the distributor for repair service or parts ordering.
Figure 2. Location of Engine Identification. 1.1.3 Engine Particulars The following information in Table 1 applies to model 4LElPW14 diesel engine.
Figure 1. Engine Details.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 002 00

Table 1. Engine Leading Particulars. Engine model name Engine family Engine code Engine type Combustion type No. of cylinders - bore x stroke - mm (in) Engine displacement - liter (ind Number of piston rings Compression ratio Compression pressure - kg/cm (psig) Firing order Timing drive system Type of combustion chamber Rated power: SAE net kW (HP)/rpm Fuel flow at maximum rated power (gph)_1.66 Maximum torque: SAE net Ibs-ft/rpm Fuel flow at maximum torque (gph)_0.993 Idling speed - rpm Exhaust emission control system Injection pump Nozzle injection pressure - kg/cm (psig)
Injection timing - BTDC
2 2
3
4LEIPW14 WSZXLO2. IDNA 21DNA Water-cooled, 4-cycle, in-line overhead valve type Direct injection 4 - 85 x 96 (3.35 x 3.78) 2.179 (133.0) 2 compression rings, 1 oil ring 21.5 to 1 31 (441) or more at 250 rpm I -3 -4- 2 Gear drive Swirl chamber 39.0 (52.3)/3000 104/1750
850 Engine modification Bosch, PFR type 135 (1920)

160
Governor Injection nozzles Valve clearance (cold) - intake and exhaust - mm (in) Intakce valve
Valve operating
Variable speed, mechanical type Throttle type 0.4 (0.0157) 150

290
Open (BTDC)
Close (ABDC)
timing Exhaust valve Lube oil capacity -liters (qts) Engine oil grade (API grade) Oil pump Oil filter Fuel type Coolant volume (engine only) - liters (qts) Starter - Volts - kW Open (BBDC)
Close (ATDC)
400
160
About 8.5 (9) CC or CD Trochoid type Cartridge tye JP-8, JP-5, DF-1, DF-2, DF-A, DL-2, Jet-A, Jet-Al 2.8 (3.0) 12 - 1.8
T.O. 38G1-127-1 TM1-281 5-262-13&P WP 002 00 2. ENGINE FACTORY SUPPORT 211suzu Engine After Sale Service
Please feel free to contact an ISUZU dealer to obtain assistance for periodic inspection and maintenance. not use diesel fuel which has been contaminated with engine oil. Besides causing engine damage, such fuel can also affect emission control. Before using any diesel fuel, check with the service station operator to see if the fuel has been mixed with engine oil. * Do not use any fuel additive (other than as recommended under "Biocide" in this section). At the time this manual was printed, no other fuel additive was recommended.
2.2 Isuzu Genuine Parts

The ISUZU genuine parts are identical with those used in the engine production, and, accordingly, they are warranted by ISUZU MOTORS LIMITED. The ISUZU genuine parts are supplied by the ISUZU distributors or the authorized parts suppliers. Please designate "ISUZU Genuine Parts" when you need engine parts.
3. FUEL, LUBRICANT, AND COOLANT

3.1 Fuel
3.1.1 Fuel Selection
Do not use home heating oil or gasoline in your diesel engine; either may cause engine damage. This engine is designed to use JP-8, JP-5, DF-1, DF-2, DFA, DL-2, Jet-A, and Jet-Al fuels. The primary fuel for this engine's service (the Self Generating Nitrogen Servicing Cart, or, SGNSC) is JP-8. However, for better fuel economy, use DF-2 diesel fuel whenever possible. At temperatures less than 200 F, DF-2 fuel may pose operating problems. At colder temperatures, use JP-8 or Jet-A fuel (if available). 3.1.3 Handling of the Fuel
The following specific advantages are required for the diesel fuel. a. Must be free from minute dust particles. b. Must have adequate viscosity. c. Must have high cetane value. d. Must have high fluidity at low temperature. e. Must have low sulfur content. f. Must have little residual carbon. 3.1.2 Fuel Requirements
The fuel containing dust particles or water will cause engine failure. Therefore, the following precautions must be observed. (This is for the engine as installed in the
SGNSC.)
a. Take care to prevent the fuel from entry of dust particles or water when filling the fuel tank. b. When fueling is done from an oil drum directly, keep the drum stationary over a long time so that clean fuel can be used after the dust particles or water is completely sedimented. c. Always fully fill the fuel tank. Drain the sedimented particles in the fuel tank frequently by removing the tank draining plug. 3.1.4 Water in Fuel
The fuel injection pump, injector, or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive, other than those specifically recommended by Isuzu. Such damage is not Isuzu's responsibility, and is not covered by the Warranty. To help avoid fuel system or engine damage, please heed the following:
e Some suppliers mix used engine oil with diesel
IWARNING | THE WATER/DIESEL FUEL MIXTURE IS FLAMMABLE AND COULD BE HOT. DO NOT TOUCH THE FUEL COMING FROM THE DRAIN VALVE AND DO NOT EXPOSE THE
fuel. Some manufacturers of large diesel engines allow this; however, for your diesel engine, do
T.O. 38G1-127-1
TM1-2815-262-13&P WP 002 00
FUEL TO OPEN FLAMES OR SPARKS. BE SURE YOU DO NOT OVERFILL THE CONTAINER. HEAT CAN CAUSE THE FUEL TO EXPAND. IF THE CONTAINER IS TOO FULL, FUEL COULD BE FORCED OUT OF THE CONTAINER. THIS COULD LEAD TO A FIRE AND THE RISK OF PERSONAL INJURY AND/OR VEHICLE OR EQUIPMENT DAMAGE. During refueling, it is possible for water (and other contaminants) to be pumped into your fuel tank along with the diesel fuel. This can happen if a fuel supplier does not regularly inspect and clean its fuel tanks, or if a fuel supplier receives contaminated fuel from its supplier(s). To protect your engine from contaminated fuel, there is a fuel filter system on the engine which allows you to drain excess water. 3.1.5 Biocides | AUIN| Fungus or bacteria can cause fuel system damage by plugging the fuel line, fuel filters, or injector. They can also cause fuel system corrosion. In warm or humid weather, if there is water in the fuel, fungus and/or bacteria may form in diesel fuel. Use a diesel fuel biocide to sterilize the fuel system (follow the biocide manufacturer's instructions). 3.1.6 Smoke Suppressants Because of extensive testing of treated fuel versus untreated fuel, the use of a smoke suppressant additive is not recommended because of the greater possibility ofstuck rings and valve failure, resulting from excessive ash deposits.
3.2 Lubricant
The quality of engine oil may largely affect engine performance, startability and engine life. Use of unsuitable engine oil will result in piston rung, piston and cylinder seizure and accelerate the sliding surface wear causing increased oil consumption, lowered output and, finally, engine failure. To avoid this, use the specified engine oil. 3.2.1 Engine Qil Selection The engine oil should conform to the specification listed below. 4LElPW14 - APL CC or CD grade, or equivalent.
ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
Ambient Temperature
-25C -2O@C -152C (-13F) (4F) (5F)
-0C (32TF)
150C (59*F)
250C 30"C (770F) (86WFl
Figure 3. Recommended Oil Viscosity Grades.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 002 00

3.3.2 Oil Viscosity
Engine oil viscosity largely affects engine startability, performance, oil consumption, speed of engine wear and occurrence of seizure, etc. Using lubricants whose viscosity is selected according to the atmospheric temperature is important. Figure 3 shows the recommended grades of engine oil for the various ambient conditions. NOTE Using a mixture of different brand or quality oils will adversely affect the original oil quality; therefore, never mix up different brands or different types of oils. Don't use API, CA, CB grade and refined engine oil. Engine damage due to improper maintenance, or using oil of the improper quality and/or viscosity, is not covered by the warranty.
g. Measurement criteria are defined by the terms "standard" and "limit." A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable. "Limit" should be thought of as an absolute value. A measurement, which is outside the "limit", indicates that the applicable part or parts must be either repaired or replaced. h. Components and parts are listed in the singular form throughout the subordinate work packages. i. Directions used in these Work Packages and Subordinate Work Packages are as follows:
Front Right The cooling fan side of the engine viewed from the flywheel. The injection pump side of the engine. The exhaust manifold side of the engine. The flywheel side of the engine.
3.3COOLANT
Use a 40/60 water/ethylene (anti-freeze) mixture for the coolant and replace it periodically. 4. NOTES ON THE FORMAT OF THESEWORK
Left Rear
PACKAGES
These Work Packages and Subordinate Work Packages are applicable to the 4LEIPW14 industrial diesel engines. a. Find the applicable section by referring to the Table of Contents at the beginning of each work package or subordinate work package. b. Common technical data such as general maintenance items, service specifications, and tightening torques are included in other work packages of this manual. c. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reassembly. d. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. e. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. f. Each service operation section in the subordinate work packages begin with an exploded view of the applicable area. As an example, Figure 4 shows the applicable major components to be disassembled or reassembled. The numbers in parentheses "( )" show the order of disassembling or reassembling.
Cylinder numbers are counted from the front of the engine. The front most cylinder is No. 1 and rear most cylinder is No.4 The engine's direction of rotation is counterclockwise as viewed from the flywheel.
Swatr
Figure 4. Example of Major Components Order of Disassembly and Reassembly.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 003 00
WORK PACKAGE MASTER LIST OF SPECIAL TOOLS AND CONSUMABLES

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LElPW14

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TABLE OF CONTENTS
paragrah
1. 2. Special Tools .......................... Consumable Materials .....................
Fg
2 4
figt
1 2 3 4 5 6 7 8 9 10 11 Valve Spring Compressor ................... Front Oil Seal Installation Tool ........ Rear Oil Seal Installation Tool ......... Drive Bar .......................... 3 ...... 3 ...... 3 3
Valve Guide Seal Installation Tool............ 3 Bearing Removal Tool ..................... Compression Gauge ....................... Compression Gauge Adapter ......... Filter Wrench .......................... Injection Nozzle Tester ..................... Piston Ring Compressor .................... 3 3 ....... 3 3 3 3
LIST OF TABLES
IAb1& Eag= Master List of Special Tools ................. 2 Master List of Consumable Materials ......... 4
1
2
T.O. 38G1-127-1 TM1-281 5-262-1 3&P WP 003 00 1. SPECIAL TOOLS Table 1 below lists the special tools necessary to service the engine.
Table 1. Master List of Special Tools.

Tool Part Number 1-8522-1029-0 CAGE Code S0226 Figure and Index No. Nomenclature l Piston Ring Pliers Removing and installing piston rings - SWP 006 01 and SWP 006 03 Disassembly and re-assembly of bushing and pins Use
5-8840-0007-0
S0226
Figure 4
Drive Bar
SWP 006 01 5-8840-0015-0

5-8840-2008-0
S0226
S0226
Figure 6
Figure 7
Bearing removal tool

Compression Gauge
Removing press fit bearings

from shafts - SWP 006 01 Checking compression pressure on the cylinders -
SWP 005 03
5-8840-2009-0 S0226 Figure 8 Compression Gauge Adapter Attaching the compression gauge to the glow plug port in the head - SWP 005 03 Installing the crankshaft front oil seal - SWP 006 03
5-8840-2061-0 5-8840-9004 5-8840-9007-0 5-8840-9015
S0226 S0226 S0226 S0226
Figure 2 Figure 3 Figure 5 Figure 9
Front Oil Seal Installation Tool
Rear Oil Seal Installation Tool Installing the crankshaft rear oil seal - SWP 006 03 Valve Guide Seal Installation Installing valve stem seals -
Tool
Filter Wrench
SWP 006 03
Removing and installing fuel and oil filter cartridges SWP 005 03 Testing the spray pattern of the injection nozzles SWP 005 03 Installing the pistons into the cylinders - SWP 006 03 Removing and installing valve springs and valves SWP 006 01 and SWP 006 003
5-8840-9016-0
S0226
Figure 10
Injection Nozzle Tester
5-8840-9018-0 Commercial Tool
S0226
Figure 11 Figure 1
Piston Ring Compressor Valve Spring Compressor
T.O. 38G1-127-1 TM1-2815-262-13&P WP 003 00
x_}DFigure 1. Valve Spring Compressor. Figure 7. Compression Gauge.
Figure 2. Front Oil Seal Installation Tool.
Figure 8. Compression Gauge Adapter.
6
Figure 3. Rear Oil Seal Installation Tool. Figure 9. Filter Wrench.
Figure 4. Drive Bar.
Figure 10. Injection Nozzle Tester.
Figure 5. Valve Guide Oil Seal Installion Tool.
Figure 11. Piston Ring Compressor.
Figure 6. Bearing Removal Tool.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 003 00 2. CONSUMABLE MATERIALS

Table 2 below lists the consumable materials required for the servicing of the engine. Table 2. Master List of Consumable Materials. Nomenclature Gasket sealant Specificationl Part No. TB1207C CAGE Code S0226 Use Sealing engine gaskets Reference SWP 005 02, paragraph 2; SWP 006 03, paragraphs 4.1.5, 4.1.10, 4.1.12, 4.1.17, 4.1.21, 5.3.3, 5.3.4, 5.3.7, 5.3.11; WP 008 00, paragraphs 2.1.1, 2.2.3 WP 009 00, paragraph 2.1 SWP 005 01, paragraph 3 WP 008 00, paragraph 2.2.2 SWP 005 02, paragraph 2 SWP 005 01, paragraphs 4.2, 4.3; WP 008 00, paragraph 2.2.3
Locking compound Molybdenum disulfide grease Sealant Teflon pipe thread sealing tape Thread locking compound
Loctite No. 601 MIL-G-21164 BELCO bond No. 4 MIL-T-27730A Loctite No. 262
08028 81349
Securing bushings to the governor control lever Lubricating bolt threadss Water pump impeller seal
81349 08028
Sealing pipe threads Locking bolt and nut threads
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 004 00
WORK PACKAGE ENGINE OPERATION


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TABLE OF CONTENTS
Paragrap Foreword .................. Safety Summary ......... 1. 1.1 2. 2.1 2.2 2.3 2.4 3. 3.1 3.2 3.3 4. 4.1 Engine Operation ............. Engine Exhaust Gas Caution ................ Pre-operational Check .................. Engine Oil Level ................... Fan Belt Check .................. Coolant Level Check .................. Battery Cable Connection ................... Engine Starting ........ .......... Pre-starting Preparations .................. Pre-heating Procedures ................... Engine Starting ........ .......... ......... ...... Pngc 2 Paragraph 4.2 5. 5.1 5.2 6. 7. 8. 9. 10. 10.1 10.2 10.3 10.4 10.5 Check After the Engine Start-up ....... Care in the Engine Operation ......... Engine Oil Pressure ....................... Coolant Temperature ...................... Engine Stopping ........................ Operation and Care For New Engine ......... Engine Care For Over-cooling ........ Starting the Engine After Long Periods of Non-use ................... Engine Care In Cold Season ................ Fuel ................... Coolant............................... ...... ...... 6 ...... 7 7 7
2 4 4
4
8
9 9 9 9 9 9
4 5 5
5 5 5
5 6
6
Engine Oil .............................. 9 Battery ................................. 9 Engine Starting .......................... 9
Check and Operation After the Engine Start-up. . 6 Warming-up Operation ...................
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 004 00
FOREWORD
This Work Package (WP) provides information on starting and operating the diesel engine on the SGNSC. It also provides information on general care of the engine to maximize trouble-free service life.
SAFETY SUMMARY ROTATING MACHINERY

There are two areas where rotating components present a hazard. One is at the rear of the engine where the cooling water pump and feed air compressor are driven by a belt and pulley drive off the engine output shaft. The other is at the front of the engine where the cooling fan is driven by a belt drive off the engine front crankshaft pulley. The unit should always be operated with the enclosure in place and secured down on the unit chassis. If there is any reason to operate the unit with the enclosure lifted or removed, special precautions must be observed, such as placing a barrier in front of the rotating parts to prevent coming in contact with them, or other such positive means.
IWARNING IN ADDING OIL, TAKE CARE NOT TO SPILL IT. IF YOU SPILL OIL ON THE ENGINE OR EQUIPMENT, WIPE IT UP COMPLETELY, OR THIS COULD LEAD TO A FIRE AND THE RISK OF PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. IWARNING DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT. WARNIG DO NOT TOUCH THE RED (HOT) CONTROL RESISTANCE COIL OR ALLOW COMBUSTIBLE MATERIALS ON IT. THIS COULD LEAD TO A FIRE. IWARNING IF THE ENGINE COOLANT TEMPERATURE GAUGE (TIl) SHOWS AN OVERHEAT CONDITION OR YOU HAVE OTHER REASON TO SUSPECT THE ENGINE MAY BE OVERHEATING, CONTINUED OPERATION OF THE ENGINE MAY RESULT IN A FIRE AND THE RISK OF PERSONAL INJURY.
HOT SURFACES
The diesel engine surfaces and exhaust system have extremely hot surfaces. Do not touch them during operation or within 30 minutes of stopping the engine.
WARNING AND CAUTION STATEMENTS

The following warning and caution statements appear in this Work Package:
IWARNING
DO NOT BREATHE EXHAUST GAS BECAUSE IT CONTAINS CARBON MONOXIDE, WHICH, BY ITSELF, HAS NO COLOR OR ODOR. CARBON MONOXIDE IS A DANGEROUS GAS. IT CAN CAUSE UNCONSCIOUSNESS AND CAN BE LETHAL.
WARNING
TO AVOID INJURY CONDUCT THE INSPECTIONS BEFORE START-UP AND WITH THE ENGINE STOPPED.
T.O. 38G1-127-1 TM1-2815-262-13&P WP 004 00
SAFETY SUMMARY (continued)
IWARNING
S|IANNG |
DO NOT SPILL ANTIFREEZE OR ENGINE COOLANT ON THE EXHAUST SYSTEM OR HOT ENGINE PARTS. UNDER SOME CONDITIONS THE ETHYLENE GLYCOL IN THE ENGINE COOLANT IS COMBUSTIBLE.
DO NOT OPEN THE ENGINE ACCESS COVER
IF YOU SEE OR HEAR STEAM OR ENGINE

COOLANT ESCAPING FROM THE ENGINE COMPARTMENT. WAIT UNTIL NO STEAM OR ENGINE COOLANT CAN BE SEEN OR HEARD BEFORE OPENING THE ENGINE COVER. DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT.
| ATON| Do not use starting "aids" in the air intake system. Such aids can cause immediate engine damage.
T.O. 38G1-127-1 TMI-2815-262-1 3&P WP 004 00 1. ENGINE OPERATION All operational instructions pertain to the engine as installed in the Self Generating Nitrogen Servicing Cart (SGNSC). 1.1 Engine Exhaust Gas Caution |WAR
DO NOT BREATHE EXHAUST GAS BECAUSE IT CONTAINS CARBON MONOXIDE, WHICH, BY ITSELF, HAS NO COLOR OR ODOR. CARBON MONOXIDE IS A DANGEROUS GAS. IT CAN CAUSE UNCONSCIOUSNESS AND CAN BE LETHAL. If at any time you think exhaust fumes are leaking, have the cause determined and corrected as soon as possible. If you must operate the engine under these conditions, operate with caution. Protect against carbon monoxide concentration around the control panel of the system. The best way is to keep the engine exhaust system properly maintained. We recommend that the exhaust system be inspected by a competent technician: * Each time the vehicle has an oil change. * Whenever a change is noticed in the sound of the exhaust system. * Whenever the exhaust system, underbody or cab is damaged or becomes corroded. See Maintenance Schedule, SWP 004 02, for parts requiring inspection. To allow proper operation of your vehicle's ventilation system, keep the air inlet and outlet ducts clear of snow, leaves or other obstructions at all times. Do not run the engine in confined areas (such as garages or next to a building) any more than needed to move the vehicle or the equipment. Keep the exhaust tailpipe area clear of snow and other material to help reduce the buildup of exhaust gasses under the vehicle or the equipment. This is particularly important when parked in blizzard conditions.
2. PRE-OPERATIONAL CHECK | WARNING |

TO AVOID INJURY CONDUCT THE INSPECTIONS BEFORE START-UP AND WITH THE ENGINE STOPPED. 2.1 Enalne Oil Level
a. Place the engine on a level surface. b. Remove the dipstick from the crankcase, wipe it with cloth. Insert if fully and take it out gently again. c. Check the oil level by the level marks on the dipstick. The oil level must be between the "Max" level mark and the "Min" level mark as illustrated. |IWARNING I
IN ADDING OIL, TAKE CARE NOT TO SPILL IT. IF YOU SPILL OIL ON THE ENGINE OR EQUIPMENT, WIPE IT UP COMPLETELY, OR THIS COULD LEAD TO A FIRE AND THE RISK OF PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. d. Take care not to add too much engine oil. f. Drain oil to the max oil level if oil level is above the max level mark. g. Add oil to the max oil level if oil level is below the min level mark. h. Also check the sample oil on the dipstick for fouling and degrees of viscosity. NOTE Oil level check must be made after the engine has been stopped for ten or twenty minutes. When the oil level check is necessary while the engine is running, stop the engine and keep it stationary ten or twenty minutes until the oil thoroughly flows down to the crankcase. e. Oil is poured either through the oil filler at the front of the cylinder head cover or through the oil filler on the right side of the timing gear case.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 004 00

A certain period of time is required before the engine oil completely flows down from the oil filler to the crankcase. Check the oil level ten or twenty minutes after oil replenishment. NOTE If the engine oil is splashed on the fan drive belt, it causes belt slippage or slackness; therefore, take care to avoid it. View from engine fro Push here
2.2 Fan Belt Check

Check the fan belt for tension and abnormalities. a. When the belt is depressed about 10 mm (0.39 in) with the thumb with about 10 kg (22 lb) pressure midway between the fan pulley and alternator pulley, the belt tension is correct (see Figure 1). b. When the belt tension is too high, it will result in alternator failure. Contrarily, a loose belt will cause belt slippage which may result in a damaged belt and abnormal noise. c. Check the belts. Replace them if any damage is found. 2.3 Coolant Level Check Figure 1. Checking Belt Tension. c. Never reverse (+) and (-) terminals when reconnecting cables after disconnection. Even a short period of reverse connection will damage the electrical parts. e. When handling such metallic articles as a tool near the batteries, be sure not to contact the (+) terminal. As the vehicle body is (-), it may cause a hazard. f. When disconnecting the terminals, start with the (-) terminal. When connecting them, connect the (-) terminal last.
||WARIGi
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT. a. The coolant level must be 1/2 inch below the radiator filler neck. Check and see that the level is correct. b. When the coolant level is lower than the low point, replenish the radiator by the filler port. c. Use a 40/60 ratio of water/ethylene glycol (anti-freeze) for the coolant. d. After the replenishment of the coolant, install the radiator cap. Make sure the cap is securely installed.
3. ENGINE STARTING
3.1 Pre-starting Preparation a. Make sure that all hydraulic control levers etc. on the equipment are in the nuetral or off position. (Refer to the SGNSC operating instruction manual, T.O. 35D29-7-6-InTMI-3655-234-12.)
b. Set the main circuit breaker to the ON position. c. Switch ON the ignition switch. d. Make sure that the panel meters are functioning. 3.2 Pre-heatina Procedures As an engine starting aid, preheating is required in a cold engine starting. a. Turn the starter switch key counter-clockwise to the PREE-EAT position in order to heat the glow plugs on the engine. A pre-heating time of 5 seconds is required until the control resistance coil becomes red.
2.4 Battery Cable Connectlon

a. Check the battery cable connections for looseness or corrosion. The loosened cable connection will result in hard engine starting or insufficient battery charge. b. The battery cables must be tightened securely.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 004 00

Relationship between water temperature and pre-heating time. 50 0C (122 0 F)
0 200 C (68 FT)
d. When repeating starting operation, return the switch to the OFF position and then pre-heat and start the engine once again. e. If the engine still remains unstarted, something may be wrong with the engine. Check the appropriate parts to locate the cause.
About I sec. About 2 sec. About 3.5 sec. About 5 sec. About 7 sec.
00 C (320 F) -150 C (5-F) -31 0 C (-25IF)
4. CHECK AND OPERATION AFTER THE ENGINE START-UP 4.1 Warming-up Operation
Do the warming-up operation at 1500 RPM for about ten minutes after the engine has started. While the lubrication for the entire engine systems is warming-up, do not speed up and load it abruptly. Particularly, observe this in cold season operation.
SWARNING |
DO NOT TOUCH THE RED (HOT) CONTROL RESISTANCE COIL OR ALLOW COMBUSTIBLE MATERIALS ON IT. THIS COULD LEAD TO A FIRE. b. Turn the starter switch clockwise to the START position as soon as the control resistance coil glows red, approximately 5-7 seconds.
4.2 Check After the Engine Start-up

Check the following items in the engine warming-up operation. a. Engine oil pressure. Although the engine oil pressure gauge readings vary depending on ambient temperature or type of oil, the gauge registers around 4 to 5 kg/cm (57 to 71 psi) while the engine is warming-up. b. Charge condition. The charge condition is normal when the ammeter registers on the plus side a large amount after the engine is started, then gradually the meter will return to zero charge. c. Engine noise and exhaust smoke color. Pay attention to engine noise and, if any abnormal noise is heard, check the engine to detect the cause. Check the fuel combustion condition by exhaust smoke color. The exhaust smoke color after engine warming-up and at no-load operation is as follows: Colorless or light blue: Normal (Perfect combustion) Black color: Abnormal (Imperfect combustion) White color: Abnormal (Imperfect combustion) NOTE Engine noise after start-up might be noisier than that of a warmed-up engine and, the exhaust smoke color also might be more blackish than the normal condition. However, it will be normalized after warmingup the engine. d. Leakage in the systems. Check the following items.
3.3 Engine Starting
Do not use starting "aids" in the air intake system. Such aids can cause immediate engine damage. a. Turn the starter switch clockwise to the START position. The cranking period must not exceed ten seconds. Continuous starter operation of more than ten seconds will lead to overdischarge of the batteries as well as starter seizure. b. If the engine cannot be started in one attempt, keep the batteries and the starter stationary at least 30 seconds for their functional recovery; then repeat the pre-heating and the starting operations. NOTE Continuous re-engagement of the starter to the flywheel ring gear without giving it a break will result in a damaged starter pinion gear and flywheel ring gear. c. If, despite repeated operations, the engine does not start, wait for a minute or more until the functions of the batteries and starter are recovered; then repeat preheating and starting operations.
T.O. 38G1-127-1 TM1-2815-262-13&P WP 004 00

4.2.1 Lube oil leakage Check both sides and the bottom of the engine assembly for lube oil leaks, paying particular attention to the lube oil pressure gauge pipe joint, lube oil filter and lube oil pipe joints. 4.2.2 Fuel leakage Check the fuel injection pumps, fuel lines and fuel filter for leakage. 4.2.3 Coolant leakage Check the radiator and water pump hose connections and also the water drain cocks on the radiator and cylinder body for leakage. 4.2.4 Exhaust smoke or gas leakage 4.2.5 Checking coolant level
When no lack of engine oil or no oil leakage is found, contact your equipment supplier to determine the cause of the abnormal reading. 5.2 Coolant Temperature The engine performance will be adversely affected if engine coolant temperature is too hot or too cold. The normal
coolant temperature is 750 to 850C (1670 to 185 0F).
5.2.1 Overheating |WARNING IF THE ENGINE COOLANT TEMPERATURE GAUGE (TIl) SHOWS AN OVERHEAT CONDITION OR YOU HAVE OTHER REASON TO SUSPECT THE ENGINE MAY BE OVERHEATING, CONTINUED OPERATION OF THE ENGINE MAY RESULT IN A FIRE AND THE RISK OF PERSONAL INJURY. If you see or hear escaping steam or have other reason to suspect there is a serious overheat condition, stop and park the equipment as soon as it is safe to do so and then turn off the engine immediately. Then move a safe distance from the equipment. The engine cooling system may overheat, if the engine coolant level is too low, if there is a sudden loss of engine coolant (such as hose splitting), or if other problems occur. It may also temporarily overheat during severe operating condition such as rapidily stopping after high rpm operation. If the engine Coolant Temperature gauge shows an overheat condition, or you have reason to suspect the engine may be overheating, take the following steps: a. Don't turn off your engine.
||WANNG |
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT. The coolant level could drop, depending on the equipment, because the mixed air is expelled in about 5 minutes after the engine is started. Stop the engine, remove radiator cap, and add coolant, if necessary.
S. CARE IN THE ENGINE OPERATION

In the engine operation, always pay attention to the following items if the engine indicates any sign of abnormalities.
5.1 Engine Oil Pressure Engine oil pressure is normal when the oil pressure gauge
shows 3 to 4 kg/cm2 (43 to 57 psi)) in a warmed-up en-
b. Decrease the engine speed to about one-half full operating speed or 1200 RPM, maximum. c. Bring the idle speed back to normal after two or three minutes. d. If the engine coolant temperature does not start to drop within a minute or two let the engine run at normal idle speed for two or three minutes. e. If the engine coolant temperature does not start to drop, turn off the engine and get a safe distance from the equipment and proceed as follows:
gine. In the continuous engine operation, engine oil pressure is slightly lower than the pressure at start-up time. When the engine oil pressure gauge shows the following abnormal condition, stop the engine immediately and check the engine oil amount in the oil sump and oil leakage: a. The engine oil pressure gauge shows below 2 kg/cm2 (28) psi), though the engine speed is raised. b. The oil pressure gauge indicator oscillates greatly in the engine low speed range.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 004 00

5.2.2 Overcooling
IWARNING | DO NOT OPEN THE ENGINE ACCESS COVER IF YOU SEE OR HEAR STEAM OR ENGINE COOLANT ESCAPING FROM THE ENGINE COMPARTMENT. WAIT UNTIL NO STEAM OR ENGINE COOLANT CAN BE SEEN OR HEARD BEFORE OPENING THE ENGINE COVER. DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT. If no steam or engine coolant can be seen or heard, tilt open the engine access cover. If the engine coolant is boiling, wait until it stops before proceeding. If necessary pour engine coolant into the radiator. Make sure the fan belts are not broken, or off the pulleys, and that the fan turns when the engine is started. I WARNING ||
DO NOT SPILL ANTIFREEZE OR ENGINE COOLANT ON THE EXHAUST SYSTEM OR HOT ENGINE PARTS. UNDER SOME CONDITIONS THE ETHYLENE GLYCOL IN THE ENGINE COOLANT IS COMBUSTIBLE. If the engine coolant level is low, look for leaks at the radiator hoses and connections, heater hoses and connections, radiator, and water pump. If you find major leaks, or spot other problems that may have caused the engine to overheat, do not run the engine until these problems have been corrected. If you do not find a leak or other problem, carefully add engine coolant to the radiator. (Engine coolant is a mixture of 40% water and 60% ethylene glycol antifreeze. If the engine coolant level in the radiator is at the correct level but there is still an indication on the instrument panel of an overheat condition YOU MUST LET THE ENGINE COOL FIRST. You may then add an engine coolant directly to the radiator. Once the Engine Coolant Temperature Gauge no longer signals an overheat condition, you can resume operating at a reduced speed. Return to normal operation after about ten minutes, if the gauge pointer does not again show an overheat condition. If no cause for the overheat condition was found, see a qualified service technician.
The engine operation at low coolant temperature will not only increase the oil and fuel consumption but also will lead to premature parts wear, which may result in engine failure. 5.2.3 Engine Hourmeter (Engine Operation Hour Indicat-
This meter indicates the engine operation hours. Make sure that the meter is always working during engine operation. Periodic engine maintenance is scheduled on the operation hours indicated on the hourmeter. 5.2.4 Liquid and Exhaust Smoke Leakage Be careful with lubricant, fuel, coolant and exhaust smoke leakage. 5.2.5 Abnormal Engine Noise Pay attention to the noise from the engine or other related parts, checking if the noise is normal. 5.2.6 State of the Exhaust Smoke Be careful with exhaust smoke color; check to see if it is whitish or blackish. 5.2.7 Electrical System Do not turn the switch to the OFF position while the engine is running at high rpm. This may cause electrical parts damage.
6. ENGINE STOPPING
a. Make sure that all of the controls on the equipment are in their proper position for shutting down.. b. Before stopping the engine, cool down the engine by operating it a low idle speed for about three minutes. During this time, check the engine noise and the engine oil pressure for abnormalities. c. To stop the engine, turn the ignition switch to the OFF position. Switch off the main circuit breaker. NOTE Leaving the ignition switch in the ON position for a long while, after the engine has been stopped, will discharge the battery wastefully.
T.O. 38G1-127-1 TM1-281 5-262-13&P WP 004 00

7. OPERATION AND CARE FOR NEW ENGINE Your ISUZU engine is carefully tested and adjusted in the factory, however, further, thorough run-in (i.e. break-in) operation is necessary. If the new engine is harshly operated, lubricating oil film will be reduced, leading to abnormal wear or seizure. Particularly, avoid a harsh engine operation within the initial 100 operational hours observing the following notice. a. Do the warming-up operation continuously until the engine is warmed-up. In this operation, do not race the engine. b. Also, do not operate the engine with rapid acceleration, rapid machine starting and continuous high-speed operation. 8. ENGINE CARE FOR OVER-COOLING Engine over-cooling causes premature wear and increased fuel consumption. When the coolant temperature is not raised to 750 to 850 C (1670 to 185 0F) indefinitely, use the radiator baffle provided on the SGNSC equipment. 9. STARTING THE ENGINE AFTER LONG PERIODS OF NON-USE When the vehicle or equipment is left unused for more than three months without running the engine (warmingup), conduct a thorough inspection of the equipment before starting the engine. After starting the engine, be sure to warm it up for more than ten minutes at 1000 rpm. 10. ENGINE CARE IN COLD SEASON IWARNING I DO NOT SPILL ANTIFREEZE OR ENGINE COOLANT ON THE EXHAUST SYSTEM OR HOT ENGINE
PARTS. UNDER SOME CONDITIONS THE ETHYLENE GLYCOL IN THE ENGINE COOLANT IS COMBUSTIBLE.
A 60/40 ethylene glycol base antifreeze/water mix should be used at all ambient temperatures. Concentrations over 65% adversely affect freeze protection, heat transfer rates, and silicate stability, which may cause water pump leakage. Never exceed a 60/40 antifreeze/water mix. (which provides protection to about -50'C (-58 0F).
NOTE
Methyl alcohol base antifreeze is not recommended because of its effect on the non-metallic components of the cooling system and because of its low boiling point. High silicate antifreeze is ALSO not recommended because of causing serious silica gelation problems. Usage and mixing ratio etc. should be followed to the antifreeze manufacturer's recommendations.
Engine oil viscosity largely affects engine startability, so the use of lubricant with selected viscosity according to the atmospheric temperature is important. (Refer WP 002 00 for recommended viscosity grades.) At low atmospheric temperature, engine oil viscosity will increase causing hard engine starting.
10.1 FUEL
10.1.1 Fuel Selection In cold zones, the fuel might be frozen, resulting in hard engine starting; therefore, select a suitable fuel for such engine operation. It is best to use JP-8 or Jet-A for sub-freezing temperatures. 10.2 COOLANT Where the atmospheric temperature falls below the freezing point, the cooling system should be drained after engine operation. To eliminate the need for repeated draining and refilling, the use of anti-freeze solution is highly recommended. Always pay attention to charging the battery completely in cold season. As the discharge current from the battery is large in cold engine starting, it takes a comparatively long while to recharge the batteries than the recharge after the normal engine starting. Pay attention to keeping the batteries warm in the cold season. 10.5 ENGINE STARTING In cold engine starting at ambient temperatures below 00 C (32 0 F), pay attention to the following items:
Do not use starting aids in the air intake system. Such aids can cause immediate engine damage.
T.O. 38G1-127-1 TMI-2815-262-1 3&P WP 004 00 a. Do the preheating operation before cranking the engine with the starter. b. Set the engine throttle to the full position of the stroke. c. If the engine does not start with the initial cranking, keep the battery stationary awhile to recover its power and, re-attempt the preheating and the cranking operation. d. In order to protect the starter, one time cranking must be limited to within 10 seconds. e. In cranking operation, when the phenomenon of the starter pinion and the flywheel ring gear repeatedly engaging and disengaging occurs, it is a sign of weakened battery power, charge the battery with an external electrical source. f. In extreme cold temperature engine starting, do the engine cranking for no longer than 10 seconds at a time (2-3 times) while setting the throttle lever at no fuel position to allow the engine rotating parts to free themselves from the adhesive cold lubricant. After that, do preheating and cranking at full throttle to start the engine.
10
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 01
SUBORDINATE WORK PACKAGE PERIODIC INSPECTION AND MAINTENANCE

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPWI4
LIST OF EFFECTIVE SWP PAGES

Page No. 1-7 ... 8 Blank ... Change No. 0 0 Total number of pages in this SWP is 8 Change No. Page No. Page No. Change No
TABLE OF CONTENTS
Paragra= . Foreword .......................... Safety Summary .......................... 1. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 Lubricating System ........................ Engine Oil and Filter Element Change ........ Check After Oil and Filter Changes ........... Engine Oil Additives ...................... Used Oil Disposal ......................... Used Engine Oil .......................... P=age 2 2 3 3 3 3 3 3 Paragraph Epa Fuel F ilter Element Change ................. 5 3.2 3.3 4. 4.1 5. 5.1 5.2 5.3 6. 6.1 6.2 6.3 6.4 6.5 6.6 Gover nor Control Seals .................... Air In ake System ..................... Air Cl eaner ..................... Engine Electrical ...................... e Batter.y Servicing ..................... Altern ator Servicing ..................... Wirinj gConnections ..................... Engine Assembly and Others ............... Fuel I ijection Nozzle ..................... Valve Clearance Adjustment ................ Adjusi tment of Injection Timning ............. Starteir and Alternator Servicing ............. Radiai tor Pressurization Valve Check .........
6 6 6 6
6 6 6 6 6
Cooling System............................ 4 Fan Belt Tension .......................... Fan Belt Change .......................... 4 4
7 7
7 7
Coolant Change........................... 4 Cleaning Outside of Radiator ................ Cooling System Circuit Cleaning ............. Fuel System Air Bleeding ................... 5 5 5
Cylindler Compression Pressure Measurement. . 7
Fuel System.............................. 5
Figt 1 2 Checking Belt Tension ..................... Belt Tension Adjustment Points ..............
P=g
4 4
Eig=r
3
e Engine Block Drain Plug ...................
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 01
FOREWORD
This Subordinate Work Package (SWP) contains instructions for general periodic maintenance of the diesel engine used on the SGNSC. This SWP also provides guidelines for periodic inspection of the engine.
SAFETY SUMMARY
Some procedures in this SWP require draining of fluids. Some fluids may be hot if the engine was recently operated. Use protective gloves when touching any hot or warm surfaces on the engine. The engine should be allowed to cool down a minimum of one hour after stopping before any maintenance is performed.
IWARNING
NEVER CHECK AND ADJUST FAN BELT TENSION WITH THE ENGINE RUNNING. IWARNING DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT.
WARNING AND CAUTION STATEMENTS

The following warning and caution statements appear in this Work Package:
EINGE
TO AVOID BEING BURNED, DO NOT DRAIN OIL WHILE THE ENGINE IS STILL HOT.
IWARNING I
WHILE USING A NOZZLE TESTER, HIGHPRESSURE COULD BLOW OFF THE FUEL OIL. KEEP AWAY FROM NOZZLE END. USE EYE PROTECTION.
EING
USED OIL CONTAINS HARMFUL CONTAMINANTS THAT HAVE CAUSED SKIN CANCER IN LABORATORY ANIMALS. AVOID PROLONGED SKIN CONTACT. CLEAN SKIN AND NAILS THOROUGHLY USING SOAP AND WATER - NOT MINERAL OIL, FUELS OR SOLVENTS. LAUNDER OR DISCARD CLOTHING, SHOES, OR RAGS CONTAINING USED ENGINE OIL.
ICAUTION|
The rocker arm is made of die-cast aluminum. Therefore, be careful not to tighten the adjusting screw to excess.
T.O. 38G1-127-1
TM1-2815-262-1 3&P SWP 004 01 1. LUBRICATING SYSTEM

Servicing of the engine oil or the oil filter element will affect the engine performance as well as the engine life. Change the engine oil and the oil filter element periodically with the specified ones. Refer to WP 002 00 for the recommended engine oil. c. Use a filter wrench to further turn in the cartridge by 3/4 turn. 1.1.5 Engine Oil Refilling a. Close the oil pan drain valve. b. Fill with new engine oil by the oil filler port.
1.1 Engine Oil and Oil Filter Element Change

Engine oil change and oil filter element change must be made according to the following change schedule. 1.1.1 Change Interval 1.2.1 Oil Leakage Check * Engine Oil: Initial 50 hours and thereafter every 250 operating hours * Oil Filter Element: Initial 50 hours and thereafter every 500 operating hours 1.1.2 Enngine Oil Draining Idle the engine to raise the oil pressure; then check for oil leakage. 1.2.2 Oil Level Recheck a. Stop the engine and keep it stationary for about twenty minutes. b. Use the dipstick to recheck the oil level. c. Replenish with engine oil, if necessary, to the specified level. NOTE When the engine is started, the oil level will slightly drop from the initial level as the oil fully comes into the entire oil circuit. c. Wait about fifteen minutes until the oil gets down to the oil pan. Then check the oil level with a dipstick.
1.2 Check After Oil and Filter Changes
I WARNING]
TO AVOID BEING BURNED, DO NOT DRAIN OIL WHILE THE ENGINE IS STILL HOT. a. Wipe clean around the oil filler cap, taking care that no foreign particles enter. Remove the filler cap. b. Connect a 3/8 inch hose to the oil pan drain valve. Open the oil pan drain valve and drain the engine oil completely. It is advisable that draining be done while the engine is warm to minimize the draining time. NOTE Use a receptacle to receive the drained oil so that the engine and equipment may not be stained with the drained oil. 1.1.3 Oil Filter Element Removal Use a filter wrench to remove the cartridge type oil filter element. 1.1.4 Oil Filter Element Installation a. Apply engine oil lightly to the O-ring. b. Turn in new cartridge until its sealed face comes in contact with the O-ring.
1.3 Engine Oil Additives

Engine oils contain a variety of additives. Your engine should not need any extra additives if you use the recommended oil quality and change intervals.
1.4 Used Oil Disposal

Do not dispose of used engine oil (or any other oil) in a careless manner, such as pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a used oil collection facility, which may be found in your locale.
1.5 Used Enaine Oil

Discard used engine oil and other oils properly.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 01
E|ING
USED OIL CONTAINS HARMFUL CONTAMINANTS THAT HAVE CAUSED SKIN CANCER IN LABORATORY ANIMALS. AVOID PROLONGED SKIN CONTACT. CLEAN SKIN AND NAILS THOROUGHLY USING SOAP AND WATER - NOT MINERAL OIL, FUELS OR SOLVENTS. LAUNDER OR DISCARD CLOTHING, SHOES, OR RAGS CONTAINING USED ENGINE OIL.
2. COOLING SYSTEM 2.1 Fan Belt Tension AdrJustment

Figure 2. Belt Tension Adjustment Points. Adjust fan belt tension when belt slackness is greater than the specified amount and when the belts are replaced. Belt tension adjustment is made by pivoting the alternator at the alternator mounting bolt. See Figure 2. a. Loosen the alternator adjusting plate bolt and the alternator mounting bolt. b. Pivot the alternator at the mounting bolt toward the engine left or right hand side, as required. c. Tighten the mounting bolt and the adjusting bolt. Belt tension is normal when it is depressed 10 mm (0.39 in) with the thumb midway between the fan pulley and alternator pulley with about 10 kg (22 lb) depressing force. See Figure 1. 2.1.1.1 Adzuqtingpnadnr NOTE Belt tension may vary slightly after the alternator is fixed. Therefore, recheck the belt tension after tightening the bolts. d. After the adjustment, operate the engine about five minutes at a low idle speed and recheck the belt tension. Particularly, pay attention to this matter when installing new belts. Belt tension may loosen due to the new belt conforming to the pulleys.
EWING
NEVER CHECK AND ADJUST FAN BELT TENSION WITH THE ENGINE RUNNING 2.1.1 lBelt Tensio
View from engine froi
2.2 Fan Belt Change

Use of a fan belt with poor quality will result in premature belt wear or belt elongation leading to engine damage, such as overheating. Therefore, use of the ISUZU genuine fan belts are highly recommended.
2.3 Coolant Change

The coolant must be changed at intervals of six months. If the coolant is excessively fouled, it will lead to engine overheating or coolant blow-off from the radiator.
Figure 1. Checking Belt Tension.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 01

2.3.1 Coolant Draining
2.4 Cleaning Outside of Radiator
WARNING|
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT. a. Remove the radiator cap. b. Open the drain cock at the radiator lower part to drain the coolant in the radiator. c. Drain away the coolant from the engine by loosening the water drain plug at the rear of alternator on the left side of cylinder body. See Figure 3.
Mud or oily sludge caught between radiator fins will block the airflow, resulting in lower cooling efficiency. Clean the radiator fins with steam or pressurized water, as required. Further, if the fins are deformed, repair them or replace the radiator. 2.5 Cooling System Circuit Cleaning When the cooling system circuit is fouled with water scales or sludge particles, cooling efficiency will be lowered. Periodically clean the circuit interior with a cleaner. The recommended interval for cleaning is yearly. 3. FUEL SYSTEM The fuel injection pumps and fuel injection nozzles are precisely manufactured. Therefore, using fuel which contains water or dust particles will result in either injection pump plunger seizure or injection nozzle seizure, and a fouled fuel filter element with sludge or dust particles will lead to decreased engine output. In addition, a clogged filter element can cause low output or automatic air bleeding failure. Perform inspection and maintenance periodically as follows. 3.1 Fuel System Air Bleeding The entry of air into the fuel system will cause hard engine starting or engine malfunction. Once the servicing such as emptying the fuel tank, draining the water separator, and the fuel filter element change is done, be sure to perform air bleeding.
Figure 3. Engine Block Drain Plug.

2.3.2 Filling With Coolant a. Close or tighten the coolant drain plug.
Because of the "automatic air-bleeding system" employed on this engine, turn the ignition switch to the ON position to begin bleeding the air. This activates the electromagnetic fuel pump to bleed the air.
3.1.1 Air Bleeding Procedure
b. Use a mixture of 40% water and 60% ethylene glycol (anti-freeze) as the coolant. c. Fill the radiator with the coolant until the level comes up to 1/2 inch of the filler port neck. Fill gradually to prevent air entry. The engine and radiator coolant volume is about 2-1/2 gallons. d. Operate the engine about five minutes at a low idle speed. This allows the air contained in the coolant circuit to be bled. This causes the coolant level to drop. e. Stop the engine and replenish with the coolant.
a. When the ignition switch is set to the ON position to activate the electromagnetic fuel pump, fuel is forcibly sent to the fuel valve of each injection pump and further to the bleed-off pipe of each nozzle holder, where air in the fuel bleeds off automatically to the fuel tank. b. Start the engine and check the fuel system for fuel leaks. 3.2 Fuel Filter Element Change The fuel filter element should be changed every 500 operating hours. Follow the steps below for changing the fuel filter.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 01 a. Loosen the fuel filter turning it counterclockwise with a filter wrench. b. With a rag wipe clean the fitting face on the upper cover, so that new fuel filter can be seated properly. c. Lightly oil the seal on the new filter. To reinstall, turn the filter assembly clockwise carefully, to prevent the fuel from spilling, until the seal is fitted against the sealing face of the filter cover. Turn 213 turn further with the filter wrench. 3.3 Governor Control Seals As the governor (timing gear case) is precisely adjusted at the factory, most of the controls are sealed. Please do not break them. When an adjustment is necessary, contact your equipment supply source. NOTE The manufacturer does not warrant the claim on the engine with broken governor seals.
4. AIR INTAKE SYSTEM 4.1 Air Cleaner
function. When the battery can no longer hold a charge, the battery must be replaced. 5.1.1 Battery Terminal Connections Periodically, check the battery terminals for loose connections and corrosion. Loose connections will cause hard engine starting or deficient battery charging. If the terminals are excessively corroded, disconnect the battery cables and polish them with a wire brush or sandpaper. Never reverse
the "+" and
"-"
terminals when reconnecting the cables.
Even a short period of reverse connection could damage the electrical parts. 5.1.2 Cleaning of Battery When the battery surfaces are dirty, clean them with clean water or warm water and wipe them with a dry cloth to remove the water. Apply a light coat of grease to the battery posts. 5.2 Alternator Servicina The polarity of the alternator is a negative grounding type. When an inverted circuit connection takes place (swapping the positive and negative cables), the circuit will be in short circuit instantaneously resulting in the alternator failure. Do not put water directly on the alternator. Entry of water into the alternator leads to electrolyte corrosion, causing an alternator failure. When the battery is charged with an external electric source, be sure to disconnect the battery cables.
5.3 Wiring Connections
Engine performance and life vary with the air intake conditions. A dirty air cleaner element reduces the amount of intake air, causing reduced engine output or a malfunctioning engine. Also, a damaged element leads to abrasion of cylinders and valves, resulting in increased oil consumption, reduced output and shortened engine life. Perform periodic inspection and maintenance, following the equipment manufacturer's instructions. NOTES 1. Shorten the cleaning or change interval when the equipment is used in dusty areas. 2. Change the element if element damage is found during air cleaner cleaning. 3. Take care not to cause air leakage (sucking) when reassembling the air cleaner. 5. ENGINE ELECTRICAL
Frequently check all of the electric wiring connections for looseness and damage.
6. ENGINE ASSEMBLY AND OTHERS
To continue trouble free engine operation over a long period of time, the servicing items need a skilled maintenance technician; therefore, consult your equipment supply source on the following items when necessary.
6.1 Fuel Injection Nozzle
WARNING
The ISUZU engine uses a 12 volt dc system and a negative grounding type for the electrical system.
5.1 Battery Servicing

The equipment that this engine is used on (SGNSC) uses a sealed battery which requires no water or electrolyte to
WHILE USING A NOZZLE TESTER, HIGHPRESSURE COULD BLOW OFF THE FUEL OIL. KEEP AWAY FROM NOZZLE END. USE EYE PROTECTION
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 01 Use an injection nozzle tester to check the static injection starting pressure and the fuel spray conditions. * Injection nozzle pressure test interval: Every 500 operation hours. When the injection starting pressure is too high or too low or the fuel spray pattern is improper, an abnormal fuel combustion takes place in the engine, leading to a lowered output and blackish exhaust smoke. Further, it causes a piston seizure or piston damage etc. In such cases, the injection nozzle test or the nozzle replacement is required. * Injection starting pressure: 12.7-13.7 Mpa (18501990 psig) 6.2 Valve Clearance Adjustment The valve clearance should be adjusted every 1000 operating hours, or whenever the valve rocker is abnormally noisy, or in an engine malfunction, even though the fuel system is properly working. * Valve clearance: 0.40mm (0.0157 in) (When the engine is cold.) 6.2.1 AdjustmentProcedure a. Turn the crankshaft clockwise so that the mark groove on the crank pulley is aligned with the TDC mark (cast mark) on the timing gear case cover. b. Remove the cylinder head cover and check to see if cylinder No. 1 is at TDC in the compression stroke or at TDC in the exhaust stroke. When the intake and exhaust valves are closed, the cylinder is at TDC in the compression stroke, and when only the exhaust valve is open, it is at TDC in the exhaust stroke. c. In accordance with the conditions of cylinder No. 1, measure and adjust, if required, the clearance of the valves marked with either e or (Din the table below. Cylinder No. ValveArrangement No. I cylinder TDC for compression No. 4 cylinder TDC for compression I _ 1 E _ I ff E 2 E I 3 E _ e I 4 E A pressurization valve is incorporated in the radiator cap assembly. Check the valve actuating pressure with a radiator compression tester. For the pressurization valve actuating pressure and the check interval, follow the equipment manufacturer's standards. d. On completion of the valve clearance adjustment in (c) above, make the mark alignment as in (a) above by turning the crankshaft in the normal direction (counter-clockwise, facing the flywheel). Then measure and adjust the clearance of the other valves. | AUIN | The rocker arm is made of die-cast aluminum. Therefore, be careful not to tighten the adjusting screw to excess.
6.3 Adjustment of Injection Timing
The injection timing may not be readjusted. Take care not to forget to insert a shim on the mounting surface when reassembling the injection pump after it is removed. 6.4 Cylinder Compression Pressure Measurement The cylinder compression pressure measurement should be done every 1000 operation hours, or whenever the engine output is reduced. * Compression pressure: 3.04 MPa (441 psi) * Test condition: Cranking speed 250 rpm * Coolant temperature: 750C (167 0F)
6.5 Starter and Alternator Servicing
Do the starter and the alternator servicing every 1000 operating hours on the following items. * Starter commutator cleaning. * Alternator slip ring cleaning. * Carbon brushes and the brush contact check.
6.6 Radiator Pressurization Valve Check
eD
7/(8 blank)
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 02
SUBORDINATE WORK PACKAGE ENGINE MAINTENANCE SCHEDULE


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1-4
TABLE OF CONTENTS
ParagraW 1. Engine Maintenance Schedule ............ PA= ... 2 Paragraph 2. -w 3 Explanation of Maintenance Schedule ........
FOREWORD
This Subordinate Work Package (SWP) provides information on maintenance functions required on the diesel engine and the periodic schedule for performing those maintenance functions.
T.O. 38G1-127-1 TM1 -281 5-262-13&P SWP 004 02 1. ENGINE MAINTENANCE SCHEDULE When performing the following items, the daily inspection items should also be carried out.
NO. Description of Check and Maintenance
Description 1 I Oil level and oil fouling
Pre-stt
50
250 50To 750 1000
prating Hours
Remark
X X X (X)X (X) X X X X X X X X X X
_ _ -
2 3
Oil leakage check Oil pressure gauge indication Replace engine oil Replace oil filter cartridge Fuel leakage check Drain water in fuel/water separator Replace fuel filter cartridge Replace fuel/water separator element Coolant level and fouling check Coolant leakage check
4
5 6 7 8 9 11 12
X
X
X
X
10 Check fuel injection nozzle (*)
13 Radiator filler cap condition 14 Fan belt tension check (replace if necessayX 15 Coolant temperature indication
See "2. EXPLANATION OF MAINTENANCE SCHEDULE"
16 Replace coolant (see equipment T.O.)

17 Clean radiator external face (as required) 18 Clean coolant system circuit (yearly) 19 Radiator filler cap function check (*) (as reqd) 20 Clean battery 21 Battery charge condition (ammeter indication) 22 Starter and alternator check and cleaning (*) 23 Wiring and connection check 24 Preheating condition check (glow plug condition) 25 Replace air cleaner element X X 26 Engine starting conditions and noise conditions 27 Exhaust smoke condition 28 Cylinder compression pressure X X X X
_
_
S l l
X X
29 1Check valve clearance (*)

\
ffi
Note: 1. The service intervals after 1000 hours should also be made every 250 operation hours in accordance with this check and maintenance schedule.
2. When the servicing on the asterisked (*) items are necessary, consult the equipment supplier. 3. The items designated (X) are required on new engines only.
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 004 02 2.EXPLAN ATIONOFMAINTENANCE SCHEDULE
The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule charts.
Oil level and oil fouling Oil leakage check Oil pressure gauge indication Replace engine oil Replace oil filter cartridge Fuel leakage check Draining water in fuel/water separator Replace fuel filter cartridge Replace fuellwater separator element Injection nozzle check Coolant level and fouling check Coolant leakage check Radiator filler cap condition Fan belt tension check Coolant temperature indication Replace coolant Clean radiator external face Clean cooling system circuit Radiator filling cap function check Clean battery Battery charge condition Starter and alternator check and cleaning
Check that the oil level is between the maximum level mark and the minimum level mark. Drain oil to the maximum level mark if oil level is above the maximum level mark. Add oil to the maximum level mark if oil is below the minimum level mark. Replace any damaged or malfunctioning parts which could cause leakage. Engine oil pressure is normal at about 43 to 71 psi in warmed-up condition. Check and repair the lubrication oil system, if it is abnormal. Change oil at every 250 hours. Change cartridge at every 500 hours. Inspect the fuel lines for damage which could cause leakage. Replace any damaged or malfunctioning parts. Drain water in fuel/water separator if water reaches the fuel/water separator. Change cartridge at every 500 hours. Change element at every 1000 hours. Check and adjust injection opening pressure and spray condition. (This is a recommended maintenance) Check coolant level and add coolant if necessary. Repair part for coolant leakage. The radiator cap must be installed tightly. Check and adjust fan belt deflection. Look for cracks, fraying and wear. Coolant temperature is normal at about 75 to 85 0C (167 to 185 0F). Check and repair the cooling system if coolant temperature is abnormal. Change coolant at intervals of 6 months or 12 months respectively if coolant is plain water, or long life coolant (LLC). According to the equipment manufacturer's specification. Clean the cooling system circuit yearly. Check radiator pressure cap periodically for proper operation according to the equipment manufacturer's specification. Clean the terminals. Ammeter indication goes to plus (+) side while engine is running. Check wear condition of brush and commutator every 1000 hours of operation.
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 004 02 Wiring and connection check Preheating condition check Replace air cleaner element Engine starting condition and noise condition Exhaust smoke condition Cylinder compression pressure Valve clearance check
Check according to the equipment specifications. Check preheating condition of the system and the health of the glow plugs. Change element every 1000 hours of operation. Check engine stability and noise.
Check exhaust smoke color. Check at every 1000 hours. Incorrect valve clearance will result in increased engine noise and lower engine output. Thereby adversely affecting engine performance. Check and adjust at every 1000 hours.
T.O. 38G1 -127-1 TM1-281 5-262-1 3&P SWP 004 03
SUBORDINATE WORK PACKAGE ENGINE TROUBLESHOOTING

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LE1PW14

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TABLE OF CONTENTS
paragraph
1. Simple Engine Trouble Shooting .............
F=
2
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 03 1. SIMPLE ENGINE TROUBLESHOOTING

This item contains a simple troubleshooting table (Table 1) for when the engine is installed in the SGNSC. When a failure takes place on your engine, diagnose the cause referring to this troubleshooting table. If the cause of the failure cannot be detected or you are unable to remedy the failure, consult your equipment supply source or nearest ISUZU engine service outlet.
Table 1. Simple Engine Trouble Shooting (Sheet I of 5).
TROU-LE
Engine does not turn over.
IPROBABLE CAUSE
Battery is discharged. Loose battery cables. Starter or ignition switch (SW3) failure. Safety relay failure (R102) failure.
-REMEDY
Charge the battery. Tighten the cables. Replace the starter or ignition switch. Replace the safety relay. Turn the ignition switch off then back on again and start the engine before 30 seconds has elapsed. Determine cause of open switch and repair. The problem is usually a result of low compressor coolant. Service compressor coolant or replace TS5. Repair or replace the fuel stop solenoid.
Engine cranks but does not start.
Engine fault delay timer (TR1) has timed out. Feed air compressor high air temperature switch (TS5) is open.
Engine fuel stop solenoid is sticking or has failed. Fuel tank empty. Clogged fuel filter element. Air in the fuel system.
Fill the tank. Replace the element. Purge the air from the fuel system. Determine the source of the air leak and repair it. Repair sticking control rack. Hold the ignition switch (SW3) in the preheat position for the proper period of time before attempting to start the engine. Replace the glow plug(s). Repair or replace the fuel stop solenoid. Adjust injection timing. Engine probably in need of an overhaul or a leaky head.
Control rack is stuck in the off position. Fuel is too cold.
Glow plug failure. Engine fuel stop solenoid is malfunctioning. Incorrect injection timing. Low cylinder compression pressure.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 03

Table 1. Simple Engine Trouble Shooting (Sheet 2).
TROUBLEngine starts but stalls quickly.
RBLECAUSE
Air in the fuel system.
IMB
I Purge the air from the fuel system. Determine the source of the air leak and repair it. Drain the water from the fuel/water separator (F6). Drain the water from the fuel tank. Increase the idle speed. Add oil to the engine or determine the cause of the low oil pressure.
Water in the fuel.
Idle speed is too low. Engine suddenly stops while in normal operation. Low oil pressure switch closed and caused the fault timer to close the fuel stop solenoid. The engine over temperature switch closed and caused the fault timer to close the fuel stop solenoid. The feed air compressor high air temperature (HAT) switch opened and closed the fuel stop solenoid. Engine idles roughly. Crack or leak in injection pipe. Defection injection nozzle. Faulty engine fuel stop solenoid. Uneven compression between the cylinders. Low idle speed is too high. Incorrect control lever adjustment. Governor malfunction. Engine is hunting (surging) in the medium speed range. Engine runs poorly at high speeds. Governor spring has deteriorated.
Add coolant to the radiator or determine the cause of the high temperature. Add compressor coolant to the coolant separator tank or determine the cause for the switch to open. Tighten or replace the injection pipe. Repair or replace the injection nozzle. Replace the fuel stop solenoid. Engine probably in need of an overhaul or a leaky head gasket. Adjust the control lever. Repair or replace the governor. Replace the governor spring. Purge the air from the fuel system. Determine the source of the air leak and repair it. Replace the fuel filter element. Tighten or replace the piping.
Air in the fuel system.
Clogged fuel filter element. Fuel piping leaking or restricted (pinched or flattened). Deteriorated or broken governor spring. Uneven fuel injection amount between plungers.
Replace the governor spring. Repair or replace the injection pump(s).

-
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 004 03

TROU Engine runs poorly at high speeds (continued).
PRABLCAUSE Incorrect valve clearance.
REMEDY Adjust the valve clearance.
Deteriorated or broken valve spring(s). Engine speed cannot be reduced. Engine control malfunction.
Replace the valve spring(s). Repair or replace the malfunctioning component (governor, control rack, throttle cable, etc.). Lift the baffle away from the radiator and latch in the up position with the spring pin. Close the enclosure warming door. Fill the radiator with coolant. Tighten the fan belt or replace it. Replace the thermostat. Replace the radiator hose.
Engine overheats.
Radiator low temperature operation baffle is deployed. The enclosure warming door is open. Insufficient coolant. Fan belt is slipping or is broken. Thermostat is faulty. Broken radiator hose causing loss of coolant. Radiator filler cap malfunctioning. Cooling system interior is fouled. Exterior radiator fins clogged. Intake air filter element (F1) is clogged. Malfunctioning water pump.
Replace the radiator cap. Flush the cooling system. Clean the exterior surfaces of the radiator. Replace the intake air filter element. Replace the water pump. Add oil to the crankcase. Drain the oil and replace it with the proper viscosity according to the ambient conditions. Determine and repair the cause for the engine to overheat. Replace the oil filter element. Clean the strainer. Replace the bearings. Replace the oil pump.
Low oil pressure.
Low oil level. Improper oil.
High coolant temperature.
Clogged oil filter. Clogged oil pump inlet strainer. Worn bearings. Faulty oil pump.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 03

TROUI
BABLECAUSE
Faulty relief valve. Incorrect injection timing. Injection nozzle malfunction. Low fuel in tank. Air in the fuel.
EEY
Replace the relief valve. Adjust the injection timing. Repair or replace the injection nozzle(s). Fill the tank. Purge the air from the fuel system. Determine the source of the air leak and repair it. Replace the fuel filter element. Repair or replace the overflow valve. Adjust the governor engine control. Replace the governor spring. Adjust the valve clearance.
Low oil pressure (continued). Low engine power.
Fuel filter clogged. Injection pump overflow valve malfunction. Governor engine control out of adjustment. Faulty governor spring. Low compression due to improper valve clearance. Low compression due to a misaligned injector nozzle holder. Low compression due to cylinder bore wear. Low compression due to a clogged intake filter. Excessive oil consumption. Crankcase is over-filled.
Align the nozzle holder.
Overhaul the engine.
Replace the intake air filter element. Drain some oil to achieve the proper oil level. Drain the oil and replace it with the proper viscosity according to the ambient conditions. Overhaul the engine. Replace the valve stem seal(s). Replace the gasket. Tighten the bolts. Re-install (or tighten) the oil filter cartridge.
Improper oil viscosity.
Faulty cylinder liner and/or piston rings. Faulty valve stem seal(s). Oil leakage due to a damaged gasket. Oil leakage due to loose bolts. Oil leakage due to an improperly installed oil filter.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 004 03

I- PROBA
L CAUSE
REMEDY
Locate the source of the leakage and repair it. Adjust the injection pump(s). Replace the intake air filter element. Replace the injector nozzle. Adjust the injection nozzle. Repair the injection timing. Use the proper fuel. Replace the valve stem seals. Overhaul the engine. Repair the injection timing. Use the radiator baffle for low ambient temperature operation. Adjust the fan belt or replace it. Replace the alternator. Tighten the terminals or replace the wiring.
Excessive fuel consumption.
Fuel leakage.
Excessive fuel injected into the cylinder. Excessive black smoke from the exhaust. Clogged intake air filter. Injector nozzle damage. Injection nozzle is misadjusted. Injection timing failure. Improper fuel. Excessive white smoke from the exhaust. Oil coming down from the valve stems.
Oil bypassing the piston rings. Injection timing failure. Low coolant temperature. Excessive discharging of the battery. Loose or damaged fan belt causing the alternator to slip. Faulty alternator. Damaged or loose wiring.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 005 00
WORK PACKAGE GENERAL REPAIR INSTRUCTIONS


Page No. 1-4 . Change No. 0 Total number of pages in this WP is 4 Pane No. Change No. Page No. Change No
TABLE OF CONTENTS
Paragraph Foreword ..................... Safety Summary ...................... 1. 2. 3. Views of Engine ....................... General Repair Instructions ................. Main Engine and Specifications .............. Fg 2 2
3 3
4
Eigum 1 2 Left Side View of the Engine ............... Right Side View of the Engine ............... EWg 4 4
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 005 00
FOREWORD
This Work Package (WP) contains general instructions for overhauling the diesel engine used on the SGNSC.
SAFETY SUMMARY
There are no specific safety related issues in this WP. General shop safety practices should be observed when overhauling the diesel engine.
WARNING STATEMENTS
The following warning statements appear in this Work Package:
E ARINGS
DO NOT DIRECT AIR STREAMS TOWARDS SELF OR OTHER PERSONNEL. AIR PRESSURE SHALL BE REDUCED TO LESS THAN 30 PSIG AND USED WITH EFFECTIVE CHIP GUARDING AND PERSONAL PROTECTIVE EQUIPMENT.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 005 00 1. VIEWS OF ENGINE

Figure 1 shows the left side view of the engine. Figure 2 shows the right side of the engine.
b. Always use the proper tool or tools for the job at hand. Where specified, use the specially designed tool or tools. c. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines. d. Never reuse cotter pins, gaskets, O-rings, lock washers, and self-locking nuts. Discard them as you remove them. Replace them with new ones.
2. GENERAL REPAIR INSTRUCTIONS a. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery. This will reduce the chance of cable damage and burning due to short-circuiting.
-Thermostat housing Engine control lever
oil
Figure 1.Left Side View of the Engine.
Nater pump
Starter
Figure 2. Right Side View of the Engine.
T.O. 38G1 -1 27-1 TM1-2815-262-1 3&P WP 005 00 e. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation. It is especially important to keep fastening parts separate. These parts vary in hardness and design, depending upon their installation position. IWARNING DO NOT DIRECT AIR STREAMS TOWARDS SELF OR OTHER PERSONNEL. AIR PRESSURE SHALL BE REDUCED TO LESS THAN 30 PSIG AND USED WITH EFFECTIVE CHIP GUARDING AND PERSONAL PROTECTIVE EQUIPMENT. f. All parts should be carefully cleaned before inspection or reassembly. Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions. g. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly. h. If necessary, use a sealer on gaskets to prevent leakage. i. Nut and bolt torque specifications should be carefully followed.
j. Always release the air pressure from any machine-
mounted air tanks(s) before dismounting the engine or disconnecting pipes and hoses. k. Always check and recheck your work. No service operation is complete until you have done this. 3. MAIN ENGINE DATA AND SPECIFICATIONS Work Package WP 002 00, Table 1 shows the main data and specifications for this engine.
T.O. 38G1 -127-1 TM1-281 5-262-13&P SWP 005 01
SUBORDINATE WORK PACKAGE TIGHTENING TORQUE SPECIFICATIONS


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1-10 ...............
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0
Total number of pages in this SWP is 10 Change No. Page No.

......
Page No.
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TABLE OF CONTENTS
Paragraph 1. Tightening Torq ue Specifications for Standard Bolts. ...........................
2. 3. Tightening Torque Specifications for Flanged Bolts ............................ Angular Nut and Bolt Tightening Method .....
P= 2
3 4
Paraph P-a Tighteniing Torque on Major Components ..... 6 4. 4.1 Cooling Fan and Water Pump ...............
6 4.2 4.3 CylinderrHead and Cylinder Head Cover ...... Cylinder-Block and Other Components .......
7 7
LIST OF ILl .-USTRATIONS

Figum 1 2 3 4 Ea 4 Applying Grease to Threads ................. Snug Torquing Nut or Bolt .................. 4 Marking Bolt Head or Nut .................. Marking Initial Alignment Line ......... Marking Angular Alignment Line ........ Rotating Bolt or Nut to Angular Alignment Line ................... Degrees of Angular Rotation ............... 4 ..... 4 .... 4 Eigue=
12 8 9 10 11 Cylinder Block and Other Components ...... Torque Values (3) .... Cooling Fan and Water Pump Torque Values .. Cylinder Head and Cylinder Head Cover Torque Values ........ Cylinder Block and Other Components 10 6 7
5
6 7
Torque Values (1) .
.........
8
9
Cylinder Block and Other Components Torque Values (2) ... .......
LIST OF TABLES
Tabl
Torque Specifications For Standard Bolts
ae 2
Iabl 2
Torque Specifications For Flanged Bolts
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 01 1. TIGHTENING TORQUE SPECIFICATIONS FOR STANDARD BOLTS The tightening torque values given in Table 1 below are applicable to the bolts, unless otherwise specified.
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials, such as cast iron. Those shown in parentheses in the strength class indicate the classification by the old standard.
Table 1. Torque Specifications For Standard Bolts. Strength Class 4.8 (4T) (7T) Refined Bolt Identification 8.8 Non-Refined .&h 9.8 (9T)
S i'No mark
Bolt Size M6 x 1.0 M8 x 1.25 M10 x 1.25 M12 x 1.25 M14x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2.0 *MIO x 1.5 *M12 x 1.5 *M14 x 2.0 0.4 - 0.8 (2.9 - 5.8) 0.8 - 1.8 (5.8 - 13.0) 2.1 - 3.5 (15.2 - 25.3) 5.0 - 7.5 (36.2 - 54.2) 7.8- 11.7 (56.4 - 84.6) 10.6 - 16.0 (76.7 - 115.7) 15.4 - 23.0 (111.1 - 166.4) 21.0 - 31.6 (151.9 - 228.6) 25.6 - 42.2 (185.2 - 305.2) 36.6 - 55.0 (264.7 - 397.8) 2.0 - 3.4 (14.5 - 24.6) 4.6 - 7.0 (33.3 - 50.6) 7.3 - 10.9 (52.8 - 78.8)
Torque Value - kg-m (lb-ft) 0.5 - 1.0 (3.6 - 7.2) 1.2 - 2.3 (8.7 - 16.6) 2.8 - 4.7 (20.3 - 34.0) 6.2 - 9.3 (44.8 - 67.3) 9.5- 14.2 (68.7 - 102.7) 13.8 - 20.8 (99.8 - 150.4) 19.9 - 29.9 (143.9 - 216.3) 27.5 - 41.3 (198.9 - 298.7) 37.0 - 55.5 (267.8 - 401.4) 43.9 - 72.5 (317.5 - 523.9) 2.8 - 4.6 (20.3 - 33.3) 5.8 - 8.6 (42.0 - 62.2) 9.0 - 13.4 (65.1 - 96.9) 1.7 - 3.1 (12.3 - 22.4) 3.8 - 6.4 (27.5 - 46.3) 7.7 - 11.6 (55.7 - 83.9) 11.6- 17.4 (83.9 - 125.6) 16.3 - 24.5 (118.9 - 177.2) 23.4 - 35.2 (169.3 - 254.6) 32.3 - 48.5 (233.6 - 350.8) 43.3 - 64.9 (313.2 - 469.4) 56.5 - 84.7 (408.7 - 612.6) 3.7 - 6.1 (26.8 - 44.1) 7.3 - 10.9 (52.8 - 78.8) 10.9 - 16.3 (78.8 - 118.9)
T.O. 38G1-1 27-1 TM1-281 5-262-1 3&P SWP 005 01 2. TIGHTENING TORQUE SPECIFICATIONS FOR FLANGED BOLTS
The tightening torque values given in the table below are applicable to the bolts, unless otherwise specified. Table 2. Torque Specifications For Flanged Bolts.
Bolt Head Marking
Bolt Size M6 x 1.0 M8 x 1.25 MLO x 1.25 *M1O x 1.5 M12 x 1.25 *M12 x 1.75 M14 x 1.5 *M14 x 2.0 M16 x 1.5 0.5 - 0.9 (3.6 - 6.5) 1.1- 2.0 (7.9 - 14.5) 2.3 - 3.9 (17.3 - 28.2) 2.3 - 3.8 (16.6 - 27.5) 5.6 - 8.4 (40.5 - 60.7) 3.5 - 9.5 (37.6 - 56.4) 8.5- 12.7 (61.5 - 91.9) 7.6 - 11.5 (57.1 - 85.3) 11.8 - 17.7 (85.3 - 128.0)
Torque Value - kg-m (lb-ft) 0.6 - 12 (4.3 - 8.7) 1.4 - 2.9 (10.1 - 20.9) 3.6 - 6.4 (26.0 - 44.1) 3.5 - 5.8 (25.3 - 41.9) 7.9 - 11.9 (57.1 - 86.1) 7.3 - 10.9 (52.8 - 78.8) 11.7 - 17.6 (84.6 - 127.3) 11.1 - 16.6 (80.3 - 120.1) 17.1 - 26.5 (125.8 - 189.5) 1.9 - 3.4 (13.7 - 24.6) 4.3 - 7.2 (31.1 - 52.1) 4.1 - 6.8 (29.6 - 49.2) 8.7 - 13.0 (62.9 - 94.0) 8.1 - 12.2 (58.6 - 88.2) 12.6- 18.9 (91.1 - 136.7) 11.8 - 17.7 (85.3 - 128.0) 18.0 - 27.1 (130.2 - 196.0)
A bolt with an asterisk (*) is used for female threaded parts of soft material, such as cast iron.
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 005 01 3. ANGULAR NUT AND BOLT TIGHTENING METHOD The following instructions show the anglular method of tightening nuts and bolts. a. Carefully wash the nuts and bolts to remove all oil and grease. b. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. See Figure 1.
Center line
Figure 3. Marking Bolt Head or Nut.
Figure 1. Applying Grease to Threads.

c. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench. See Figure 2.
Figure 4. Marking Initial Alignment Line. f. Draw another line [F-G] on the face of each of the parts to be clamped. This line will be in the direction of the specified angle [Q] across the center [E] of the nut or bolt. See Figure 5.
Figure 2. Snug Torquing Nut or Bolt. d. Draw a line [A-B] across the center of each bolt. See Figure 3. e. Draw another line [C-D] on the face of each of the parts to be clamped. This line should be an extension of the line [A-B]. See Figure 4.
Coinciding line Figure 5. Marking Angular Alignment Line.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 01

g. Use a socket wrench to tighten each nut or bolt to the point where the line [A-B] is aligned with the line [F-G]. See Figure 6.
Figure 6. Rotating Bolt or Nut to Angular Alignment Line. Example: Specified Angle and Tightening Rotation. See Figure 7 and the table below.
Figure 7. Degrees of Angular Rotation.
A B C D E
300 600 900 1800 3600
1/12 of a turn 1/6 of a turn 1/4 of a turn 1/2 of a turn One full turn
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 005 01 4. TIGHTENING TORQUE ON MAJOR The following figures show the recommended tighten torque for assembling and installing the major components of the engine. 4.1 COOLING FAN AND WATER PUMP Figure 8 shows the tightening torque for the coolin fan and water pump.
-s
Figure 8. Cooling Fan and Water Pump Torque Values. kg-m Ob-ft)
T.O. 38G1-127-1 TM1-281 5-262-1 3&P SWP 005 01 4.2 CYLINDER HEAD AND CYLINDER HEAD COVER Figure 9 shows the tightening torque for cylinder head and cylinder head cover. 4.3 CYLINDER BLOCK AND OTHER
COMPONENTS Figures 10, 11 and 12 show the tightening torque for the cylinder block and other components.
1 0.8-1.2
(lApply locktite No.262 to this part.)
2.5 -3.5 1118.0 - 26.3) (Apply engine oil.)
1 1.9-2.91
[13.7 -21.01
Figure 9. Cylinder Head and Cylinder Cover Torque Values. kg-rn (lb-ft)
T.O. 38G1 -127-1 TM1-281 5-262-1 3&P SWP 005 01
(*): Apply Locktite No.262 to set up side of stud. (Important)
Figure 10. Cylinder Block and Other Components Torque (1). kg-rn (lb-ft)
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 01
I10.8-18.0)
i1129.0-36.21
i-Z
-'' ~
1. - 2-)
-. 9 - -2.-9 1
Figure 11. Cylinder Block and Other Components Torque (2). kg-rn (lb-ft)
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 01
(With PTO provided)
Figure 12. Cylinder Block and Other Components Torque (3). kg-rn (Ib-ft)
10
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 02
SUBORDINATE WORK PACKAGE ENGINE GASKETS


Page No. 1-3 ... 4Blank ... Change No. 0 0 Total number of pages in this SWP is 4 Change No. Page No. Page No. Change No
TABLE OF CONTENTS
Paragrap2h
1. 2.
Gasket Locations ...................... Sealant Application Locations ...............
Ew 2 3
Figure
Gasket Locations on Engine .................
LIST OF TABLES
Tabk 1
Locations of Sealant Application .......
...... 3
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 02 1. GASKET LOCATIONS Figure 1 shows the location for all of the gaskets on the engine. Gasket; joint bolt Gasket; nozzle holder Gasket; nozzle holder Gasket; headcover
/,, Sealant should not be
.t-S / y m { Corrugated washer Gasket; heat shield

_C
applied. |
9_>
Seal; valve Gasket;
water outlet p)ipe

Gasket; idle spring set screw 0-ring; fuelcutlever
AZGasket;
cylinder head
Gasket;
i04O,^>governor$
cover
.
mI
_
O s
i~1
-crankshaft
~~~rear
0-ring;
-v, U
'. yu.
Oil pump Figure 1.Gasket Locations on Engine.
Gasket; exhaust silencer
T.O. 38G1-127-1 TM1 -2815-262-13&P SWP 005 02 2. SEALANT APPLICATION LOCATIONS

Table 1 shows the locations where it is necessary to apply sealant, the purpose for the sealant and the type of sealant to be used. Table 1. Locations of Sealant Application.
Location No. Name of Part Oil pan Rocker bracket Air inlet pipe Front plate Timing case Water pump assembly Water pump rear cover Housing cover; injection pump Fuel stop solenoid Oil seal retainer Name of Mating Part Cylinder block Cylinder head Cylinder head cover Cylinder block Front plate Cylinder block Water pump body Cylinder block Cylinder block Cylinder block
___________ ._____ ______ _ __ _
Condition For Use Object to be Sealed Engine oil (lOW-30) Engine oil (IOW-30) Air Engine oil Groove to be Applied Not provided Provided Provided Provided Provided Not provided Provided Provided Provided Provided Name of Sealant
1 2 3 4 5 6 7 8 9 10
TB1207C TB1 207C TB1207C TB1207C TB1207C TB1207C TB1207C TBI207C TB1207C TB1207C
(lOW-30)
Engine oil (IOW-30) Cooling water Cooling water Engine oil (1OW-30) Engine oil
(lOW-30)
Engine oil -30)
(1OW
3/(4 blank)
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 03
SUBORDINATE WORK PACKAGE ENGINE MAINTENANCE AND ADJUSTMENTS

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LElPWI4

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TABLE 01I CONTEr ITS

haragrob
Foreword ......................... Safety Summary ........................ 1. 2. 2.1 3. 3.1 Valve Clearance and Adjustment ..... Lubrication System ........................ Oil Filter Cartridge ........................ Cooling System ........................ Cooling Fan Belt Adjustment ................
Eg
2 2 ........ 3 3 3 4 4
Paragra
4. 4.1
5.
Injection Timing ........................ Bleeding Air From Fuel.................... Compression Pressure Measurement .......... Fuel System ......................... Fuel Filter Replacement ................... Injection Nozzle ........................ Recommended Lubricating Oil ......
EM 4 5
5
6
6.
6.1 6.2 7.
6 6
........ 7
Fi gure
1
Rn
Top Dead Center (TDC) Mark ..... .......... 3 9 10 11 12 13 14 15 Injecti on Pump Timing Adjustment Shim ..... Injecti .on Pumps and Fuel Flow.............. Comp ression Gauge and Adapter ............ Comp ression Gauge Pulsation.............. Fuel FFilter Cartridge ......................
X . Injecti ion Nozzle Spray Pattern .........
2 3
No. 1 Cylinder Intake and Exhaust Valves ...... 3 Valve Adjustment Chart .................... Loosening Valve Clearance Screw ............ Oil Filter Cartridge ......................... Cooling Fan Drive Belt Tension .............. Injection Pump Delivery Valve ..... TDC Timing Mark ......................... 3 3 4 4 ......... 4 5
5r 5
6 6 6
4 5
6
7 7
7 8
Injectiion Nozzle Tester ....................
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 005 03
FOREWORD
This Subordinate Work Package (SWP) contains procedures for adjusting engine and valves on the diesel engine.
It also contains procedures for checking the cylinder compression and the injection nozzle spray pattern.
SAFETY SUMMARY
Some procedures in this SWP requires the use of diesel fuel for checking the injection nozzle spray pattern. Do not allow the fuel to contact hot surfaces. Do not smoke or allow any open flames within 50 feet of the work area.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 03 1. VALVE CLEARANCE AND ADJUSTMENT Note The cylinder head bolts were previously tightened with the "Angular Tightening method." Therefore, it is not necessary to retighten the cylinder head bolts before adjusting the valve clearance. a. Bring the piston in either the No. 1 cylinder or the No. 3 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC mark on the front cover aligns with the groove mark on the crankshaft pulley (see Figure 1). Cylinder No. Valve
Arrangement
2 I E I E I
3 E I
4 E
No. 1 cylinder TDC for compression No. 4 cylinder TDC for compression
@ II I I
Figure 3. Valve Adjustment Sequence Chart.

c. Loosen each valve clearance, adjusting the screw as shown in Figure 4.
Figure 1. Top Dead Center (TDC) Mark. b. Check to see if there is play in the No. 1 intake and exhaust valve rocker arms (see Figure 2). If the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. 1 piston is at TDC on the compression Figure 4. Loosening Valve Clearance Screw. d. Insert a 0.40 mm (0.015 in) feeler gauge between the rocker arm and the valve stem end. e. Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge. f. Tighten the lock nut securely.
No.1 cyl~nder ~ ~ Noo11cy inder
No.1 r1ldr 1 inta(
exhaust
g. Rotate the crankshaft 360. Realign the crankshaft pul. ley. h. Adjust the clearances for the remaining valves as shown in Figure 3. 2. LUBRICATION SYSTEM
Figure 2. No. 1 Cylinder Intake and Exhaust Valves.

stroke. If the No. 1 cylinder intake and exhaust valve rocker arms are depressed, the No. 4 piston is at TDC on the compression stroke. Adjust the '' or 'D' marked valves as shown in Figure 3, while the No. 1 or the No. 4 cylinder is at TDC on compression stroke.
2.1 Oil Filter Cartridge

2.1.1 Removal Refer to Figure 5.
Intake and Exhaust Valve Clearance (cold)
10.40 0.05 mm
|(0.015 0.002 in)
Remover and Installer Tool: Filter Wrench p/n 5-88409015-0
T.O. 38G1 -I 27-1 TM1-2815-262-1 3&P SWP 005 03
Figure 5. Oil Filter Cartridge. a. Loosen the used oil filter by turning it counterclockwise with the filter wrench. b. Discard the used oil filter. 2.1.2 Inistallatio a. Wipe the oil filter mounting face with a clean rag. This will allow the new oil filter to seat properly. b. Lightly oil the O-ring. c. Turn in the new oil filter until the sealing face is fitted against the O-ring. d. Use the filter wrench to turn in the oil filter an additional 34 of a turn or one turn. e. Check the engine oil level and replenish to the specified level if required. f. Start the engine and check for oil leakage from the oil filter. 3. COOLING SYSTEM 3.1 Cooling Fan Drive Belt AdJustment a. Check the cooling fan drive belt for cracking and other damage. b. Check the drive belt tension by exerting a force of 10 kg (22 lb) midway between the fan pulley (1) and the generator pulley (2). Refer to Figure 6. c. Adjust the belt tension by loosening the generator mounting bolt and the generator adjusting bolt and pivoting the generator.
Figure 6. Cooling Fan Drive Belt Tension. d. Be sure to retighten the bolts after adjusting the belt tension.
Cooling Fan Drive

Belt Deflection
8.0 - 12.0 mmn

(0.3 - 0.5 in)
4. INJECTION TIMING Note Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made. a. Remove the injection pipe of the No. 1 cylinder. b. Remove the delivery valve holder of the injection pump of the No. 1 cylinder, and then pull out the delivery spring. Refer to Figure 7.
Delivery valve _ holder
Figure 7. Injection Pump Delivery Valve. c. With the spring removed, install the delivery valve holder. d. Slowly turn the crankshaft pulley clockwise and, at the same time, continue to feed the fuel. When the fuel stops flowing out of the No. 1 delivery valve holder,
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 03 stop turning the crankshaft. This crank angle position is the starting point of injection. e. In the condition at step (d) above, confirm what degree the "groove mark" of the crank pulley is at, when seen by the "timing mark" (see Figure 8), provided in the timing gear case. When the value is out of the range of the normal injection timing, adjust it accordingly. Note For each of the injection pumps of the four cylinders, the shim adjustment is made at the same time. When a shim is missing, while overhauling the engine, and the shim thickness is unknown, assemble the engine with the provisional shim inserted. After assembling the engine, check the injection timing and adjust the shim until the normal injection timing is obtained. Reference: Each 0.1 mm (0.0039 in.) shim thickness corresponds to 1 of crankshaft angle advance. 4.1 Bleeding Air From Fuel When the starter switch is set to "IGN," the electromagnetic pump is activated to force-feed fuel to the fuel pipe and the leak-off pipe, and the air in the fuel system is automatically bled. Refer to Figure 10 for fuel flow direction. Figure 8. TDC Timing Mark.
Injection timing
BTDC 160
f. Adjust the injection timing with a shim between the injection pump and the cylinder block (see Figure 9). The shim is available in the following 9 types, and the "identification mark" is stamped (or imprinted) on the top face. Figure 10. Injection Pumps and Fuel Flow. 5. COMPRESSION PRESSURE MEASUREMENT a. Operate the engine to warm-up until the coolant temperature reaches to 750 C (1670 F). b. Remove all of the glow plugs and the injection pipes. c. Attach a compression gauge to the No. 1 cylinder glow plug installation threads. Refer to Figure 11. Figure 9. Injection Pump Timing Adjustment Shim.
Identification mark of shim and its thickness - mm Mark Thickness Mark Thickness Mark Thickness 0.8 8 0.5 5 0.2 2 3 0.3 6 0.6 10 1.0 1.2 12 0.7 7 0.4 4
Note Compression pressure may be measured starting at any cylinder and in no particular cylinder order. However, it is very important that the compression pressure be measured in each cylinder. Therefore, start at the No. 1 cylinder and work back. In this way, you will be sure to measure the compression pressure in each cylinder.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 03

exceeding 2.0 kg/cm2 (28 psi) is unacceptable. If the measured value exceeds the specified limit, the related parts must be checked.
6. FUEL SYSTEM 61 Fuel Filter Replacement 6.1.1 Removal

a. Loosen the fuel filter by turning it counterclockwise with the filter wrench or your hand. Discard the used filter. Refer to 13.
Figure 11. Compression Gauge and Adapter. Special tools required: Compression Gauge Compression Gauge Adapter p/n 5-8840-2008-0 p/n 5-8840-2009-0
0i
d. Crank the engine with the starter motor and take the compression gauge reading. The values in the table below is with the engine speed at 250 rpm. The pressure gauge may pulsate (see Figure 12) so take the average reading (midpoint of the pressure swing).
Figure 13. Fuel Filter Cartridge. Tool required: Filter Wrench p/n 5-8840-9015-0
b. Wipe the fuel filter fitting face clean with a rag. This will allow the new fuel filter to seat properly. 6.1.2 Installation a. Apply a light coat of engine oil to the O-ring.
FT~~~~~~.
',
Limit I
-
b. Supply fuel to the new filter. This will facilitate air bleeding. c. Turn in the new fuel filter until the filter O-ring is fitted against the sealing face. d. Use the filter wrench to turn in the fuel filter an additional 2/3 of a turn.
Figure 12. Compression Gauge Pulsation.
6.2 Injection Nozzle

Standard 31.0 kg/cm (441 psig) 26.0
(370 psig)
e. Repeat the procedure, steps (b) and (c), for the remaining cylinders. The compression pressure should be approximately the same for each cylinder. A variation
Check to see if the spray condition and the injection pressure are normal. Adjust them to the specified value respectively when they don't meet the standard value. Refer to Figure 14.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 005 03

good No good No good No good
/
About
40,
Figure 14. Injection Nozzle Spray Pattern. Using a nozzle tester, adjust the injection pressure with a shim. Refer to Figure 15. Special tool: Nozzle tester p/n 5-8840-9016-0
Figure 15. Injection Nozzle Tester.
7. RECOMMENDED LUBRICATING OIL

See Work Package WP 002 00, paragraph 3.2, for the recommended lubricating oil for this engine.
7/(8 blank)
T.O. 38G1-127-1 TM1 -2815-262-1 3&P WP 006 00
WORK PACKAGE ENGINE DISASSEMBLY, INSPECTION AND REPAIR, AND REASSEMBLY


Total number of pages in this WP is 2 Page No.
1..
Change No.
0
Page No.
Change No.
Page No.
Change No
2 Blank.
TABLE OF CONTENTS
Paragraph Page
1. 2. 2.
Engine Disassembly Inspection and Repair. Engine Reassembly.
....................... 1 1 1
1. ENGINE DISASSEMBLY
Subordinate Work Package SWP 006 01 shows the disassembly steps for the engine. Work Package WP 005 00 outlines the general format used in these instructions.
2. INSPECTION AND REPAIR

Subordinate Work Package SWP 006 02 shows the inspection and repair steps for the engine. Work Package WP 005 00 outlines the general format used in these instructions.
3. ENGINE REASSEMBLY
Subordinate Work Package SWP 006 03 shows the reassembly steps for the engine. Work Package WP 005 00 outlines the general format used in these instructions.
1/(2 blank)
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 006 01
SUBORDINATE WORK PACKAGE ENGINE DISASSEMBLY PROCEDURES


Page No. 1-14 .
Change No.
0
Total number of pages in this SWP is 14 Page No. Change No.
Page No.
Change No
TABLE OF CONTENTS
paragraph Foreword ....................... 1. 1.1 1.2 1.3 1.4 1.5 1.6 Figure 1 2 3 4 5 6 7 8 9 10 Engine Disassembly
Ea
2 2 3 4 3....................
PEge Paragraph 6 Internal Parts ........................... 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Rocker Bracket and Push Rod .............. Cylinder Head Assembly. Valve Mechanism .10 Timing Gear .10 Camshaft .10 Piston and Connect Rod .10 Piston Ring...................... Piston Pin .11 Ea= 10 10 11 12
11
Safety Summary ........................-.
10 10
Left Hand Side External Parts ............... 3 Right Hand Side External Parts .4.. Fuel Piping and Injections Pumps .5 Backlash of Timing Gear ................... 5 Idler Gear End Play.. Crankshaft End Play ....................... Em 3 4 6
Left Side External Parts .................... Right Side External Parts ................... Injection Pump and Fuel Piping .5 Fuel Stop Lever.5 Injection Pump Control Link ................ 5 Injection Pump and Shim ................... 5 ..................... Engine Internal Parts (1).7 Engine Internal Parts (2) .................... Engine Internal Parts (3) .................... Rocker Bracket .10 717 8 9 18 19 Eiur 11 12 13 14 15 16 Cylinder Head Assembly. Cylinder Head Bolt Removal Sequence . Cylinder Head Assembly .................. Timing Gear Parts................ Camshaft .13 Piston and Connecting Rod .13 Crankshaft .13 Removing Piston Ring .14 Removing Piston Pin .14
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01
FOREWORD
This Subordinate Work Package (SWP) contains instructions for complete disassembly of the diesel engine used on the SGNSC.
SAFETY SUMMARY
There no specific safety related issues in this SWP. General shop safety practices should be observed when disassembling the diesel engine.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01 1. ENGINE DISASSEMBLY

(9) 1.1 Left Hand Side External Parts Figure 1 shows the sequence of disassembly for the external components on the left side of the engine. Legend for Figure 1: (1) (2) (3) (4) (5) (6) (7) (8) Cooling fan and spacer Fan belt Fan pulley Generator Starter Exhaust manifold and gasket Cylinder head cover and air intake pipe Water outlet pipe and thermostat Water pump assembly
(5)
Figure 1. Left Side External Parts.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 006 01 1.2 Right Hand Side External Pats Figure 2 shows the sequence of disassembly for the external components on the right side of the engine. Legend for Figure 2: (10) Injection pipe; 4 pcs. (11) Fuelhose (12) Fuel leak off pipe (13) Fuel pipe (14) Engine stop solenoid (15) Injection pump housing cover (16) Injection pump and shim; 4 sets (17) Oil filter (18) Oil level gauge
(16)
(17) _ (15)
(18)
Figure 2. Right Side External Parts.
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 006 01

1.3 Fuel Piping and Injection Pumps 1.3.1 Injection Pipe, Leak Off Pipe, and Fuel Pipe a. Loosen the sleeve nuts on the nozzle holder side and on the injection pump side, and then disconnect the injection pipes. Refer to Figure 3.
I Injection pipe Leak off pipe As I ;
I pin
Control link
injection pump
center position
Injection pump rack

e'~Eye bolt g
Figure 5. Injection Pump Control Link.
vat\
Fuel pipe
11 , @% ZNozzle holder ,
-
Injection pump
NOTE Mark each injection pump as to the cylinder from which it was removed. Do not reuse the shim; replace it with the same thickness that was removed.
Figure 3. Injection Pump and Fuel Piping. b. Disconnect the leak off pipe together with gaskets. c. Remove the eyebolt and then disconnect the fuel pipe. 1.3.2 lpffection Pumnp a. Align the hole of the fuel cut lever with the hole of the governor cover. Then insert a pin (6 0 mm) into this hole to hold the fuel cut lever. Refer to Figure 4.
Figure 6. Injection Pump and Shim.
1.4 Backlash Of Timina Gear
STANDARD CRANK GEAR/ IDLER

GEAR
LIMIT 0.20 mm (0.0079 in)

II
0.04 mm (0.0017 in) 0.03 mm (0.0012 in)
Figure 4. Fuel Stop Lever. b. Check to see if the pin groove of the control link is at the center of the injection pump. Refer to Figure 5. c. Remove the injection pump, and then take out the shim. Refer to Figure 6.
CAM GEAR/ IDLER GEAR
0.20 mm (0.0079 in)
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01 1.5 Idler Gear End Play
(15) Oil Pump Assembly (16) Idler Gear and Shaft (17) Cam Gear (18) Camshaft (19) Rear Seal Retainer 1.6 Crankshaft End Play (20) Piston Assemblies STANDARD 0.058 - 0.115 mm (0.0023 - 0.0082 in) LIMIT 0.30 mm (0.0118in) (21) Crankshaft
STANDARD
0.058 - 0.208 mm (0.0023 - 0.0048 in)
LIMIT
0.20 mm (0.0079 in)
2. INTERNAL PARTS
Figures 7, 8 and 9 show the sequence of disassembly for the internal components of the engine. Legend for Figures 7, 8 and 9: (1) (2) (3) (4) (5) (6) (7) (8) (9) Rocker Bracket Assembly Push Rods Rear Hanger Front Hanger Cylinder Head Assembly Cylinder Head Gasket Tappets Oil Pan Oil Strainer
(10) Oil Pipe (11) Crank Pulley (12) Flywheel (13) Flywheel Housing (14-1) Timing Gear Case (14-2) Front Plate
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01
(3)
't
I-.-5)
Q'\N
(7)
16)
-
Figure 7. Engine Internal Parts (1).
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01 Do not pull out this bolt. (13)
Rear
I i.I
~~~~~~~~~~~~~~~
I I
19)I
Figure 8. Engine Intemnal Parts (2).
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01
(14-2)
(15)
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 006 01 2.1 Rocker Bracket and Push Rod
5 a. Remove the rocker bracket assembly. (M6 X 1.0; 5 bolts and 6 nuts.) Refer to Figure 10. b. Pull out the push rods (8 pcs.)
--- *
4
, 0 -
3
-G
2
-
1
-: -
- 4a.
16
Figure 12. Cylinder Head Bolt Removal Sequence. a. Before disassembling the valve mechanism, remove the connector, glow plugs and nozzle holder assemblies. b. Compress the valve spring, then remove the split collar, spring seat, valve spring and valve. 2.4ZTiming Ga
Figure 10. Rocker Bracket.
2.2 Cylinder Head Assembly

Refer to Figure 14. a. Remove the rear and front hangers. Refer to Figure 11. a. Remove the idle gear and the idle gear shaft. b. Pull out the sleeve from the top end of the camshaft. c. Remove the lock nut of the camshaft gear. Then remove the flyweight assembly and the cam gear. 2.5 Camshaft Refer to Figure 15. a. Remove the snap ring, which holds down the front bearing of the camshaft, from the ring groove of the cylinder block. b. Pull out the camshaft from the cylinder block, together with the bearings. c. Remove the bearings from the camshaft using the removal tool. Bearing removal tool: p/n 5-8840-0015-0
Figure 11. Cylinder Head Assembly. b. When removing the cylinder head bolts, loosen them slowly (a little at a time) starting with the outside and working in a circular pattern inward (see Figure 12). c. Remove the cylinder head assembly and the head gasket. d. Pull out the tappet from the cylinder body. Refer to Figure 13. 2.3 Valve Mechanism Refer to Figure 13.
2.6 Piston and Connecting Rod Refer to Figures 16 and 17. a. Turning the crankshaft, position the piston to be removed at the bottom dead center.
10
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01

w (1)
Glow plug (2)
Seal; valve
.CD
%R-
Split collar (4)
Studs are applied with sealing agent. Do not pull them out. _ (5 locations) e
Seat; valve insert
Figure 13. Cylinder Head Assembly. b. Loosen the cap nut of the connecting rod, and then remove it. c. Give another rotation to the crankshaft to position the piston at the top dead center. d. With the handle of a hammer placed at the bottom of the connecting rod, push the piston assembly upward out of the cylinder block. Note Before removing the piston, scrape the carbon deposit off the cylinder wall.
When pushing out the piston assembly, care should be taken not to damage the cylinder wall. Attach a tag with a cylinder number to the removed caps and bearings to keep them in order.
Remove the piston ring with ring pliers.

Piston ring pliers:
p/n 1-8522-1029-0
2.8 Piston Po
Refer to Figure 19. a. Remove the snap rings with a commercially available tool. b. With a brass bar attached to the piston pin, push it out by hammering it lightly. Drive bar:
p/n 5-8840-0007-0
Note Keep the piston, piston pins and connecting rods in order for each cylinder.
2.7 Piston RIg Refer to Figure 18.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 01
Wear ring
Cam
Bearing
Snap ring (7) Cam gear (6)
Lock nut
Shaft; idle
Idle gear (2)
Sleeve (4)
Thrust collar
Key
Crank gear Crank pulley (1)
Washer
Figure 14. Timing Gear Parts.
12
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 006 01
Camshaft
ZN
Snprn
Figure 15. Camshaft.
Figure 17. Crankshaft.
Piston ring (4) Snap ring (5) Pis
Piston pin (6) )
-U~
Con'rod bolt (The drawing-out of the con'rod bolt must be limited to only when replaced.)
Bush (The drawing-out of the bush must be limited to only when replaced.)
Connecting rod (7)
Figure 16. Piston and Connecting Rod.
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 006 01
Figure 18. Removing Piston Ring.
Figure 19. Removing Piston Pin.
T.O. 38G1-127-1 TM1-281 5-262-1 3&P SWP 006 02
SUBORDINATE WORK PACKAGE ENGINE INSPECTION AND REPAIR PROCEDURES


Page No. 1-18 . Change No. 0 Total number of pages in this WP is 18 Page No. Change No. Page No. Change No
TABLE OF CONTENTS
Paragraph List of Illustrations ........................ Foreword ........................... Safety Summary .......................... 1. 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 5. Inspection and Repair ...................... Cylinder Block ........................... Checking Cylinder Block .......... Checking Cylinder Bore .................... Cylinder Body Upper Face Warpage ......... Cylinder Head ............................ Cylinder Head Inspection ................... Hot Plug ........................... Heat Shield Replacement ........... Pg Paragraph
2
3 3 4 4 ......... 4 4 5 5
5.1 5.2 5.3 6. 6.1 6.2 7. 8. 9. 10. 10.1 11. 12. 13.
Valve Spring Inclination .................. Valve Spring Tension .................... Valve Spring Free Length ................. Tappet and Push Rod ..................... Tappet ........................ Push Rod .......................... Camshaft ........................ Rocker Ann Shaft and Rocker Ann ......... Piston, Piston Pin and Piston Ring ..... Connecting Rod and Connecting Rod Bearing ........................ Connecting Rod Bearing Inspection ......... Crankshaft and Crankshaft Bearing ......... Flywheel and Ring Gear .................. Timing Gear ........................ -...
rag 10 11 11 11 11 12 12 13 14 15 16 16 17 18
5 6
........ 8 8
Valve, Valve Seat Insert and Valve Seal ...... Inspection of Valve Seat .................... Valve Seat Insert Replacement ............... Valve Spring ...........................
8
9 10
T.O. 38G1-127-1 TM1 -2815-262-13&P SWP 006 02
Eigt 1 2 3 4 Cylinder Block ......................... Measuring Cylinder Bore .................... Cylinder Bore Grade Marks .................. Checking Cylinder Face Warpage ............ Cylinder Face Inspection Pattern ............. Cylinder Body Height ...................... Cylinder Head ...... . Checking Cylinder Head Warpage .6 Cylinder Head Inspection Pattern .6 Cylinder Head Height. View Showing Hot Plug Depression .6 View Showing Combustion Chamber .7 Removing Hot Plug.7 Aligning Hot Plug.7 Installing Hot Plug .7 Tapping Hot Plug into Head .8 Removing Heat Shield .8 Installing Heat Shield.8 Valve Seat Dimensions .8 Valve Thickness .9 Measuring Valve Stem Diameter .9 Valve Seat Insert Removal .9 Installing Valve Seat Insert .10 Valve Seat Angle .10 Valve Seat Angle Cutter.10 Checking Valve Seat Contact .10 Checking Valve Spring Straightness .11 Checking Valve Spring Tension.11 Checking Valve Spring Length.11 6 PE 4 4 4 5 5 5 .33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Fuig 30 31 32
Page
Measuring Tappet Diameter ................ Measuring Tappet Travelling Bore ........... Checking Push Rod Run-out ............... Camshaft ............................ Measuring the Camshaft ................... Camshaft Inspection Locations .............. Inspecting Camshaft Run-out ............... Rocker Arm Shaft and Rocker Arm .......... Measuring Rocker Arm Shaft ................ Rocker Arm............................. Rocker Ann Shaft ..................... Measuring Piston Diameter ................ Location of Piston Grade Mark ............. Measuring Piston Pin..................... Checking Piston Ring Gap................. Checking Piston Ring Groove Clearance ...... Checking Connecting Rod Straightness ....... Checking Connecting Rod Bearing .......... Checking Connecting Rod Bearing Bore ...... Checking Crankshaft Journal ............... Checking Crankshaft Bearing Bore .......... Checking Crankshaft Runout ............... Crankshaft Gear ......................... Front Oil Seal ........................... Removing Ring Gear ..................... Measuring Idle Gear Shaft ................. Measuring Idle Gear Bore.................. 11 12 12 12 12 12 12 13 13 13 14 14 14 15 15 15 15 16 16 16 17 17 17 17 18 18 18
5
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
.................... . 5
Checking Pin to Connecting Rod Clearance. . . 16
T.O. 38G1 -127-1 TM1-281 5-262-13&P SWP 006 02
FOREWORD
This Subordinate Work Package (SWP) containns procedures for inspecting critical components of the diesel engine for the SGNSC. It also has procedures for the repair of some components and resurfacing metal parts to comply with the manufacturer's specifications.
SAFETY SUMMARY
Some of the procedures in this SWP require the use of heat to aid in the maintenance of the engine. Always handle hot parts with heavy gloves. Use general shop safety practices for any maintenance operation.
WARNING STATEMENTS
The following warning statements appear in this Subordinate Work Package:
SiWARNING |
USE EYE PROTECTION WHEN USING A GRINDER.
||WANNG |
USE EYE PROTECTION WHEN USING HAMMER AND CHISEL.
| WRNNG|
USE EYE PROTECTION WHEN USING HAMMER.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02 1. INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements, if excessive wear or damage is discovered during inspection. Measurement position: 13mm below the top (Measure in X-X and Y-Y directions.) (Near the No. 1 compression ring.) REPAIR METHOD Perform boring and honing
2. CYLINDER BLOCK 2.1 Checking Cylinder Block

Refer to Figure 1.
LIMIT 0.20 mm (0.0079 in.)
of the inside diameter.

2.2.1 Cylinder Bore Diameter and Grade Mark The grade mark is stamped on the top surface of the cylinder block (on the mating face with the cylinder head). Refer to Figure 3.
Bore grade mark /Stamp position)
Figure 1. Cylinder Block. a. Check the cylinder block for wear, damage or any other defects. b. Use the hydraulic gauge to check the water jacket water pressure. c. Apply water pressure to the water jacket at 5 kg/cm2 (71.1 psi) for three minutes.
+~~~~~a
Figure 3. Cylinder Bore Grade Marks.. BORE DIAMETER 85.000 - 85.010mm (3.3464 - 3.3468 in.) 85.011 - 85.020 mm (3.3468 - 3.3472 in.) 85.021 - 85.030 mm (3.3472 - 3.3476 in.) y GRADE MARK A B C I
2.2 Checking Cylinder Bore

Measure the cylinder bore as shown in Figure 2.
Figure 2. Measuring Cylinder Bore.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02 2.3 Cylinder Body Upper Face Warpage
a. Use a straight edge (1) and a feeler gauge (2) to measure the four sides and the two diagonals of the cylinder body upper face (see Figures 4 and 5). Figure 6 shows the measurement location for the cylinder height inspection.
Figure 6. Cylinder Body Height. Figure 4. Checking Cylinder Face Warpage. Cylinder Bodv Height (MH (Reference)
Ad Jo
~~~~~---^2 ---
a_-_---I_
ENGINE 4LEIPW14
STANDARD 307.94- 308.06 mm (12.123 -12.128 in.)
3. CYLINDER HEAD 3.1 Cylinder Head Inspection

Remove carbon deposit on the bottom surface of the head with care not to damage the valve seat. Figure 7 shows the cylinder head. Figure 5. Cylinder Face Inspection Pattern. b. Regrind the cylinder body upper face if the measured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values exceed the maximum grinding allowance listed below, the cylinder body must be replaced. Cylinder Body Upper Face Warpage Allowance STANDARD 0.075 mm (0.0029 in.) LIMIT 0.150 mm (0.0059 in.) MAXIMUM GRINDING ALLOWANCE 0.300 mm (0.0118 in.) Figure 7. Cylinder Head. Leakage: Water pressure test 5 kg/cm2 (71.5 psig) for 3 minutes. 3.1.1 Cylinder Head Lower Face WarpaPe If the measured value is less than the limit listed above, the cylinder body may be reground a. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head
T.O. 38G1-127-1 TM1-2815,262-1 3&P SWP 006 02

lower face (see Figures 8 and 9). Figure 10 shows the measurement location for the cylinder head height.
Cylinder Head Lower Face Warpage STANDARD 0.075 mm

(0.0029 in.)
LIMIT 0.150 mm
(0.0059 in.)
MAXIMUM GRINDING ALLOWANCE 0.300 mm

(0.0118 in.)
Cylinder Head Height (H) (Reference) ENGINE 4LEIPWI4 Figure 8. Checking Cylinder Head Warpage. STANDARD 63.90 - 94.10 mm
(2.515 - 2.523 in.)
Note If the cylinder head lower face is reground, the valve seat depth must be checked.
-_IeEi I
::: '4' 1 I----
A I 11
8
3.2 Hot Plug

F
1.' I
3.2.1 Checking Hot Plug Depression a. Clean the cylinder head lower face, taking care not to damage the hot plug surfaces. b. Use a straight edge and a feeler gauge to measure the hot plug depression in a straight line from the No. 1 hot plug to the No. 3 hot plug. If the measured value exceeds the specified limit, the hot plugs must be replaced (see Figure 11).
Figure 9. Cylinder Head Inspection Pattern.
Ih.
Figure 10. Cylinder Head Height.
b. Regrind the cylinder head lower face, if the measured values are greater than the specified limit but less than the maximum grinding allowance. Note If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced.
Figure 11. View Showing Hot Plug Depression.
Hot Plug Depression LIMIT 0.05 mm (0.002 in.)
T.O. 38GI-127-1 TM1 -2815-262-13&P SWP 006 02

3.2.2 Combustion Chamber Inspection a. Remove the carbon adhering to the inside of the combustion chamber. Take care not to damage the hot plug fitting positions (see Figure 12).
Figure 13. Removing Hot Plug. a. Align the hot plug knock ball (1) with the cylinder head groove (2) and tap it temporarily into position with a plastic hammer (see Figure 14). Figure 12. View Showing Combustion Chamber. b. Inspect the combustion chamber, the hot plug hole, and the hot plug machined faces for cracking and other damage. c. If cracking or damage is present, the cylinder head must be replaced. Note Be absolutely certain that there are no scratches or protuberances on the combustion chamber surfaces which will be in contact with the hot plug after it is installed. These flaws will prevent the hot plug from seating correctly. 3.2.3 Hot Plug Replacement 3.2.3.1 Hot Plug Removal a. Insert a 3.0 - 5.0 mm (0.12 -0.20 in) diameter brass bar into the nozzle holder fitting hole until it makes contact with the hot plug (see Figure 13). b. Lightly tap the bar with a hammer to drive the hot plug free. 3.2.3.2 Hot Plug Inspection Inspect the hot plugs for excessive wear and other damage. Replace the hot plugs if either of these conditions is discovered. Refer to "3.2.3.3 Hot Plug Installation." 3.2.3;3 Hot Plug Tnstallation
Figure 14. Aligning Hot Plug. b. Place a metal plate (3) approximately 25 mm (1 in) thick over the hot plug upper surface (4). Refer to Figure 15.
MU
W -a g
_9
9 M-m
Figure 15. Installing Hot Plug. c. Use a bench press (5) to exert a pressure of 4,000 5,000 kg (8,819 - 11,023 lb) on the metal plate cover-
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 006 02

ing the hot plug upper surface. This will drive the hot plug into position. d. Lightly tap the hot plug head to make sure that it is A
firmly seated.
e. Repeat the procedure, steps (a) thru (d), for the remaining hot plugs. I
E|ARING|
USE EYE PROTECTION WHEN USING A GRINDER. f. Use a surface grinder to grind off any hot plug surface protuberances. The hot plug surfaces must be perfectly flush with the cylinder head lower face. g. After grinding, make sure that the hot plug surfaces are completely free of protuberances. The hot plug surfaces must also be free of depressions. h. Once again, lightly tap the hot plug heads to make sure
__
Figure 17. Removing Heat Shield.
Figure 18. Installing Heat Shield.
Note Always install a new heat shield. Never reuse the old heat shield.
4. VALVE- VALVE SEAT INSERT AND VALVE

Figure 16. Tapping Hot Plug into Head. that they are firmly seated (see Figure 16). SEAL
4.1 Inspectlon Of Valve Seat

Refer to Figure 19.
3.3 Heat Shield Replacement

3.3.1 Heat Shield Removal After removing the hot plugs, use a hammer (1) and a brass bar (2) to lightly tap the lower side of the heat shield (3) and drive it free (see Figure 17). 3.3.2 Heat Shield Installation Install the heat shield to the cylinder head from the nozzle holder installation hole side. Lightly tap the heat shield flange into place with a hammer and a brass bar. The heat shield flange side must be facing up (see Figure 18). 45 Figure 19. Valve Seat Dimensions.
Cylinder head
Cl
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 006 02 A - Contact width: B - Valve depression
STANDARD A - Contact width B - Valve depression 2.0 mm (0.0787 in.) 0.7 mm (0.0276 in.) LIMIT 2.5 mm (0.0984 in.) 1.2 mm (0.0427 in.) Valve Stem Outside Diameter
STANDARD Intake Valve
LIMIT
7.0 mm (0.2756 in.) 6.85 mm (0.2697 in.)
Exhaust Valve 7.0 mm (0.2756 in.) 6.80 mm (0.2677 in.)
4.2 Valve Seat Insert Replacement

4.2.1 Valve Seat Insert Removal a. Arc weld the entire inside circumference (1) of the valve seat insert (2). Refer to Figure 22.
4.1.1 Valve Thickness Refer to Figure 20.
_)
Figure 20. Valve Thickness. Figure 22. Valve Seat Insert Removal. NOMINAL LIMIT REPAIR METHOD b. Allow the valve seat insert to cool for a few minutes. This will induce contraction and make removal of the valve seat insert easier. c. Use a screwdriver (3) to pry the valve seat insert free. Take care not to damage the cylinder head (4). d. Carefully remove carbon and other foreign material from the cylinder head insert bore. 4.2.2 Valve Seat Insert Installation a. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2). Refer to Figure 23. Note The smooth side of the attachment must contact the valve seat insert. b. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place. 4,000 kg (8,819 lbs.) Figure 21. Measuring Valve Stem Diameter. If the measured value is less than the specified limit, the valve must be replaced.
1.0 mm (0.0394 in.)
0.7 mm (.0276 in.)
Replace
4.1.2 Valve Stem Outside Diameter Measure the valve stem diameter at three points (see Figure 21).
4-~~~~~~~~~~~~~a
T.O. 38G1-1 27-1 TM1-2815-262-1 3&P SWP 006 02

I
f:;,%~~~~
@4
to~~~~~~~4
(D~v=
I
Figure 23. Installing Valve Seat Insert. Figure 25. Valve Seat Angle Cutter. d. Apply abrasive compound to the valve seat insert surface. e. Insert the valve into the valve guide. f. Apply light pressure to the valve while turning it to fit the valve seat insert. g. Check that the valve contact width is correct. Refer to Figure 26. Note Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result. 4.2.3 Valve Seat Insert Correction a. Remove the carbon from the valve seat insert surface. b. Use a valve cutter (150, 450, and 750 blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Refer to Figures 24 and 25.
Figure 26. Checking Valve Seat Contact. h. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Figure 24. Valve Seat Angle. c. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. d. The required valve seat angle is 450. Note Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide. Use a surface plate and a square to measure the valve spring inclination. If the measured value exceeds the specified limit, the valve spring must be replaced (see Figure 27). i. Clean the head and valves to remove the abrasive cornpound and metal particles. 5. VALVE SPRING 5.1 Valve Spring Inclination
10
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02
Figure 27.,Checking Valve Spring Straightness.
Figure 29. Checking Valve Spring Length.
STANDARD Valve spring inclination 1.8 mm (0.071 in.)
LIMIT 2.5 mm (0.098 in.) Exhaust and intake valve spring free length
STANDARD
LIMIT
42.1 mm 40.0 mm (1.658 in.) (1.575 in.) _ _ - _ -- I__ _
5.2 Valve Spring Tension

6. TAPPET AND PUSH ROD Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replaced. Refer to Figure 28. 6.1 Tappet Inspect the tappets for excessive wear, damage and any abnormalities. Use a micrometer to measure the tappet diameter. Refer to Figure 30.
A'~~~~
Figure 28. Checking Valve Spring Tension. STANDARD Valve spring tension at 29.9 mm 1(1.177 in.) length 17.0 kg. (37.48 lb.) I LIMIT 15.0 kg. (33.07 lb.) Figure 30. Measuring Tappet Diameter.
j
STANDARD Tappet diameter 20.967 - 20.980 mm (0.8255 - 0.8260 in.) Use a dial indicator to measure the clearance between the tappet and cylinder body tappet travelling bore. Refer to Figure 31.
5.3 Valve Spring Free Length

Use a vernier caliper to measure the valve spring free length. If the measured value is less than the specified limit, the valve spring must be replaced (see Figure 29).
11
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02
Camshaft
Figure 31. Measuring Tappet Travelling Bore.
Figure 33. Camshaft.
STANDARD Tappet and tappet travelling bore clearanceI 0.020 - 0.054 mm (0.0008 - 0.0021 in.)
ILIMIT 0.08 mm (0.0032 in.) I
6.2 Push Rod

Use a feeler gauge to measure the valve push rod runout. Roll the push rod along a smooth flat surface (see Figure 32). Figure 34. Measuring the Camshaft.
Be
@ A
Bz
1-11 I Figure 32. Checking Push Rod Run-out. Figure 35. Camshaft Inspection Locations.
I
Push rod run-out
LIMIT 0.3 mm (0.012 in.)
7.1 Inspection of Cam Shaft

Check the journal and the cam for evidence of wear, damage or any other defect. Refer Figures 33, 34, 35 and 36.
Figure 36. Inspecting Camshaft Run-out.
12
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02 Note With the front and rear parts of the camshaft pressed in with ball bearings, and with the cylinder block pressed in with roller bearings as the center bearing, check to see if the camshaft rotates smoothly with no play at each bearing. 7.2 Measurement of Journal and Cam 0 REPAIR METHOD Replace Replace Figure 37. Rocker Arm Shaft and Rocker Arm.
*~~
Cam
height (A - B)
STANDARD Intake Exhaust 6.13 mm (0.2413 in.) 6.43 mm

(0.2531 in.)
LIMIT 5.83 mm (0.2295 in.) 6.13 mm

(0.2413 in.)
Center journal diameter NOMINAL 52.00 mm

(2.0472 in.)
LIMIT 51.92 mm
(2.0441 in.)
REPAIR
METHOD
Replace
Figure 38. Measuring Rocker Arm Shaft. If the measured value is less than the specified limit, the shaft must be replaced.
STANDARD Rocker arm shaft diameter
Uneven wear of journal
NOMINAL 52.00 mm
(2.0472 in.) Runout of camshaft NOMINAL
LIMIT .05 mm
(0.002 in.)
REPAIR
METHOD
Replace
11.935 - 11.955 mm ((0.4699 - 0.4707 in.)
LIMIT
REPAIR
8.2 Rocker Arm Shaft and Rocker Arm Clearance
METHOD 0.02 mm
(0.0008 in.)
0.10mm
(0.004 in.)
Replace
a. Use a vernier caliper to measure the rocker arm bushing inside diameter. Refer to Figure 39.
8. ROCKER ARM SHAFT AND RQCKER ARM Inspect all the disassembled parts for wear, damage and any abnormalities. Figure 37 shows the rocker arm parts. 8.1 Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm outside diameter. Refer to Figure 38.
Figure 39. Rocker Arm.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02

STANDARD
Rocker arm bushing inside

diameter
11.960 - 11.980 mm
(0.4709 - 0.4717 in.)
b. Measure the rocker arm shaft outside diameter. Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit. Refer to Figure 40.
60
Figure 41. Measuring Piston Diameter.

f_ __x a -( - __ _
rade mark (Stamped)
Figure 40. Rocker Arm Shaft.
STANDARD Rocker arm bushing and rocker arm shaft clearance 0.005 - 0.045 mm (0.0002 - 0.018 in.)
LIMIT 0.2 nun (0.0079 in.) Figure 42. Location of Piston Grade Mark.
OUTSIDE DIAMETER OF PISTON c. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port. 84.975 - 84.985 mm (3.3454 - 3.3458 in.) 84.986 - 84.995 mm (3.3459 - 3.3465 in.) 84.996 - 85.005mm (3.3463 - 3.3466 in.)
GRADE A B
_
9. PISTON, PISTON PIN AND PISTON RING 9.1 Clearance Between Piston and Cylinder Bore
a. Measure the outside diameter of the piston at about 60 mm (2.36 in.) from the top in a right angle to the piston pin (in the unit of 1/1,000 mm). Refer to Figure 41. b. Calculate the clearance based on the measurements of the cylinder bore and the outside diameter of the piston. Clearance 0.015 - 0.035 mm (0.0006-0.0014 in.)I
Wear of piston pin (outside diameter) (see Figure 43) NOMINAL 25.0 mm (0.9843 in.) LIMIT 24.97 mm (0.9831 in.) REMARKS Replace if worn beyond limit | I
Clearance between piston pin and position pin hole

ENGINE 4LElPW14
STANDARD 0.002 -.0.012 mm (0.00008 - 0.00047 in.)
9.1.1 Outside Diameter Of Piston And Grade Mark The grade mark is stamped on the top surface of the piston. Refer to Figure 42.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02
Figure 43. Measuring Piston Pin.
Figure 45. Checking Piston Ring Groove Clearance. If worn beyond the limit, replace the rings or piston. STANDARD 1st compression ring 2nd compression ring Oil ring 0.085 - 0.105 mm (0.0033 - 0.0041 in.) 0.050 - 0.085 mm (0.0020 - 0.0033 in.) 0.030 - 0.070 mm (0.0011 -0.0027 in.) LIMIT 0.20 mm (0.0078 in.) 1.50 mm (0.0590 in.) 1.50 mm (0.0590 in.)
9.2 Piston Ring Gap

With the ring inserted into the cylinder bore, push it in with the piston head so that it becomes a right angle to the cylinder. Then measure the gap of the piston ring. Refer to Figure 44. If worn beyond the limit, replace the rings.
10. CONNECTING ROD AND CONNECTING ROD BEARING

Torsion and Parallelism of Connecting Rod (see Figure
46)
Per 100 mm (3.94 in.) Figure 44. Checking Piston Ring Gap. Torsion Parallelism STANDARD 1st compression ring 2nd compression ring 0.20 - 0.35 mm (0.0079 - 0.0138 in.) 0.35 - 0.50 mm (0.0138 - 0.0197 in.) LIMIT 1.500mm (0.0590 in.) 1.50 mm (0.0590 in.)
STANDARD 0.05 mm
(0.002 in.)
LIMIT 0.20 mm
(0.0079 in.)
(
0.05 mm
(0.002 in.) ()_______________
0. 15 mm
(0.0059 in.)
Oil ring
0.20 - 0.40
(0.0079 - 0.0157 in.)
1.00 mm
(0.0394 in.)
9.3 Clearance Between Piston Ring Groove and B10

Measure clearance at several places on the circumference. Refer to Figure 45. Figure 46. Checking Connecting Rod Straightness.
T.O. 38G1-127-1 TMl-2815-262-13&P SWP 006 02

If worn beyond the limit, repair or replace.
Clearance between small end pin hole of connecting rod and piston pin, inside diameter of bushing (see Figure
47)
STANDARD
Clearance Inside diameter 0.008 - 0.020 mm (0.0003 - 0.0008 in.) 25.00 mm (0.9843 in.)
LIMIT
0.05 mm (0.002 in.) I Figure 49. Checking Connecting Rod Bearing Bore.
Tightening torque
7.5 - 8.5 kg-rn (54 - 61 ft-lb)
Clearance between bearing and crank pin, inside diameter with bearing installed and without. . Clearance
Figure 47. Checking Pin to Connecting Rod Clearance.
STANDARD 0.035 - 0.073 mm

(0.0014 - 0.0029 in.)
LIMIT 0.10 mm
(0.0039 in.)
11. CRANKSHAFT AND CRANKSHAFT BEARING

Inspect outside diameters of journal and pin. Refer to Figure 50. If worn beyond the limits - replace
10.1 Connecting Rod Bearing Inspection

a. Fit the connecting rod bearing lower half into the connecting rod bearing cap. Refer to Figure 48.
Figure 48. Checking Connecting Rod Bearing. b. Check the connecting rod bearing lower half tension. If the tension is insufficient, the bearing must be replaced. c. Tighten the connecting rod and the bearing cap to the
Figure 50. Checking Crankshaft Journal.
Crank journal (see Figure 51)
I
|
*
STANDARD 60.0 mm (2.3622 in.)
I |
.
LIMIT 59.86 mm (2.3567 in.)
I
.
specified torque. Refer to Figure 49.
16
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02 Crank pin

STANDARD 49.0 mm (1.9291 in.)
11.1 Crankshaft gear LIMIT

48.87 mm (1.9240 in.) Check the crankshaft gear visually for damage and any other defects. Refer to Figure 53.
Note When there occurs an uneven wear to the crankshaft, replace it with a new one without grinding it for reuse. Clearance between journal and bearing inside diameter with and without bearing instafled (see Figure 51)
L _m I
STANDARD
LIMIT
0.11 mm (0.0043 in.)I Figure 53. Crankshaft Gear. 11.2 Oil seal When the lip of an oil seal is found defective, replace it with a new one.
11.2.1 Oil Seal Installation
0.029 - 0.072 mm (0.0011 - 0.0028 in.)
Use the crankshaft front oil seal installer to install the crankshaft front oil seal. Refer to Figure 54. Figure 51. Checking Crankshaft Bearing Bore. Runout of crankshaft (see Figure 52) Tool required: 5-8840-2061-0
STANDARD
0.025 mm (0.001 in.) Replace if beyond limit
LIMIT
0.05 mm (0.002 in.)
Figure 54. Front Oil Seal.
12. FLYWHEEL AND RING GEAR 12.1 Ring Gear Replacement

a. Inspect the ring gear. b. If the ring gear teeth are broken or excessively worn, the ring gear must be replaced. Figure 52. Checking Crankshaft Runout.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 02 12.2 Ring Gear Removal
EING
USE EYE PROTECTION WHEN USING HAMMER AND CHISEL. Strike around the edges of the ring gear with a hammer and chisel to remove it. Refer to Figure 55.
Figure 56. Measuring Idle Gear Shaft.
Figure 55. Removing Ring Gear. 12.3 Ring Gear Installation a. Heat the ring gear evenly to invite thermal expansion. Do not allow the temperature of the ring to exceed 100-C (212 0F). Figure 57. Measuring Idle Gear Bore.
E WARNING I
USE EYE PROTECTION WHEN USING HAMMER. b. Use a hammer to install the ring gear when it is sufficiently heated.
13. TIMING GEAR

Uneven wear of idle gear shaft (see Figure 56) NOMINAL 45.0 mm (1.7717 in.) I LIMIT 0.10 mm (0.0039 in.) | _
Clearance between idle gear bushing and shaft (see Figure 57) .
STANDARD
0.025 - 0.085 mm (0.001 - 0.0033 in.)
LIMIT
0.20 mm (0.0079 in.)
18
T.O. 38G1-127-1 TM1 -2815-262-13&P SWP 006 03
SUBORDINATE WORK PACKAGE ENGINE REASSEMBLY PROCEDURES


Page No. 1-24. Change No. 0 Total number of pages in this WP is 24 Page No. Change No. Page No. Change No
TABLE OF CONTENTS.
Paragraph List of Illustrations ........................ Foreword .............................. Safety Summary .......................... 1. 2. 2.1 3. 3.1 4. 4.1 5. 5.1 5.2 5.3 Engine Reassembly ........................ Cylinder Head Assembly .......... Important Operations in Cylinder Head Assembly .............................. Piston And Connecting Rod ......... Engine Internal Parts ....................... Reassembly Steps ......................... External Parts Reassembly ................. Right Hand Side External Parts ....... Left Hand Side External Parts ....... Detail Reassembly Instructions ...... Important Operations in Assembling Piston ..... EPag
2 3 3 4
......... 4
4
........ 6
6
8 8 18
...... 18 ....... 19 ...... 20
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03
Eigs 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Cylinder Head Assembly .4 Installing Valve Stem Oil Seal .4 Installing Valve in Cylinder Head .4 Valve Spring .5 Installing Spring Seat Split Collar .5 Injection Nozzle Holder Assembly .5 Glow Plug and Connector .5 Piston and Connecting Rod Assembly .6 Piston Heater .6 Orientation of Piston Assembly Parts .6 Installing Piston Pin Snap Ring.7 Installing Piston Rings .7 Engine Internal Parts (1).9 Engine Internal Parts (2) .10 Engine Internal Parts (3) .11 Crankshaft Bearing.5................1.... 12 Crankshaft and Bearings .12 Crankshaft Bearing Cap and Bolt .12 Positioning of Piston Rings .12 Installing Piston in Cylinder Bore .13 Connecting Rod Cylinder No. Marks .13 Seal Retainer Bolt Tightening Sequence . Camshaft Bearing Retaining Ring.14 Cam Gear and Sleeve.14 Idle Gear................................ Camshaft Timing Marks .14 Front Plate with Oil Pump Assembly .14 Front Plate. ............................. 15 Front Oil Seal .15 Timing Gear Case .15 Flywheel Housing .16 Flywheel Bolts .16 Crank Pulley Installation .16 Oil Pipe and Oil Strainer .16 Oil Pan.................................. 17 14 13 Pa Eig= 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
PE
Head Gasket ............................ Cylinder Head Bolt Tightening Sequence ..... Rocker Arm Bracket Assembly ............. Rocker Bracket Oil Gallery ....... Installing Lifting Hangers .................. Right Hand Side External Parts............. Left Hand Side External Parts .............. Oil Filter Cartridge and Dipstick ............ Fuel Stop Lever .......................... Installing Injection Pump and Shim .......... Injection Pump Control Link ............... Injection Pump Housing Cover ............. Applying Sealant to Housing Cover .......... Fuel Stop Solenoid Installation .............. Applying Sealant to Solenoid ............... Fuel Pipes ............................. Injection Pipe........................... Water Pump Assembly .................... Thermostat and Water Outlet Pipe ........... Cylinder Head Cover..................... Air Inlet Pipe ...... Exhaust Manifold ............... Starter............... Generator ............... Fan Pulley and Fan Belt............... Tensioning Fan Belt ............... Cooling Fan ............... ........ 17 17 17
......... 17 18 18 l9 1 20 20 20 29 21 21 21 21 21 22 22 22 23 23 23 23 23 24 24 24
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03
FOREWORD
This Subordinate Work Package (SWP) contains for reassembling the diesel engine used on the SGNSC.
SAFETY SUMMARY
There are no specific safety related issues in this SWP. General shop safety practices should be observed when reassembling the diesel engine.
T.O. 38G1-127-1 TMI -2815-262-13&P SWP 006 03
Figure 1. Cylinder Head Assembly.
1. ENGINE REASSEMBLY 2. CYLINDER HEAD ASSEMBLY 2.1 Important Operations In Cylinder Head Assembly
Refer to Figure 1. 2.1.1 Valve Stem Oil Seal a. Lubricate the oil seals and valve stem sealing area with engine oil. b. Use a valve stem oil seal installer to install the oil seal (see Figure 2). Valve Stem Oil Seal Installer 2.1.2 ITntake and Fxhaust Valves a. Place the cylinder head on a flat wooden surface. b. Lubricate valve stems with engine oil (see Figure 3). c. Install the valves to the intake or exhaust guides. Install the valves to their original lapped valve seats. Figure 3. Installing Valve in Cylinder Head.
La L
ORev
Figure 2. Installing Valve Stem Oil Seal.
pin 5-8840-9007-0
%4
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03

- 2.1.3 Intake and Exhaust Valve Springs Install the valve springs with their painted end (the close pitched end) facing down. Refer to Figure 4. b. Assemble to the cylinder head the gasket (heat shield), heat shield, corrugated washer and gasket (nozzle holder) in this order. Refer to Figure 6.
Nozzle holder ASM Gasket Corrugated washer
..
Figure 6. Injection Nozzle Holder Assembly. Figure 4. Valve Spring. 2.1.4 SnrinL-Seat Split Collar a. Use a spring compressor to push the valve spring into position (see Figure 5).
Split collar Spring compressor
c. Install the nozzle holder assembly, and then tighten it to the specified torque. I Tightening torque | 4.0 - 5.0 kg-m (29 - 36 lb-ft)
2.1.6 Glow Plug and Connector a. Assemble the glow plug to the cylinder head, and then tighten it to the specified torque. Refer to Figure 7.
Glow plug
Figure 5. Installing Spring Seat Split Collar. b. Install the spring seat split collar. c. Set the spring seat split collar by tapping lightly around the head of the collar with a rubber hammer. Spring Compressor Commercially available tool
Connector
Figure 7. Glow Plug and Connector. b. Install the connector to the glow plug, and then tighten until snug. PART Glow plug TIGHTENING TORQUE 1.5 - 2.0 kg-m (11 -14 lb-ft)
2.1.5 Nozzle Holder Assembly a. Before assembling the nozzle holder assembly, check to see if the spray condition and the spray pressure of the injection nozzle are appropriate (refer to SWP 005 03, paragraph 6.2).
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03
Figure 8. Piston and Connecting Rod Assembly.
3. PISTON AND CONNECTING ROD 3.1 Important Operations In Assembling Piston

3.1.1 Piston
Use a piston heater to heat the pistons to approximately 1000 C (212TF). Figure 9 shows a conventional piston heater, available commercially. 3.1.2 Connecting Rod Figure 9. Piston Heater.
(Hot plug side)
a. Install the connecting rod to the piston with setting the marks as illustrated in Figure 10. b. Install the piston pin into the piston and the connecting rod bushing.
Front mark Engine
front
direotio
n/)
Isuzu mark Cylinder number, stamped side
Figure 10. Orientation of Piston Assembly Parts.
T.O. 381-127-1
TM1 -2615-262-1 3&P SWP 006 03

3.1.3 Piston Pin Snap Ring
a. Use a pair of snap ring pliers to install the piston pin Figure snap ring. Refer to 11.
* The marked side of the two compression rings must be facing up. * The undercut side of the second compression ring will be facing down. * As the oil ring has no facing mark, it may face in either direction. c. Lubricate the piston ring surface with engine oil. d. Check that the piston rings rotate smoothly in the piston ring grooves.
Figure 11. Installing Piston Pin Snap Ring. b. Check that the piston moves smoothly on the piston pin. Piston 3.1.4 iing a. Use a piston ring installer to install the three piston rings. Piston Ring Pliers p/n 1-8522-1029-0
b. Install the piston rings in the following order. Refer to Figure 12. (1) Oil ring (2) 2nd. compression ring (3)1 st compression ring
I st
2 st
CE
oil
Figure 12. Installing Piston Rings.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 006 03 4. ENGINE INTERNAL PARTS 4.1 Reassembly Steps Refer to Figures 13, 14, and 15 for the corresponding step number and part. Legend for Figures 13, 14 and 15
(12) Oil Pipe Oil Strainer Oil Pan Tappets Cylinder Head Gasket Cylinder Head Assembly Push Rods Rocker Bracket Assembly Engine Hangers (8-2) (9) (10) (11) Timing Gear Case Flywheel Housing Flywheel Crank Pulley
(1) (2) (3) (4) (5) (6) (7) (8-1)
Crankshaft
(13)
Piston Assembly
(14)
Rear Seal Retainer

(15)
Camshaft
(16)
Cam Gear
(17)
Idler gear and Shaft

(18)
Oil Pump Assembly

(19)
Front Plate
(20)
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 006 03
r-- - - - - - - - - - - - - I
i
I
I Figure 13. Engine Internal Parts (1).
ii
me~
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03
(20)
~(18)
tJ"
{41)\(17)
115)
(161
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 006 03
(8-1) (8-2)
11
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03

4.1.1 Crankshaft Bear ng Refer to Figure 16. Note that there is an oil hole and an oil groove in the upper bearing (on the block side), but not in the lower bearing (on the bearing cap side). Fit the bearing tang firmly into the slot machined on the cylinder body bearing arches. 4.1.3 Crankshaft Bearing Cap a. Lubricate the bearing cap bolts with engine oil. b. Install the bearing caps to the crankshaft. The arrow mark must be pointing to the front of the engine. c. Tighten the bearing cap bolts to the specified torque, a little at a time, in the numerical order shown in Figure 18.
Aro
ark
Front
Figure 16. Crankshaft Bearing. 4.1.2 Crankshaft and Bearing Refer to Figure 17. Lubricate the bearing with engine oil, install the crankshaft, and install the thrust bearings with the groove facing the crankshaft.
Figure 18. Crankshaft Bearing Cap and Bolt.
| cap bolt torque . Chc tha th
Crankshaft bearing
18.5 - 9.5 kg-m (61 - 69 lb-ft)

I rnsattrssotl ymnal
d. Check that the crankshaft turns smoothly by manually rotating it. 4.1.4 Piston and Connecting Rod a. Before installing the pistons, position the rings as shown in Figure 19, making sure the ring gaps are away from the thrust side.
Thrust bearing
I St
.- u F
2 st
oil
Figure 19. Positioning of Piston Rings. Figure 17. Crankshaft and Bearings.
12
T.O. 38G1-127-1 TM1-281 5-262-13&P SWP 006 03 b. Lubricate the piston, the piston rings, and the connecting rod bearings with engine oil. c. Position the piston front mark toward the front of the engine. Refer to Figure 20.
Special tool
Note After installation, confirm that the crankshaft rotates smoothly. 4.1.5 Installation of Retainer a. After applying engine oil to the lip of the oil seal, install the retainer. Apply sealant. b. Tighten bolts on the retainer to the specified torque in the order as shown in Figure 22.
Front mark
Figure 20. Installing Piston in Cylinder Bore. d. Use the piston ring compressor to compress the piston rings.
Piston ring compressor p/n 5-8840-9018-0
(Do2
e. Use a hammer grip to push the piston in until it makes contact with the crank pin. f. At the same time, rotate the crankshaft until the crankpin reaches its highest point. g. Set the bearing cap cylinder number marks and the connecting rod cylinder number marks. Refer to Figure 21.
Figure 22. Seal Retainer Bolt Tightening Sequence..
Tightening torque 4.1.6 Camshaft Assembly
7.5 - 8.5 kg-mr (54 - 61 lb-ft)
a. Apply engine oil to the inside of the bearing of the cylinder block, and then install the camshaft assembly. Note When installing the assembly, care should be taken not to damage the bearing. b. After installation of the snap ring to the outside of the front bearing, check to see if the camshaft rotates smoothly. Refer to Figure 23.
4.1.7 Cam Gear and Sleeve
a. Install the cam gear to the camshaft so that the timing

Figure 21. Connecting Rod Cylinder No. Marks.. h. The marks must be facing the injection pump side. Connecting rod bearing cap bolts I Tightening torque | 7.5 - 8.5 kg-m (54 - 61 lb-ft)i I Tightening Torque 7.0 - 9.0 kg-m (51 - 65 lb-ft) point (a dot mark "*") comes to the front side. Refer
to Figure 24.
b. With the flyweight installed, tighten the cam gear with a lock nut.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 006 03
Figure 23. Camshaft Bearing Retaining Ring.
Figure 25. Idle Gear.
Cam gear Timing point

Sleeve
I~~~f I
~ ~ly nut ~~~~~Lock
weight
Figure 24. Cam Gear and Sleeve. c. Apply engine oil to the shaft of the sleeve and the slide of the flyweight. d. With the lip of the sleeve placed in the cavity of the flyweight, insert the shaft of the sleeve into the tip end of the camshaft. Note Check to see if the sleeve moves smoothly. 4.1.8 Idle Gear a. Install the idler gear shaft with the oil hole facing upward. Refer to Figure 25. b. Lubricate the shaft with oil. c. Install the idler gear. d. Align the timing marks as shown in Figure 26. e. Install the thrust collar and tighten the bolts to the specified torque.
Figure 26. Camshaft Timing Marks.
Tightening Torque 4.1.9 Oil Pump Assembly
2.1 - 3.1 kg-m (15.2 - 22.4 lb-ft)
Install the oil pump to the front plate. Refer to Figure 27.
A0
Front plate
A& 1A
Figure 27. Front Plate with Oil Pump Assembly.
Tightening Torque |
0.8 - 1.2 kg-m (6 -9 lb-ft)
14
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 006 03 4.1.10 Frnt Plate Apply liquid gasket to the front plate incorporated with the oil pump before installing it to the cylinder block. Refer to Figure 28. b. Put the link plate of the governor incorporated in the gear case through the connecting hole of the injection pump in advance. c. Apply engine oil to the bushes provided on both ends of the main spring lever of the governor. d. Apply sealant to the gear case, and then install it to the front plate.
0 nt plate
(with PTO)
gear case
Figure 28. Front Plate.
I Tightening Torque |
1.9 - 2.9 kg-m (14 - 21 lb-ft)
4.1.11 Front Oil Seal Install the front oil seal to the timing gear case. Installation is made according to the "L" dimension shown in Figure 29. Figure 30. Timing Gear Case.
Front oil seal
Timing gear case
Case tightening torque
[I
l
1.9 - 2.9 kg-mr (14 - 21 lb-ft)
e. Assemble the gasket and the governor cover to the top of the gear case. Then tighten them to the specified torque.
Cover tightening torque 0.8 - 1.2 kg-m (6 - 9 lb-ft) l l
Figure 29. Front Oil Seal.

4.1.13 Flywheel |
~ousing
'L' dimension
1 40.2 - 40.8 mm (1.582 - 1.606 in.) I
Refer to Figure 31. Install the flywheel housing to the cylinder body.
Refer to Figure 30. 4.1.12 Timing Gear Case with GoveMror a. Install the timing gear case to the front plate.
| Tightening torque 4.2 - 5.6 kg-mr (30 - 40 lb-ft)
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 006 03
Figure 31. Flywheel Housing. 4.1.14 Flywheel Lubricate the bolts with any grade of engine oil., Tighten a little at a time in the sequence shown in Figure 32. a. Install the oil pipe from the oil pump assembly to the cylinder block and tighten the sleeve nuts. b. Install the oil strainer to the oil pump. Then tighten the bracket of the strainer to the No. 2 bearing cap. Refer to figure 34.
To 2nd bearing cap
i
Figure 33. Crank Pulley Installation.
I
Figure 32. Flywheel Bolts.
Oii strainer
Oil pipe
Figure 34. Oil Pipe and Oil Strainer.
Tightening torque
9.0 - 11.0 kg-m (65 - 80 lb-ft)
Tightening torque
1.9 - 2.9 kg-m (14 - 21 lb-ft)
4.1.15 Crank Pulley
4.1.17 Oil Pan

a. Lubricate the lip of the front seal with any grade of engine oil. b. Install the crank pulley, lock the crankshaft and tighten the front bolt. Refer to Figure 33. Tightening torque Refer to Figure 35. a. Apply type TB1207C sealant (see WP 003 00, Table 2) to the oil pan. b. Install the oil pan to the cylinder block and tighten fixing bolts evenly. | Tightening torque | 0.8 -1.2 kg-mr
17.0 - 19.0 kg-m
4.1.16 Oil Pipe and Oil Strainer
~~~~~~~~~~~(6 -9 lb-ft)
16
T.O. 38G1 -127-1 TM1-281 5-262-1 3&P SWP 006 03
Figure 35. Oil Pan.. Figure 37. Cylinder Head Bolt Tightening Sequence. 4.1.18 Tappet and Head Gasket 4.1.21 Rocker Arm Bracket Assembly a. Install the tappet to the cylinder block. b. When installing the head gasket, turn up the stamp mark of the parts number (last 4 digits), which is between the No. 2 and No. 3 cylinders of the gasket. Refer to Figure 36. a. Apply liquid gasket to the bottom of the rocker arm bracket assembly (see Figure 38), being careful not to get any in the groove around the oil gallery as shown in Figure 39.
Parts number (Last 4 digits) Stamp mark position
Figure 36. Head Gasket. 4.1.19 Cylinder Head Assembly a. Lubricate the bolts with any grade of engine oil. b. Tighten the bolts in the sequence shown in Figure 37 to the specified torque. BOLT SIZE TIGHTENING TORQUE
Rocker arm bracket
Figure 38. Rocker Arm Bracket Assembly.
M12 x 1.5
(8 each) M8 x 1.25 (4 each) 4.1.20 Pushl Rod Install the push rods.
8.5 - 9.5 kg-m (61 - 69 lb-ft)
600 - 900
2.5 - 3.5 kg-m (18 - 25 lb-ft) Figure 39. Rocker Bracket Oil Gallery.
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 006 03 b. Install the rocker arm bracket assembly making sure the push rods align with the rocker arms and tighten to the specified torque.
Refer to SWP 005 03, paragraph 1 for the valve adjustment procedures. 4.1.23 Front Hanger and Rear Hanger
Tightening torque
0.8 - 1.2 kg-m (6 - 9 lb-ft)
Tighten the front and rear hanger mounting bolts to the specified torque shown below. Refer to Figure 40. | Tightening torque | 1.9 - 2.9 kg-m (14 - 21 lb-ft) |
4.1.22 Adjustment of Valve Clearance

Rear hanger
5. EXTERNAL PARTS REASSEMBLY 5.1 RIGHT HAND SIDE EXTERNAL PARTS

Figure 41 shows the assembly sequence for the external parts on the right hand side of the engine.
hanger
Legend for Figure 41: (1) Dipstick Oil Filter
Figure 40. Installing Lifting Hangers.
(2)
(5)
(3)
12) (4)
(1)
Figure 41. Right Hand Side External Parts.
T.O. 38GI-127-1 TMI-2815-262-1 3&P SWP 006 03

Legend for Figure 42: Legend for Figure 41: (9) (3) (4) (5) (6) (7) (8) Injection Pump (10) Thermostat and Water Outlet Pipe Injection Pump Housing Cover (11) Cylinder Head Cover Fuel Pipe (12) Exhaust Manifold Leak Off Pipe (13) Starter Fuel Hose (14) Generator Injection Pipe (15) Fan Pulley Water Pump
5.2 LEFT HAND SIDE EXTERNAL PARTS

Figure 42 shows the assembly sequence for the external parts on the LEFT hand side of the engine.
(16) Fan Belt (17 Cooling Fan
(10)
(11)
(16)
(9)
(13)
Figure 42. Left Hand Side External Parts.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03 5.3 DETAIL REASSEMBLY INSTRUCTIONS
5.3.1 Dipstick and Oil Filter Cartridge Refer to Figure 43. c. Install a new shim with the same thickness as the one that was removed. (Refer to SWP 005 03, paragraph 4, on shim selection.) Refer to Figure 45. b. This will center and hold the control link for the installation of the injection pumps.
Injection pump ASM
Shim
Cylinder block
Figure 43. Oil Filter Cartridge and Dipstick. Figure 45. Installing Injection Pump and Shim. a. Insert the dipstick. b. Apply engine oil thinly to the gasket of the cartridge. c. Screw in the cartridge until the gasket comes into contact with the seal, and then tighten it by giving it about 3/4 turns. d. Install the cartridge with a filter wrench (commercially available). Filter wrench 5.3.2 InijctionPinnmp a. Align the two (2) holes in the fuel cut lever and the governor and lock into place with a pin (6 0 mm). Refer to Figure 44. p/n 5-8840-9015-0 d. Install the injection pump, making sure the rack in is in the groove of the control rack before tightening the injection pump to the specified torque. I Tightening torque
1.9- 2.9 kg-rn
(14- 21 lb-ft)
f. Remove the rack pin (6 0 mm), which is inserted into the fuel cut lever. Then confirm that the fuel stop lever moves smoothly. Refer to Figure 46.
Injection pump center position
Fuel cut lever pin
Control link
(6 # I
Figure 46. Injection Pump Control Link. 5.3.3 Tijection Pump Housing Cover After applying sealant (TB1207C) to the housing cover, install it to the cylinder block by the side of the injection pump. Refer to Figures 47 and 48. Tighten the bolts to the specified torque.
Figure 44. Fuel Stop Lever.
20
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03
Figure 47. Injection Pump Housing Cover. Figure 49. Fuel Stop Solenoid Installation.
Housing cover Apply portion of sealant
Solenoid ASM
Installed surface surface , of sealant
(Apply
~~~~~ T
About 4mm in width around the bolt hole. from the cover edge
Screw thread Avoid the application'A ) ( of sealant Figure 50. Applying Sealant to Solenoid.
Figure 48. Applying Sealant to Housing Cover.
Tightening torque |
0.8 - 1.2 kg-m (6 - 9 lb-ft)
5.3.5 Fuel Pipe and Leak Off Pipe a. Install the fuel pipe to the injection pump. Then tighten it to the specified torque. Refer to Figure 51. b. Install the leak off pipe to the nozzle holder. Then tighten it to the specified torque.
Note The areas of the housing cover to which liquid gasket is applied are about 4 mm (0.16 in.) in width from the cover edge and about 2 mm (0.08 in.) around the bolts. 5.3.4 Solenoid Assembly a. Apply sealant (TB 1207C) to the surface (bite groove) in which the solenoid is installed. Refer to Figures 49 and 50. Note Avoid the application of sealant to the screw thread. b. Screw in the solenoid from the rear of the cylinder block (the rear of the No. 4 injection pump rack). Then tighten it to the specified torque.
Leak off pipe
~Fuel
%Nozzle holder
pipe
Fuel hose
I~~~~~~~~~
pump
Figure 51. Fuel Pipes.
Tightening torque 1
1.5 - 2.5 kg-m (11 - 18 lb-ft)
I
21
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 006 03

TIGHTENING TORQUE Fuel pipe Leak off pipe 2.0 - 2.5 kg-m (14 - 18 lb-ft) 2.5 - 3.5 kg-m (18 - 25 lb-ft)
Note When tightening the pipe, hold it securely by hand so that it will not rotate. c. Connect the fuel pipe and the leak off pipe with the fuel hose and fix them with clips.
Figure 53. Water Pump Assembly. 5.3.8 Thermostat and Water Outlet Pipe
5.3.6 14jction lie=

Install the injection pipe to the injection pump and the nozzle holder and tighten them with sleeve nuts. Refer to Figure 52. Assemble the thermostat and install the gasket and the water outlet pipe (see Figure 54). Then tighten it to the specified torque.
Injection pipe
.ozeholder
Injection pur
Figure 52. Injection Pipe.
Figure 54. Thermostat and Water Outlet Pipe.
Tightening torque
1.5 - 2.5 kg-m (11 - 18 lb-ft)
I Tightening torque |
1.9 - 2.9 kg-m (14 - 21 lb-ft)
Note Set thread of the sleeve nut securely before tightening it. 5.3.7 Water Pump Assembly Refer to Figure 53. a. Put sealant on the water pump where it contacts the block and head. b. Tighten to the specified torque. I Tightening torque | 1.9 - 2.9 kg-m (14 - 21 lb-ft) I
5.3.9 Adjustment of Valve Clearance Refer to SWP 005 03, paragraph 1 for the valve adjustment procedures. 5.3.10 Cylinder Head Cover Refer to Figure 55. a. Install the gasket to the cylinder head cover. Note Much care should be taken for the gasket not to get dislocated or twisted when installing the head cover. Avoid the application of sealant to the rubber gasket.
22
T.O. 38G1-127-1 TM1-281 5-262-1 3&P SWP 006 03
Figure 55. Cylinder Head Cover. b. Install the cylinder head cover to the rocker arm bracket and tighten it to the specified torque. I Tightening torque | 5.3.11 Air Inlet Pipe a. Apply sealant (TF1207C) to the surface in which the air inlet pipe is installed. b. Install the air inlet pipe to the cylinder head cover and tighten it to the specified torque. Refer to Figure 56.
Cylinder head cover
Figure 57. Exhaust Manifold. 5.3.13 Starter Install the starter to the flywheel housing and tighten itto the specified torque. Refer to Figure 58.
0.2 -0.4 kg-m (1.4 - 2.9 lb-ft)
Figure 58. Starter.

Air inlet pipe
Tightening torque|
9.5 - 11.5 kg-m (68.7 - 83.2 lb-ft)
5.3.14Generato Refer to Figure 59. Figure 56. Air Inlet Pipe.
I Tightening torque 1 5.3.12 Exhaust Manifold
0.8 - 1.2 kg-m (6 - 9 lb-ft)
Assemble the gasket to the cylinder head, install the exhaust manifold along the stud bolts and tighten it to the specified torque. Refer to Figure 57, I Tightening torque 1.9 -2.9kg-rn (14 -21 lb-ft)
I
.
Figure 59. Generator.
23
T.O. 38G1 -1 27-1 TM1-2815-262-1 3&P SWP 006 03 a. Tighten the adjust plate together with the water pump. Then install them temporarily. b. Install the bottom of the generator to the timing gear case. Then tighten it temporarily with bolts and nuts. - c. Install the fixing bolts onto the top of the generator through the adjusting plate. (Temporary tightening.) 5.3.15 Fan Pulley And Fan Belt a. Install the fan pulley to the water pump and then tighten. (2 locations.) Refer to Figure 60. Deflection amount. (Press the belt at
its center between the pulleys with 10 Ig (22 lbs.) force.)
0.8 - 1.2 kg-m

(6 - 9 lb-ft)
BOLT LOCATION Generator upper Generator lower Adjusting plate
TIGHTENING TORQUE 1.9 - 2.9 kg-m (14 - 21 lb-ft) 3.5 - 4.7 kg-m (25 - 34 lb-ft) 1.9 - 2.9 kg-m (14 - 21 lb-ft)
5.3.17 Cooling.Fan
Refer to Figure 62.
Figure 60. Fan Pulley and Fan Belt. Figure 62. Cooling Fan. a. Assemble the spacer before tightening the cooling fan. b. Tighten it to the specified torque. (4 locations)
Tightening torque 1
0.8 - 1.2 kg-m (6 -9 lb-ft)
b. Set the fan belt to each pulley. 5.3.16 Fan Belt Tension Adjust the alternator as specified and tighten to the specified torque. Refer to Figure 61.
Tightening torque
1.9 - 2.9 kg-m (14 - 21 lb-ft)
Figure 61. Tensioning Fan Belt.
24
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 007 00
WORK PACKAGE ENGINE LUBRICATING SYSTEM


Total number of pages in this WP is 4
Page No. 1-4 . Change No. 0 Page No. Change No. Page No. Change No
TABLE OF CONTENTS
paragraph
Foreword ......................... Safety Summary ......................... 1. 2. 2.1 Lubricating Oil Circulation System ........... Oil Pump . .........................
pap
2 2 4 4 4
Inspection and Replacement .................
Eiugn 1 2 E Lubricating Oil Circulation Diagram .......... Oil Pump .......... ............... 3 4
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 007 00
FOREWORD
This Work Package (WP) contains instructions for inspectiong and replacing the lubricating oil pump in the diesel engine used on the SGNSC.
SAFETY SUMMARY
There are no specific safety related issues in this WP. General shop safety practices should be observed when performing any procedures in this WP.
T.O. 38G1-127-1 TMI-2815-262-1 3&P WP 007 00
Valve opening pressure lkg/cm 2 (14.0 PSI)
Olftr
|Connecting rod ||G
, -1 Injectionpmp -.
* :I
S ::
II
I
I
l I
a:5
a ----| ~Volvo stem end|

I
:
L.. S~~
Piston
:
* *
.
II
~ ~
II
II~~~~~~~~~~~ I -i I I~~~~~~~~~~~ W.~~~~~~~~~~~
~~~~~~~~~~~* a
i
II
II w Oil pan -- Pressure feeding

, Non pressure feeding
---------------
Figure 1. Lubricating Oil Circulation Diagram.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 007 00

Front plate (Body; integral structure)
Pin Rotor; outer Rotor; inner
0dring _
Relief valve
Oil pump
Figure 2. Oil Pump. 1. LUBRICATING OIL CIRCULATION SYSTEM Figure 1 shows a schematic diagram of the lubricating system on the engine. 2. OIL PUMP 2.1 Inspection and Replacement When there is wear, damages or any other defects found, repair or replace the rotor. Clearance between the outer rotor or inner rotor and the pump cover Clearance between the periphery of the outer rotor and
the pump body

STANDARD LIMIT |
0.10-0.185 mm (0.0039-0.0073 in.) 0.15 mm (0.0059 in.) Clearance between the inner rotor and the outer rotor
STANDARD
LIMIT
STANDARD
LIMIT
0.040-0.085 mm (0.0016-0.0033 in.) 0.15 mm (0.0059 in.)
T.O. 38G1 -1 27-1 TM1-2815-262-13&P WP 008 00
WORK PACKAGE ENGINE COOLING SYSTEM


Page No. 1-5 .. 6 Blank ... Change No. 0 0 Total number of pages in this WP is 6 Page No. Change No. Page No. Change No
TABLE OF CONTENTS
Paragraph Foreword ............................... Safety Summary .......................... 1. 2. 2.1 2.2 2.3 3. 3.1 Cooling Water Circulation System ............ Water Pump ............................. Disassembly ............................. Reassembly .............................. Clearance, Play and Tightening Allowance Between Parts ........................... Thermostat ............................ PE=
2 2
4 4 4 4
5 5
Inspection and Replacement ................. 5
Eig 1 2 3 4 5 6 7 8 Water Pump ............................ Fan Hub and Pump Cover................... Bearing and Impeller ....................... View of Bearing Unit and Alignment Holes View of Impeller and Seal Unit ....... PA= Cooling Water Circulation System Diagram .... 3 3 4 4 .... 4
....... 4
View of Pump Cover ...................... 5 Thermostat .............................. 5
T.O. 38G1-127-1 TMI-2815-262-1 3&P WP 008 00
FOREWORD
This Work Package (WP) contains procedures for inspecting and overhauling the cooling water circulating pump on the diesel engine used on the SGNSC.
SAFETY SUMMARY
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 008 00
Radiator
Water pump
Figure 1. Cooling Water Circulation System Diagram.
Seal unit
Fan center
Cover
Figure 2. Water Pump.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 008 00 1. COOLING WATER CIRCULATION SYSTEM

Figure 1 shows a diagram of the engine coolant circulation system. Figure 2 shows an exploded view of the water pump.
2.2 Reassembly
2.2.1 Bearing Unit With a hole in the bearing unit set in line with one in the body, lock the bearing unit with a setscrew. Refer to Figure 5.
2. WATER PUMP
2.1 Disassembly 2.1.1 Fan Center and Cover a. Loosen the setscrew. Refer to Figure 3.
~A$ Body
7 4)-WSetscrew
Figure 5. View of Bearing Unit and Alignment Holes.
Figure 3. Fan Hub and Pump Cover. b. Remove the cover. Note The cover is applied with sealant (TB 1207B). When removing the cover, much care should be taken not to deform it by applying an excessive force to it. 2.1.2 Impeller, Seal Unit and Bearing Unit Remove the impeller, seal and bearing unit from the pump housing. Refer to Figure 4.
Set screw tightening torque | 2.2.2 Seal Unit And Impeller
(6 - 9 lb-t)
a. Apply BELCO bond No. 4 to the surface where the seal unit comes into contact with the body, and then assemble the seal unit. b. Press in the impeller with a press until the clearance between the pump impeller and the body gets to the specified value (see paragraph 2.3).
Impeller
0t
Seal unit
Figure 4. Bearing and Impeller.
Figure 6. View of Empeller and Seal Unit.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 008 00

2.2.3 Cover
Thermometer
a. Apply liquid gasket (TB1207B) to the surface to which the cover is installed. Then install the cover. Refer to Figure 7.
Agitating rod
Thermostat
Cover
Wooden piece
Figure 8. Thermostat.
Figure 7. View of Pump Cover. b. Apply Loctite No. 262 to the cover installation screws. Then tighten them.
2.3 Clearance, Play and Tightening Allowance Between Parts

Clearance between the pump impeller and the body
Standard
0.53 - 2.17 mm (0.0209 - 0.0854 in.)I
in the water nump ball bearina
STANDARD
0.008 -0.010 mm (0.0003 - 0.0004 in.)
LIMIT
0.2 mm (0.0079 in.)
--
Tightening allowance between the fan center and the bearing shaft
Standard | 0.26 - 0.061 mm (0.001 - 0.0024 in.)
3. THERMOSTAT 3.1 Inspection And Replacement

Replace the thermostat when there is wear, damages or any other defects found. Refer to Figure 8 Opening temperature 74.50 - 78.5 0C (1660 - 174 0F)
Valve lift
I
_______________
8 mm or more at 90'C
(0.312 in. or more at 1940F) I
51(6 blank)
T.O. 38G1-127-1 TM1-2815-262-1 3&P

WP 009 00
WORK PACKAGE ENGINE FUEL SYSTEM


TABLE OF CC )NTENTS
Paragrah Foreword .............................. Safety Summary .......................... 1. 2. 2.1 2.2 Fuel Circulation System .................... Governor .............................. Reassambly of Control Lever Related Parts ..... Reassembly of Shifter ...................... R=g 2 Paragrophb 2.3 2.4 2.5 3. 4. Reassembly of Governor Cover ....... Reassembly of Full-Load Stopper ........... Reassembly of Governor Related Components ............................ Nozzle Holder Assembly .................. Nozzle Assembly ........................ ...... 9 10
11
2 4 4
6 8
12 12
LIST OF ILLUS ,TRATIONS

Eigre PI Governor Cover .......................... View Z-Z From Figure 6 ......... Full-Load Stopper ....................... Governor Lever Related Parts ....... Nozzle Holder Assembly and Fuel Piping .... Inspecting Nozzle Body and Needle Valve .... 9 .......... 9 10 1 11....... 12 12
1
2 3 4 5 6
Fuel Circulation System Diagram ...... Structural Drawing of Governor (1) ...... Structural Drawing of Governor (2) ...... Control Lever Related Parts ........
...... 3 ..... 4 ..... 5 ......... 6 7
7 8 9 10
Assemblying Control Lever to Governor ...... Governor Shifter Assembly .................
11
12
T.O. 38G1-127-1 TM1-281 5-262-1 3&P WP 009 00
FOREWORD
This Work Package (WP) contains procedures for inspecting, overhauling and replacing components in the diesel engine used on the SGNSC. The procedures are included for the governor and related components, and for the injection nozzles.
SAFETY SUMMARY
T.O. 38G1 -1 27-1
TM1-2815-262-1 3&P
WP 009 00
1I
Nozzle holder Injection pump
Nozzle
Fuel filter
Figure 1. Fuel Circulation System Diagram.
T.O. 38G1 -127-1 TM1-2815-262-1 3&P

WP 009 00
1. FUEL CIRCULATION SYSTEM Figure 1 shows a diagram of the engine fuel circulation system. 2,GOYERNOR a. The adjustments of the governor-related parts require the engine performance test.
b. Before disassembling the governor, measure the dimensions "A" and "B" given in the structural drawing to ensure the same dimensions in reassembly. Refer to Figures 2 and 3. c. Do not disassemble the governor when the performance test cannot be conducted after reassembly.
Idle speed screw
Governor shaft
< Set
spring
Injection pump _Governor cover - Guide lever % Timing gear case

-
Tensioner lever
kngleich
Full load stopper
Figure 2. Structural Drawing of Governor (1).
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 009 00

Start spring
Figure 3. Structural Drawing of Governor (2).
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 009 00 2.1 Reassembly of Control Lever Related Parts Refer to Figure 4. a. Put the lever (main spring) through the hole of the timing gear case lever. Note Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case lever, respectively. c. Assemble the bushes. Assemble the bush of the lever (main spring) first, and then the control lever bush. Note When assembling the bushes, apply Loctite No. 601 to the periphery of the bushes. d. Hook both ends of the return spring (control lever) securely to the protrusion and the pin of the lever (main spring), respectively. b. Pit the return spring of the control lever through the shaft of the lever (main spring).
Lever; Main spring Bush
Apply Loctite No.601 \ to the periphery
Protrusion
Return spring Timing gear case
Bush (( Apply Loctite No.601 to the periphery
Figure 4. Control Lever Related Parts.
T.O. 38G1-127-1 TM1-281 5-262-1 3&P

WP 009 00
Control lever
O-ring
Bush
Washer
Spring washer Nut
Figure 5. Assembling Control Lever to Governor.

e. Assemble the control lever (see Figure 5). f. Assemble the O-ring to the groove of the bushes (control lever) first; then assemble the washers and the control lever before tightening up the control lever with a nut.
Control lever tightening torque
1.2 - 1.8 kg-m (9 -13 lb-ft)
Note Tighten the control lever after locking the control lever firmly. (Do not tighten the control lever after locking the main spring lever.) After assembly, confirm that the control lever moves smoothly.
T.O. 38G1-127-1 TM1-2815-262-1 3&P

WP 009 00
2.2 Reassembly of shifter

a. Assemble the shifter to the guide lever, put the shaft through it, and assemble the snap ring (see Figure 6).
b. After assembly, confirm that the shaft moves smoothly.

c. Also, confirm that the shifter shakes smoothly.
Guide lever
Shifter
Snap ring
Shaft
Figure 6. Governor Shifter Assembly.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 009 00 [Stopl Governor cover Governor (Bent-up part) .\ Retun . I [Operate]
Shaft
Figure 7. Governor Cover. 0, Cap I Cap nut

/
M
2.3 Reassembly of Governor Cover

a. Assemble the related parts such as the fuel stop lever and the idle spring to the governor cover. Refer to Figure 7. b. When assembling the shaft, apply engine oil to the sliding portion with the governor cover. c. Set both ends of the return spring securely to the notched groove at the bottom of the cover and the bent-up arm of the lever, respectively. d. After reassembling the governor cover, confirm that the governor moves smoothly. e. When assembling the timing gear case to the governor cover, tighten the "A" dimension shown in the illustration to 2 - 3 mm (.079 - .118 in.), temporarily. The parts shown in the rectangle indicated by (*) in Figure 8 are assembled after the performance test.
Packing
-,
Lock nut
ase (t)
I A M IN 0
Gasket
r7L er
N0, I
Idle screw
Governor lever
*
C
Washer/f
Tensioner lever Idle spring
it
Washer
"A" dimension
(When assembly temporarily) 2 2-3mm(0.079-0..118 in.)
Snap ring
(Z view of the drawing above) Figure 8. View Z-Z From Figure 6.
T.O. 38G1-127-1 TM1-2815-262-1 3&P

WP 009 00
2.4 Reassembly of Full-Load Stopper Install the full-load stopper to the timing gear case; then tighten it with a nut temporarily. Refer to Figure 9.
'-
Timing gear case
Full load stopper
- Nut; setscrew
Figure 9. Full-Load Stopper.
10
T.O. 38G1 -127-1 TM1-2815-262-1 3&P

WPOO9 00 2.5 Reassembly of Governor Lever Related Components Assemble each lever and spring to the timing gear case (see Figure 10). 2.5.1 Notes When Assembling Governor Related Componenlts
b. Install the set spring securely to the groove of the pin, connecting the floating lever, with much care to its assembling direction. c. Confirm that each lever moves by its dead weight before installing the start spring. d. After assembly, confirm that each lever moves smoothly. And also confirm that each spring operates properly.
a. When assembling components, apply engine oil to each slide (such as the end face of the lever, the hole in the shaft, and the periphery of the shaft).
Figure 10. Governor Lever Related Parts.
11
T.O. 38G1-127-1 TM1-2815-262-1 3&P

WP 009 00
)era HHeat shield Gasket
Figure 11. Nozzle Holder Assembly and Fuel Piping.
3. NOZZLE HOLDER ASSEMBLY

Disassembly of the nozzle holder assembly is shown in Figure 11.
them thoroughly (see Figure 12). Then check to see if the valve moves smoothly in the body. If it does not move smoothly, repair or replace the nozzle.
4. NOZZLE ASSEMBLY
4.1 Inspection and replacement Place the removed nozzle in the clean light oil, disassemble it into the nozzle body and the needle valve, and clean
4.2 Adiustment of Inlection Pressure

For the adjustment of the injection pressure and the spray condition of fuel, refer to Subordinate Work Package SWP 005 03 "ENGINE MAINTENANCE".
Figure 12. Inspecting Nozzle Body and Needle Valve.
T.O. 38G1-127-1 TM1-2815-262-1 3&P WPO10 00
WORK PACKAGE ENGINE TROUBLESHOOTING CHARTS

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LE1PW14

TABLE OF CONTENTS
Paragp 1. Troubleshooting Charts ..................... Pa 2
LIST OF TABLES
iTahoi 1 Car Engine Trouble Shooting Charts........2
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP010 00 1. TROUBLESHOOTING CHARTS

The following charts describe some problems that may occur and the logical steps for solving those problems. Also see T.O. 35D29-7-6-1/TM1-3655-230-12, WP 006 00, Table7.
Table 1. Engine Trouble Shooting Charts (Sheet 1 of 5).
7r l
Defective starter (Bring It to a specialty shop for repair)
* Note: 'Bring it to a specialty shop' means that defective parts of the injection pump and electricals must be brought to a specialty shop for repair. (This note Is applicable to all the following procedures.)
T.O. 38G1 -127-1 TM1-2815-262-1 3&P

WP010 00 Table 1. Engine Trouble Shooting Charts (Sheet 2).
Defective Ivalve return I (Adjust) i
!clogging or bending
Check high pressure pipe for cracking.
Defective injection pump (Bring it to a
specialty shop for

repair)
Defective injection pump (Bring it to a specialty shop for repair)
Defective injection pump (Bring it to a specialty shop for repair)
T.O. 38G1-127-1 TM1 -2815-262-13&P WP010 00 Table 1. Engine Troubling Shooting Charts (Sheet 3).
Insufficient output
Fuel system
i
i Mechanical system I
Check fuel for air1 I mixing I
air
Check fuel filter or fuel hose for clogging
Clogged '(Cleanor' Replace)
Check high I ipressure pipe for
! bending
clogging or
T.O. 38G1 -127-1 TM1-2815-262-1 3&P WPO10 00

Table 1. Engine Trouble Shooting Charts (Sheet 4).
Air cleaner clogged
* Replace air
OK
cleaner element:
Check air hose for crash
I.
Low I
l
ItOK
.r Pshop Excessive
as bakfo valve and asket (Repai
Defective injection pump r (Bring it to a specialty for repair)
Check up andI down u

movement of oil
blow-by gas:
|Stuck (Overhaul
| I
Abnormal
Bring it to a battery shop
T.O. 38G1 -127-1 TMI-2815-262-1 3&P WPO10 00

Table 1. Engine Trouble Shooting Charts (Sheet 5).
Oil pressure too low

Check oil level Low (Replenish) OK
iil consumption too much

Check for oil leakage Leaking (Retighten. replace packing seal) Check nozzle
r-
*pii consumption too muchl

l
II Check for oil leakage

Leaking (Retighten. replace packing seal) Check oil quality
I
OK
_
OK
Check cooling water temperature High (See 'Overheat') Check oil in crankcase
|
OK Defective (Repair or replace)

Ch-ck njection timing Abnormal (Adjust)
Poor quality (Changeto specified oil) Check bleeder for clogging Clogged (Clean) i
_7
Improper viscosity
!K
O7K
Water or fuel mixed. Check fuel system and cooling system Check relief valve Defective (Repair or replace) 1. 2. 3. 4. Oil pump malfunction Loosened or cracked pipe Wear of sliding part Oil pump clogged {Overhaul) OK
Check compression ratio Low OK
lCheck up and down movement of oill .1. Oil pump malfunction
Defective injection pump, I1ring it to a specialty I shop for repair) Excessive blow-by gas Gas leak from valve and gasket (Repair or replace)
I 3.
,4.
2. Loosened or cracked pipe Wear of sliding part

Oil pump clogged (Overhaul)
5. Defective valve stem seal () Worn boreand worn or broken ring (Measure compression pressure, and check entrance of dust)
1I
Engine knocking
.
Fuel system
-_-__
Mechanical system
Check up movement of oilI .Oil stained (Overhaul)|
Check injection timing Abnormal (Adjust) Check nozzle Defective (Repair or replace) O| K OK
Check compression pressurei Low OK To fuel system

r
~~~~~~~~~~~~~~~~~~~~~~~~I
Gas leak from valve and gasket (Repair or replace)
Note: Fuel used is of poor quality.
Excessive - blow-by gas {Overhaul) (
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 998 00
WORK PACKAGE ILLUSTRATED PARTS BREAKDOWN


Total number of pages in this WP is 4 Page No. 1-4 . Change No. 0 Page No. Change No. Page No. Change No
TABLE OF CONTENTS
Paragraph 1. 2. 3. 4. 5. 6. 7. 8. 9. General .......................... Supporting Documents ..................... Finding Part Number Using Assembly Name .. Finding an Illustration For a Known Part Number .......................... Table of Contents ......................... List of Illustrations ........................ Maintenance Parts List (SWP 998 01) ........ Maintenance Parts List Arrangement .... Numerical Index (SWP 998 02) .... Page
2
2 2 2 2 2 2 ...... 3 ......... 3
T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 998 00 1.GENERAL

This Illustrated Parts Breakdown (IPB) section lists and describes, in as close to disassembly order as possible, all assemblies and parts of the diesel engine for the Self Generating Nitrogen Servicing Cart (SGNSC), NSN 3655-01-4633338. The engine is manufactured by Isuzu Motors. The part number is 4LEIPW14, NSN 2815-01-470-8023. c. Go to the page determined in step (b). d. Find the index number determined in step (b) on the parts breakdown for the full description of the part. e. Find the index number on the illustration for the location of the part on the assembly.
5. TABLE OF CONTENTS 2. SUPPORTING DOCUMENTS

This IPB amplifies information given in companion handbooks by providing part numbers for items mentioned by description only. The companion handbooks are, T.. 35D29-7-6-ITIMl-3655-230-12 - Operation and Maintenance Instructions T.Q. 35D29-7-6-3TMl-3655-230-30 - Overhaul Instructions T.O. 35D29-7-6-4/TM1-3655-230-23&P - Illustrated Parts Breakdown The table of contents lists the paragraphs and sub-paragraphs of the text portion of the IPB. Also listed are the assemblies illustrated in the IPB. The page numbers represent the page that the parts list for the applicable illustration begins.
6. LIST OF ILLUSTRATIONS
The List of Illustrations on the Maintenance Parts Lists (SWP 998 01) lists the figure number, the description of the illistration and the page where the figure can be located.
7. MAINTENANCE PARTS LIST (SWP 998 011

The Maintenance Parts List, SWP 998 01, lists the parts of the diesel engine. Parts lists are shown on the same page as the applicable illustration or immediately following the applicable illustration. Where possible, the illustration will be on the same page as the applicable parts list or on the left page with the parts list on the facing right page. 7.1 Repair PartKits When repair parts kits are supplied for an assembly, the statement "(Repair kit available)" will follow the description of the applicable assembly. All parts that are included in the kit will have the description indented one position from the applicable assembly and will have an SMR code of KF or KD. The kit part number will follow the last part listed for the applicable assembly and the description will have the same indentation as the applicable assembly. The repair kit will have an SMR code of PAFZZN. The kit will not be illustrated. 7.2 Symbols Used in Parts List The following symbols may be used in the parts list to describe special characteristics for the part number. a. An equal sign (=) preceding the part number one space to the left denotes that the part is an acceptable alternate part for the preceding part number. The part will have the same index number as the preceding part.
3. FINDING PART NUMBER USING ASSEMBLY

NAME When only the name of an assembly in which the part is used is known, the following steps should be used to find the part number of the part. a. Turn to the Table of Contents and find the page number for the parts breakdown of the assembly in which the part is used. b. Turn to the page determined in step (a). c. Locate the part and its index number on the illustration. d. Find the index number on the parts breakdown of the illustration for the part number and complete description of the part.
4. FINDING AN ILLUSTRATION FOR A KNOWN PART NUMBER

When the part number of a part is known, the following steps should be used to locate the illustration of the assembly that it is used on. a. Refer to SWP 998 02, Numerical Index and find the part number. b. Turn to the List of Figures and find the page number for the figure number listed in the Numerical Index for that part.
T.O. 38G1 -127-1 TM1-2815-262-13&P WP 998 00

8. MAINTENANCE PARTS LIST ARRANGEMENT The following sub-paragraphs describe the columnar arrangement for the Maintenance Parts List, SWP 998 01. 8.1 Figure and Index No. Column 8.5 Units Per Assembly Column. The first number (before the dash) refers to the illustration number in the Maintenance Parts List. The second number (after the dash, or find number) refers to the location of the part on the illustration (corresponding find number on the illustration). The first number will only appear on the first entry for the assembly of the applicable parts list and on the first entry of a new page when the parts list is more than one page long. 8.2 Part Number Column 8.6 SMR Code Column. This column contains the Government Standard, vendor and Pacific Consolidated Industries part numbers. 8.3 CAGE Code Column. The Commercial and Government Entity (CAGE) code is a five digit code that is published in H4-1, H4-2 and H4-3 Cataloging handbooks. This code appears in this column. 8.4 Description Column. This column lists the complete description by Government Standard, vendor and drawing title. Abbreviations are per MIL-STD-12. 8.4.1 Indentation System. For proper identification of detail parts and next higher assemblies (NHA), the description listings are in the system of indentation. 1234567 ASSEMBLY DETAIL PARTS FOR ASSEMBLY SUBASSEMBLY DETAIL PARTS FOR SUBASSEMBLY SUB-SUBASSEMBLY ... DETAIL PARTS FOR SUB-SUBASSEMBLY The next higher assembly for any detail part may be determined by locating, in the next column to the left, the first item above the detail in question. For example, if a detail part or subassembly has two leader points (..) preceding its description, the next higher assembly will be the first item above it that has one leader point (.) preceding its description. 8.4.2 Attaching Paits. The numerical index (SWP 998 02) lists all part numbers contained in the Maintenance Parts List. Some part numbers will appear more than once in this list. This is because some assemblies and subassemblies use the same parts. Part numbers appearing with no index number following the dash, are separate breakdowns of subassemblies that appear on the parts list of the next higher assembly and can be located on its NHA's illustration.. Items of a like nature, listed under the same index number, are interchangeable when no code appears in the "Usable The Source, Maintenance and Recoverability (SMR) Codes used in this manual are the Joint Military Services Uniform SMR Codes only. Definitions of the SMR codes are available in T.O. 00-25-195. The codes that appear in this column describe, among other things, the level of maintenance and recoverability for the part or assembly. 8.7 Usable on Code Column. These numbers are the total quantity used in the next higher assembly. The detail parts indented under assemblies indicate only the quantity used on the applicable assembly, and are not necessarily the total quantity used in the generating plant. When "REF" appears in this column, it indicates that the part is shown and listed on another illustration. Refer to paragraph 4 for instructions on locating the illustration for a known part number. Any parts used exclusively for attaching subassemblies or detail parts will immediately follow the applicable part and be indented the same as the part that it attaches to the NHA. The description of the attaching part will be followed by the description "(AP)".
on Code" column opposite such listings. 9. NUMERICAL INDEX (SWP 998 02)
9.1 Part Number Column.

This column lists in alphabetical and numerical sequence,
all Government Standard, vendor and Pacific Consolidated Industries part numbers required to overhaul and maintain the engine. No part numbers are listed unless they appear in the Maintenance Parts List. 9.1.1 Part Number Arrangement. The part numbers are arranged from the extreme lefthand position and continue from left to right, one position at a
T.O. 38G1 -127-1 TM1-2815-262-1 3&P WP 998 00 time. The order of precedence for the first position is as follows, letters A through N and P through Z, then, numerals 0 through 9 Note The alphabetic 0 is considered to be a numeric 0. The second and succeeding characters in the part number have precedence as the following sequence shows, Space, diagonal (/), period (.), dash (-), letters A through N, P through Z, numerals 0 through 9. 9.2 Figure and Index Number Column. This column contains the figure and index number(s) where the part is listed in a parts list and shown on an illustration. The first number is the figure number for the illustration that shows the part. The number following the dash is the index number on the applicable illustration and in the parts list for the applicable illustration. When the figure number is preceded by "F' it indicates that the part number follows the applicable figure and index number in the Maintenance Parts List.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
SUBORDINATE WORK PACKAGE MAINTENANCE PARTS LIST WITH ILLUSTRATIONS

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPWl4

Total number of pages in this SWP is 32 Page No. 1-32 . Change No. 0 Page No. Change No. Page No. Change No
TABLE OF CONTENTS
Pargraph List of Illustrations ......... 1. Maintenance Parts List ....... Diesel Engine Parts List ...... Page ............... 2 .............. 3 .............. 5 7 EPaga Injection Pump Assembly Parts List .... Injection Nozzle Assembly Parts List ........ Starter Assembly Parts List ...... ..... 28 29
.......... 30 31
Cylinder Head Parts List .................... Cylinder Block Parts List ......
Generator Assembly Parts List .............
............. 9 10 13 14 15 17 19 20 21 23 24 25 26
Timing Gear Case Parts List ................ Flywheel Housing Parts List ................ Oil Pan Parts List ........................ Oil Pump Parts List ....................... Crankshaft, Flywheel, Piston and Connecting Rod Parts List ........................ Valve Mechanism Parts List ................ Oil and Fuel Filter Parts List ................ Cooling System Parts List .................. Exhaust System Parts List .................. Fuel System Parts List .................... Engine and Generator Brackets Parts List ..... Injection Pump and Camshaft Parts List ..... Electrical Components Parts List ....
........ 27
T.O. 38G1-127-1 TM1-2815-262-1 3&P

SWP 998 01
Eig=
1 2 3 4 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20
LIST OF ILLUSTRATIONS Ea
Diesel Engine Group Breakdown ...... Cylinder Head, Cover and Other Parts ..... Cylinder Block and Other Parts ....... ....... 4 .... 6 ....... 8
Timing Gear Case and Other Parts (Sh 1 of 2). 10 Timing Gear Case and Other Parts (Sh 2) ..... Flywheel Housing and Other Parts ...... Oil Pan and Other Parts .................... Oil Pump and Fixing Parts ................. Crankshaft, Flywheel, Piston and Connecting Rod .............................. Valve Mechanism, Rocker Arm ....... Oil and Fuel Filters and Fixing Parts ..... 11
..... 13 14 15 16 :.
...... 18 .... 20
Cooling System (Sh 1 of 2) ................. 21 Cooling System (Sh 2) .................... Exhaust System .......................... Fuel System, Injectors and Fuel Pipe ..... Engine and Generator Brackets .............. 22 23 .... 24 25
Injection Pump, Camshaft and Other Parts ..... 26 Electrical Parts ........................... Injection Pump Assembly ......... Injection Nozzle Assembly ......... Starter Assembly ......................... Generator Assembly .............. 27 ......... 28 ........ 29 30 ........ 31
T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 998 01 1. MAINTENANCE PARTS LIST This Maintenance Parts List shows the illustrations and parts lists for all groups and subassemblies of the diesel engine for the Self Generating Nitrogen Servicing Cart (SGNSC), NSN 3655-01-463-3338. The engine is manufactured by Isuzu Motors. The part number is 4LElPWl4, NSN 2815-01-470-8023.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 998 01
(FAR SIDE)
Figure 1. Diesel Engine Group Breakdown.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01 Figure & Index No.
1-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15
Part Number
CAGE 1234567
4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
Description
Units Per Assy
SMR Code
PAFDDT XC XC XC XC XC XC XC XC XC XC XC XC XC XC XC
Usable on Code
4LEIPW14 FIG. 1 FIG. 2 FIG. 3 FIG.4 FIG. 5 FIG. 6 FIG. 7 FIG. 9 FIG. 12 FIG. 13 FIG. 15 FIG. 16 FIG. 18 FIG. 19 FIG. 10
ENGINE, Diesel- 4 cylinder- 54 hp ...... ........... REF CYLINDER HEAD, Cover and other parts ..... ...... 1 . CYLINDER BLOCK AND OTHER PARTS ..... ..... 1 TIMING GEAR CASE AND OTHER PARTS ..... 1.... . FLYWHEEL HOUSING AND OTHER PARTS ........ 1 . OIL PAN AND OTHER PARTS ....... ............. 1 . OIL PUMP AND FIXING PARTS ...... ............ 1 . CRANKSHAFT, Flywheel- piston & connecting rod .... 1 . VALVE MECHANISM, Rocker arm ...... ........... 1 . COOLING SYSTEM, Fan and water pump ..... ...... I . EXHAUST SYSTEM ............................. 1 . FUEL SYSTEM, Injectors and fuel pipe ..... ......... 1 . BRACKETS, Engine and generator .................. 1 . INJECTION PUMP, Camshaft and other parts .... ..... I . ELECTRICAL PARTS .......... .................. 1 . OIL FILTER, Fuel filter and fixing parts (not shown) .... 1
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
SEE FIG 16 SEE FIG 14

16 20E$
lcirX
I-24
23
I4\ SEEFIG
"V SEE
SEE FIG
Figure 2. Cylinder Head, Cover and Other Parts.
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 998 01

Figure & Index No. 2-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 Part Number CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 CYLINDER HEAD, Cover and other parts ..... . HEAD ASSEMBLY, Cylinder ....................... .. CUP, Sealing- d=22. .. CLIP, Sealing- d=44.5. . . PLUG, Drilled passage- d=8. . . GUIDE, Valve exhaust and inlet. .. SEAT, Valve insert- inlet. .. SEAT, Valve insert- exhaust. .. PLUG, Glow .......... . STUD, Rocker bracket. . STUD, Water pump. . STUD, Manifold- 1=79. . SEAL, Valve. . PLUG, Heater- switch- left .I . GASKET, Cylinder head. . BOLT, Cylinder head- 1=25. . BOLT, Cylinder head- 1=89 .10 . COVER ASSEMBLY, Cylinder head .1 . VALVE ASSEMBLY, Ventilator .1 . SCREW, Valve. . CAP ASSEMBLY, Oil filler .1 .. PACKING, Oil filler cap .1 GASKET, Cylinder head cover .1 . BOLT, Head cover. . BOLT, Head cover. Description Units Per Assy ...... REF 1 6 1 5 8 4 4 4 6 1 2 8 1 5 SMR Code XC XB XB XB XB XB XB XB XB XB XB XB XB XB PAFZZN XB XB XB XB XB PAFZZN XA PAFZZN XB XB Usable on Code
FIG.1 897114-7130 109600-0112 109600-0051 511119-0090 897031-7490 897126-1390 897045-3920 897115-3150 897094-6410 904110-8400 509300-0650 894110-5591 509605-0050 897136-3240 894463-7840 897036-9591 897118-2052 894329-5490 903910-4100 894133-2075 894123-6231 897119-2990 028080-6200 028080-6450
5 5
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
Figure 3. Cylinder Block and Other Parts.
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 998 01

Figure & IndexNo. 3-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25, -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 Part Number FIG.2 897169-1920 894167-4701 894229-8530 109600-0112 509600-0130 109600-0121 897047-0560 897047-1421 909664-0010 909204-5100 109605-0040 109605-0190 897118-9891 091150-2060 028080-6140 028080-6200 904110-6160 894343-8960 904110-6160 897102-5501 897039-4953 908160-8160 911229-0581 908160-6160 509604-0160 909572-0140 894200-8190 911229-0581 909878-5320 109305-0050 904110-8400 509300-0650 904110-8500 897166-9600 897231-0300 509625-0940 028080-6200 897106-4150 909571-4160 909524-6220 894368-5010 CAGE 1234567 Description Units Per Assy SMR Code Usable on Code
4N530 CYLINDER BLOCK AND OTHER PARTS ..... .... REF XC 4N530 . BLOCK ASSEMBLY, Cylinder ..................... I XB 4N530 .. BOLT, Metal cap .10 XB 4N530 .. CUP, Sealing- d=35. 5 XB 4N530 .. CUP, Sealing- d=22. 1 XB 4N530 .. CUP, Sealing- d=12. 7 XB 4N530 .. CUP, Sealing- d=32. 1 XB 4N530 . BEARING, Needle- cam ............... 1........... XB 4N530 . PLUG, Thrust cam ............................... 1 XB 4N530 . PLUG, Water drain ............................... 1 XB 4N530 . PLUG, Oil gallery- 1/8 npt ......................... 3 XB 4N530 . PLUG, Oil gallery- 1/8 npt ......................... 1 XB XB 4N530 . PLUG, Oil gallery- 1/4 npt ............. 1............ 4N530 . COVER, Injection pump housing ..................... 1 XB 4N530 . NUT, Cover ................................. 2 XB 4N530 . BOLT, Cover ................................. 4 XB 4N530 . BOLT, Cover ................................. 2 XB 4N530 . STUD, Injection pump- housing cover ...... ......... 1 XB 4N530 . STUD, Injection Pump- housing cover ...... ......... 1 XB 4N530 . STUD, Oil pan ................................. 2 XB 4N530 . STUD, Oil filter .......................... 1 XB 4N530 . PIN, Control link.......................... 2 XB 4N530 . PIN, Straight- housing............................ 2 XB 4N530 . DOWEL, Oil pump .......................... 2 XB 4N530 . PIN, Straight- retainer .......................... 2 XB 4N530 . PLUG, Cylinder block- m14 ....................... 1 XB 4N530 . PACKING, Plug ............... ........... I XB 4N530 . DOWEL, Cylinder head .......................... 2 XB 4N530 . DOWEL, Front plate .......................... 2 XB 4N530 . PIN, Straight- injection pump ....................... 8 XB 4N530 . STUD, Injection pump- 11=20 ...... ................ 8 XB 4N530 . STUD, Water pump- 11=40......................... 1 XB 4N530 . STUD, Timing case- 11=79 ......................... 1 XB 4N530 . STUD, Timing case- 11=50 ......................... 1 XB 4N530 . LEVEL GAUGE, Oil- 1=121 ....... ................ 1 XB 4N530 . RETAINER, Crank- rear ........................... 1 XB 4N530 . SEAL, Oil- crank- rear .......................... 1 XB 4N530 . PACKING, Retainer- bonded .................... A/R XB 4N530 . BOLT, Retainer .......................... 6 XB 4N530 . VALVE ASSEMBLY, Check ....................... 1 XB 4N530 . GASKET, Check valve .......................... 1 XB 4N530 . CLIP, Fuel pump lead wire ......................... 1 XB 4N530 . NUT, Stud- oil cooler .......................... 1 XB
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
22
0-46
0-44 18
FIG 15
31 33 87 37
x,00
86 Units Per Assy SMR Code XC XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB Usable on Code
Figure 4. Timning Gear Case and Other Parts. (Sheet 1 of 2) Figure & - Part Number Index No. 4-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 FIG. 3 897045-6175 897147-4890 908160-8500 897034-5945 897034-6382 908213-6250 909185-4040 897093-5491 897034-6374 897034-6422 8941304380 897076-9040 897148-5480 908160-5450 109605-0500 CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description
TIMING GEAR CASE AND OTHER PARTS ....... REF . FLYWEIGHT ASSEMBLY ....... ................. 1 . SLEEVE ASSEMBLY . ........................... 1 . SHAFT, Lever- d=8, 1=50 .......................... 1 . LEVER ASSEMBLY, Guide ...... ................. 1 . SHIFTER, Governor .............................. 1 SHAFT, Shifter- d=6, 1=25 ....... .................. 1 . RING, Snap ..................................... 1 . LEVER KIT, Governor ............................ 1 .. LEVER, Tension- governor .1 .. LEVER, Main spring .1 . NUT HOLDER . ................................. 1 . SPRING, Main . ................................. 1 LEVER ASSEMBLY, Floating ...................... 1 SHAFT, Floating lever ...... ...................... 1 PLUG, Shaft- 1/8 npt ....... ...................... 1
10
' T.O. 38G1 -127-1 TM1-2815-262-1 3&P SWP 998 01
V57
.56 58 61 6
63
72
Figure 4. Timing Gear Case and Other Parts. (Sheet 2) Figure & Index No.
4 -16 -17 -18 -19 -20 -21 -22 -23 -24 -26
Part Numl ber
CAGE
1234567 4N530 4N530 4N530 4N530
. .
Description
Units Per
Assy 1
SMR
Code XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB PAF2ZN XB XB XB
Usable
on Code
897112-2650 109747-0020 897148-5500 897034-6432 897083-7140 897148-8650 109747-0020 897164-3340 897016-9400 897038-8021
4N530
4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4F040 4N530 4N530 4N530
-25 894369-5450 -27 -28 -29 -30 -31 -32

-33
894454-6150 897049-3280 109623-0550 509503-1350 909110-5080 908160-4360

909150-5080
-34 894317-6381 -35 909111-4060 -36 897039-5841
PIECE, Guide- pin- governor lever ...... ............ PIN, Spring- governor lever ......................... . PLATE ............................... . SPRING, Start ............................... . SPRING, Set .............................. . LINK ASSEMBLY, Control ........................ . PIN, Snap- link plate .............................. . ANGLEICH KIT .............................. . SPRING, Return .............................. . BUSH, Lever- main spring ......................... . BUSH, Lever- main spring ......................... . CUP, Sealing- bushing- d=10 ....................... . LEVER, Governor control ......................... . O-RING, Control shaft ............................ . WASHER, Thrust .............................. . NUT, Lever to shaft ............................. . PIN, Control spring ............................... . WASHER, Spring .............................. . SCREW, Control- L-38 ........................... . NUT, Screw .............................. . SCREW, Set- full load ............................
I
1
1
1 1 1
1 1
1 1
1 1 1 1 I
1
1 2
2
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. 4 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46 -47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 -60 -61 -62 -63 -64 -65 -66 -67 -68 -69 -70 -71 -72 -73 -74 --75 -76 -77 -78 -79 -80 -81 -82 -83 Part Number CAGE 1234567 Description Units Per . SMR Code Assy XB XB 1 XB 1 XB 1 XB 1 XB 2 XB 1 XB 1.....XB 1........... XB I XB 1 XB 1 XB 1 XB 1 XB 1 XB 1 XB 1 PAFZZN I XB 1 PAFZZN 4 XB I XB 1 XB 1 XB 1 XB I XB 1 XB 1 XB 1 PAFZZN I XB 1.. XB 1 XB 6 XB 2 XB 2 XB 4 XB 3 XB I PAFZZN XA 1 XB 1 XB 1 PAFZZN 2 XB 2 XB 1.......... XB 1 XB 1 XB Usable on Code
909110-4060 515729-2391 897016-4410 909160-5040 909160-7040 909185-4030 509503-1320 509400-0480 909111-4060 515669-0021 897016-9361 897016-4460 897039-5461 897016-4492 109623-OSS0 509503-1350 909110-5080 909150-5080 897125-9740 897064-6881 028080-6200 897085-1771 509605-0192 897169-1941 897169-1971 109605-0500 897039-2644 511129-0060 909561-2530 028080-6140 897072-8300 911229-0581 028080-8800 028090-8600 091150-2080 028080-8450 028080-8300 894425-6852 894123-6231 511321-0910 511321-0360 511322-0180 509302-0081 091150-2100 897169-8890 900006-0070 900006-2070
4N530 . NUT, Screw ............................. 4N530 . EYE, Start spring ............................ 4N530 . SCREW, Set- idle spring ........................... 4N530 . WASHER, Idle spring- lower ....................... 4N530 . WASHER, Idle spring- upper ....................... 4N530 . RING, Snap- idle spring........................... 4N530 . PACKING, Set screw ............................ 4N530 . NUT, Cap- set screw ............................ 4N530 . NUT, Set screw ....................... 4N530 . CAP, Idle set ................. 4N530 . SPRING, Idle ................... ......... 4N530 . SHAFT ASSEMBLY, Fuel stop ..................... 4N530 . SPRING, Return- fuel stop ......................... 4N530 . LEVER, Fuel stop ............................. 4N530 . O-RING, Shaft ............................. 4N530 . WASHER, Thrust ............................ 4N530 . NUT, Shaft- lever ............................ 4F040 . WASHER, Spring............................. 4N530 . COVER, Governor lever ........................... 4N530 . PACKING COVER ............................. 4N530 . BOLT, Cover ............................ 4N530 . CASE, Gear- timing ............................ 4N530 . PLUG, Timing case ............................ 4N530 . PLATE ASSEMBLY, Sub- front ..................... 4N530 .. PLATE, Front. 4N530 .. PLUG, Front plate. 4N530 . COVER, Angleich ............................ 4N530 . CUP, Sealing- d=16 ............................. 4N530 . O-RING, Cover- angleich .......................... 4N530 . BOLT, Cover fix .................... ....... 4N530 . BOLT, W/detent hole- 1=16 ...................... 4N530 . DOWEL, Timing case ........................... 4N530 . BOLT, Timing case-block .......................... 4N530 . BOLT, Timing case- block ......................... 4N530 . NUT, Timing case ........................ ... 4N530 . BOLT, Timing case- front plate ..................... 4N530 . BOLT, Front plate- body ........................... 4N530 . CAP ASSEMBLY, Oil filler ........................ 4N530 .. PACKING, Cap .1 4N530 . SPACER, Plate- pump- t=18 ........................ 4N530 . COVER, Plate right reart .......................... 4N530 . PACKING, Plate- pump ......................... 4N530 . STUD, Timing case ......................... 4N530 . NUT, Cover ......................... 4N530 . GEAR, Pto- z=30 ............... 4N530 . BEARING, Ball- gear- front ........................ 4N530 . BEARING, Ball- gear- rear ........................
1 1
12
T.O. 38G1-127-1 M1-281 5-262-13&P SWP 998 01

Figure & Index No. 4 Part Number CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy I 2 2 2 1 1 1 3 SMR Code XB XB XB XB XB XB XB XB Usable on Code
-84 897081-9280 -85 900006-0070 -86 115739-0020 -87 981325-4460 -88 897047-0521 -89 109605-0190 -90 909565-2130 -91 509625-0790
. GEAR, Idle- z=66 ................................ . BEARING, Ball- idle gear ........ ................. . SEAL, Lead ..................................... . WIRE, Lead seal ................................. . BRACKET, Start spring ........................... . PLUG, Cover- governor ........................... . PACKING, O-ring- oil ........ .................... . SEAL, Oil- crank- front ........ ...................
4
Figure 5. Flywheel Housing and Other Parts. Figure & Index No. 5-1 -2 -3 -4 Part Number
CAGE 1234567
Description
Units Per Assy
SMR Code XC XB XB XB XB
Usable on Code
FIG.4 897171-8380 028181-0250 109302-1070 091150-2100
4N530 FLYWHEEL HOUSING AND OTHER PARTS ....... REF 4N530 . HOUSING, FLYWHEEL- L=100 .... ............... 1 4N530 . BOLT, HOUSING- BLOCK ..... .................. 4 4N530. STUD, BLOCK- HOUSING ..... .................. 2 4N530 . NUT ....................................... 2
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
.4
Figure 6. Oil Pan and Other Parts.
Figure & Index No. 6-
Part Number
CAGE 1234567
Description
Units Per Assy
SMR Code XC XB XB
Usable on Code
FIG. 5
-1
-2 -3 -4
897147-9990
109623-0570 897135-1410 897137-8360
-5
-6
4N530 OIL PAN AND OTHER PARTS ....... ........... REF 4N530 . PAN ASSEMBLY, Oil- w/find no. 4 packing ........... 1 . . VALVE, Oil drain (refer to 35D29-7-6-4 find 2-58) . REF 4N530 . . O-RING, Drain plug ............... .............. I 4N530 .. PACKING, Oil pan (bonded to find no. 1) .REF 4N530 . BOLT, Oil pan ............... 20 4N530 .NUT, Oil pan ............... 2
XB
XA XB XB
14
T.O. 38GI-127-1 TM1-2815-262-1 3&P SWP 998 01
Figure 7. Oil Pump and Fixing Parts.
Figure & Figure &

Index No. 7-1 -2 -3 -4 -5
Pan Number
FIG.6 897083-5761 894235-5671 894104-6150 897113-3320 897102-3071
Part Number
-
CAGE 1234567
Description
Units Per Assy
SMR Code
Usable on Code
-6 -7 -8 -9 -10 -11 -12
908160-6160 897109-6790 028080-6300 028080-6500 897117-2990 028080-8160 109623-4960
4N530 OIL PUMP AND FIXING PARTS ... ............. REF XC 4N530 . PUMP SUB-ASSEMBLY, Oil....................... 1 XB 4N530 . VALVE, Relief .............................. XB 4N530 . PLUG, Valve .............................. 1 XB 4N530 . SPRING, Valve .............................. 1 XB 4N530 . PIPE, Oil pump-cylinder block ..................... 1 XB 4N530 . PIN, Oil pump .......................... 2 XB 4N530 .O-RING, Oil pump ........................... 1 XB 4N530 .BOLT, Oilpump ............... ........... 2 XB 4N530 . BOLT, Oil pump ............... 1........... XB 4N530 . STRAINER ASSEMBLY, Oil ...................... 1 XB 4N530 . BOLT, Strainer ............. ............. 1 XB 4N530 . O-RING, Strainer- id=13.8 ......................... 1 XB
T.O. 38G1-127-1 TM1-2815-262-13&P SWP 998 01
.4 15
10
14
I
19
Figure 8.Crankshaft, Flywheel, Piston and Connecting Rod.
16
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. 8-1 -2 -3 -3 -4 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 --15 -16 -17 -18 -19 -20 -21 Part Number CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy SMR Code Usable on Code
FIG.7 897141-2100 511599-0031 897146-9960 897170-4010 897141-2080 897141-2090 897047-0240 894216-2064 894224-2362 512251-0070 512211-0180 894114-0491 897115-1770 897164-5300 894419-6020 897023-2680 894133-3281 894201-6410 897034-5920 897109-3721 894386-0790 894134-7920 894156-0840
CRANKSHAFT, Flywheel, piston and connecting rod.. REF XC 1 XB . BEARING KIT, Crank ............................ 2 XB . METAL, Thrust ................................ . PISTON, Standard ............................... 4 XB . PISTON, Oversize 0.25 mm ........................ 4 XB ............ 4 XB . RING SET, Piston standard ............ ......... 4 XB . RING SET, Piston oversize 0.25 mm ....... . ROD ASSEMBLY, Connecting rod ........ .......... 4 XB 2 .. BOLT, Connecting rod. XA 2 .. NUT, Connecting rod. XA .. BUSH, Connecting rod .1 XA ................ 4 . PIN, Piston ........... XB 8 XB . RING, Snap ........................... 1...... . CRANKSHAFT ASSEMBLY ................ XB 1 XB . FLYWHEEL ASSEMBLY ......................... 1 XB . GEAR, Ring- z=108 ........................... 6 XB . WASHER, Flywheel ........................... ....... 6 XB . BOLT, Flywheel .................... 1 XB . KEY, Woodruff ........................... 1 XB . GEAR, Crankshaft- z=37 .......................... 1 XB . PULLEY, Crankshaft ........................... 1............ . BOLT, Pulley ............... XB 1...... . WASHER, Pulley ..................... XB 4 XB . METAL SET, Connecting rod ......................
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
13
10
7'6
I-_
nI
46 -,
I
EXHAUST
Figure 9. Valve Mechanism, Rocker Arm.
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. Part Number CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy SMR Code XC XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB XB Usable on Code
9-
FIG.9 -1 897118-1964 -2 897118-6561 -3 911129-0830 -4 897039-5260 -5 908160-5160 -6 897116-4480 -7 897116-4500 -8 897010-4850 -9 909111-5060 -10 897070-6982
-11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21
-22
999202-3140 909571-4140 091150-2060 028080-6250 028080-6500 897102-1230 897045-4102 897034-6291 894251-0311 894239-5010 897124-3690
897069-5752
VALVE MECHANISM, Rocker arm ....... ........ REF . BRACKET, Rocker .............................. 1 . SHAFT, Rocker ............................... 1 . CUP, Sealing- d=12 .............................. 1 . CUP, Sealing- d=8 ............................... 1 . PIN, Rocker shaft ...................... . . 1 . ARM, Rocker- inlet .......... ........... 4 . ARM, Rocker- exhaust ..................... 4 . SCREW, Adjusting ..................... 8 . NUT, Adjusting screw .......... .......... 8 . SPRING, Rocker ..................... 4 . PLUG, Rocker shaft ........ ............ 1 . PACKING, Plug ...... .............. 1 . NUT, Rocker bracket ........... .......... 6 . BOLT, Rocker bracket ............. ........ 5 . BOLT, Rocker bracket .......... .......... 5 . VALVE, Inlet .... ................. 4 . VALVE, Exhaust ..................... 4 . SPRING, Valve ..................... 8 . SEAT, Valve spring ..................... 8 . COLLAR, Split .................... 16 .TAPPET .................... 8 . ROD, Push ..................... 8
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
OIL FILTER FUEL FILTER
11 12
Figure 10. Oil Filter, Fuel Filter and Fixing Parts.
Figure & Index No. 10-
Part Number
CAGE 1234567 4N530 4N530 4N530 S0226 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
Description OIL FILTER, Fuel filter and fixing parts ............ . CARTRIDGE, Oil filter ........................... . FILTER ASSEMBLY, Fuel ......................... .. CARTRIDGE, Fuel filter .1 BODY, Filter- fuel .1 BOLT, Eye joint- in ..... ............. PACKING, Eye joint- out .................. JOINT, Eye- filter out ...... ............ PLUG, Fuel filter ..... ............. PACKING, Plug- fuel filter ............ . JOINT, Eye- filter in ...... ............ ........... . BRACKET, Fuel filter ....... BOLT, Bracket .................. . BOLT, Fuel filter .................
Units Per Assy REF
SMR Code
Usable on Code
FIG. 10 -1 894456-7411 -2 897014-2040 -3 894132-9471 -4 894132-9480 -5 909906-3251 -6 909572-0140 -7 509674-0810 -8 999202-3140 -9 909571-4140 -10 894148-3900 -11 897111-5520 -12 028181-0200 -13 028081-0300
XC 1 PAFZZN 1 XB PAFZZN XB 2 XB 4 XB 1 XB 1 XB 1......XB 1 XB 1 XB 2 XB 2 XB
20
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
NSS= NOT SEPARATELY SUPPLIED
14 13
Figure 11. Cooling System. (Sheet 1 of 2) Figure & Index No. 11-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 Part Number FIG. 12 897182-8530 509605-0050 028080-8400 091150-2080 897211-2090 894365-6741 897169-0150 109605-0500 028680-8300 897038-4030 028080-8500 897063-4001 989136-4230 028080-8450 CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy
-
SMR Code XC PAFZZN XB XA XB XB PAFZZN PAFZZN XB XB XB XB XB XB XB XB
Usable on Code
COOLING SYSTEM, Fan and water pump ..... ..... REF . PUMP ASSEMBLY, Water- w/find no. 3 packing ....... 1 . PLUG, Heater- 3/8 npt .......... .................. 1 .......... REF . PACKING, Water pump (bonded) ...... . BOLT, Water pump- 1=40 ......... ................. 3 . NUT, Water pump ................................ 2 1 ................................ . THERMOSTAT . . PACKING, Outlet pipe ............................ 1 . PIPE, Water- upward outlet ........................ 1 . PLUG, Switch- 1/8 npt ............................ 1 . BOLT, Outlet pipe ................................ 2 1 .PULLEY, Fan- d=103 ............................. . BOLT, Clip fix . ................................. 1 . SPACER, Fan- pulley- t=4.5 ........ ............... 1 . SPACER, Fan- pulley- t=18 ........ ................ 1 . BOLT, Fan ...................................... 4
T.O. 38G1-127-1 TM1-2815-262-1 3&F SWP 998 01
23
//~~~~~~~~~-
22
20
Figure 11. Cooling System. (Sheet 2) Figure & Index No. 11 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 Part Number CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Pulley-water pump ......................... Cooling fan- 1=901 ......................... . HOSE, Connection to water pump .......... . CLIP, Oil cooler hose ............................. . COOLER ASSEMBLY, Oil ........................ . PACKING, Oil cooler ............................. . JOINT, 3-way ............... .................... .CLIP ........ . CONNECTOR, Cylinder head .............. . HOSE, Head to oil cooler .......................... . HOSE, Oil cooler to connector ...................... . CLIP, Hose .............. ............... . SPACER, Clip . ............................
. BELT, . BOLT,
Description
Units Per Assy
SMR Code
Usable on Code
020800-6120 897162-0810 897102-8790 894466-3820 897102-3200 894370-8280 897102-3080 909915-2811 894241-9620 897148-3430 897148-3450 109701-0411 515419-0360
2 XB 1 PAFZZN 1......... XB 4 XB 1 XB 1 XB 1............. XB 2 XB 1........ XB 1 XB 1 XB 1 XB 1 XB
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
2 1
Figure 12. Exhaust System. Figure & Index No. 12-1 -2 -3 -4 -5 -6 Part Number CAGE 1234567
4N530 4N530 4N530 4N530 4N530 4N530 4N530 EXHAUST SYSTEM ......................... . MANIFOLD, Exhaust ......................... . GASKET, Exhaust manifold ....................... . NUT, Exhaust manifold ......................... . BOLT, Exhaust manifold ......................... . STUD, Exhaust pipe ......................... . GASKET, Exhaust pipe .........................
Description
Units Per Assy

REF
SMR Code
XC
Usable on Code
FIG. 13 897117-5900 897126-1860 091150-2080 028080-8700 904110-8200 897042-0280
1 XB 1 PAFZZN 2 XB 6 XB 4 XB 1 PAF2ZN
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
1 9 12
;rK
11I
o'EE
FIG 17
Description Units Per Assy SMR Code Usable on Code
Figure 13. Fuel System, Injectors and Fuel Pipe.
Figure & Index No. 13-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12
Part Number
CAGE 1234567 4N530 S0226 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
FIG. 15 897079-9761 894106-0551 894257-5920 894257-5930 894106-0403 897102-1371 509707-0051 897144-7240 897126-1880 897046-7940 894379-6880 894144-5880
FUEL SYSTEM, Injectors and fuel pipe ...... ...... REF XC . NOZZLE ASSEMBLY, Injector ..................... 4 PAFZZN . HEAT SHIELD, Nozzle ........................... 4 XB . GASKET, Nozzle holder ........................... 4 PAFZZN . GASKET, Heat shield ............................. 4 PAFZZN . WASHER, Cormgated ............................ 4 XB . PIPE ASSEMBLY, Injection ........................ 4 XB . CLIP, Fuel hose ................................. 2 XB . PIPE ASSEMBLY, Fuel suction ..................... 1 XB . PIPE ASSEMBLY, Fuel- leak off .......... 1.......... XB . HOSE, Fuel feed- leak off .......................... 1 XB .BOLT, Eye ................................. 4 XB . GASKET ................................. 8 PAFZZN
24
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01
SEE FIG 20
6
Figure 14. Engine and Generator Brackets. CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy SMR Code XC XB XB XB XB XB XB XB Figure & Index No. 14-1 -2 -3 -4 -5 -6 -7 Part Number Usable on Code
FIG. 16 897085-3890 897085-3900 028080-8160 897161-9690 028081-0700 028080-8200 091150-2100
REF BRACKETS, Engine and generator ................. 1 . HANGER, Front .............................. 1 . HANGER, Rear .............................. 2 . BOLT, Front and rear hanger ....................... 1 . PLATE, Adjusting- generator ....................... 1 . BOLT, Generator ............................... ................. 1 . BOLT, Adjusting plate- generator . 1 . NUT, Generator ...............................
T.O. 38GI-127-1 TMI-2815-262-1 3&P SWP 998 01
18
22
INLET ,1 2' I
12 10
11 \ f
Figure 15. Injection Pump, Camshaft and Other Parts.
Figure & Index No. 15-1 -2 -3 -4
Part Numl)er
CAGE
Description
Units Per
1234567
4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
Assy
SMR Code XC PAFFFP PAFZZN XB XB XB XB XB XB XB XB XB XB XB XB
Usable on Code
FIG. 18 897147-5800 897126-3560 091150-2080 028080-8200
-5 -6 -7 -8
-9 -10 -11 -12 -13 -14
897145-1980 897062 0480 909878-6260 900090-6100

900090-6570 897102-2880 509400-0530 909180-1620 897129-7800 897129-7820
INJECTION PUMP, Camshaft and other parts ....... REF . PUMP ASSEMBLY, Injection ........ .............. 4 . SHIM, Injection pump- t=0.2 ......... .............. 4 . NUT, Injection pump ............... .............. 8 . BOLT, Injection pump ............ ................ 8 . SHAFT, Cam- injection pump and valve ...... ........ 1 . . RING, Wear- camshaft .1 .. PIN, Camshaft .1 .. BEARING, Ball- front .1 . . BEARING, Ball- rear. I . GEAR, Injection pump and valve- z=74 ..... ......... 1 . NUT, Cam gear .................................. 1 . RING, Snap- camshaft front ....... ................. 1 . SHAFT ASSEMBLY, Idle gear ...... ............... 1 . GEAR, W/bush- idle- z=44 ....... ................. 1
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. 15 -15 -16 -17 -18 -19 -20 -21 -22 Part Number 512535-0051 028090-8450 897183-0130 897166-4750 028080-6120 897166-4820 897111-5701 509707-0041 CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 . COLLAR, Thrust- idle gear ........................ . BOLT, Shaft ...... .................. . PUMP ASSEMBLY, Fuel- electric ................... . BRACKET, Fuel pump ........................ . BOLT, Fuel pump ......... ............... . HOSE, Fuel pump- fuel pipe ....................... . HOSE, Pump- fuel filter ........................ . CLIP, Fuel hose ........................ 5 Description Units Per Assy 1 2 1 1 2 1 1 4 SMR Code XB XB PAFZZN XB XB XB XB XB Usable on Code
,1
10
14
Units Per Assy REF 1 2 1 1 1 1 1 .......... 1 4 1 1 SMR Code XC PAFZZN XB PAFZZN XB PAFZZN PAFZZN XB PAFZZN PAFZZN XB PAFZZN Usable on Code
Figure 16. Electrical Parts. Figure & Index No. 16-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 Part Number FIG. 19 897135-3430 028181-2300 909150-5080 909111-4080 897048-9681 982720-0690 109605-0500 897183-0140 897106-5490 897138-6070 897125-6001 CAGE 1234567 4N530 4N530 4N530 4F040 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 ELECTRICAL PARTS .......................... STARTER ASSEMBLY ........................... BOLT, Starter .......... ................. WASHER, Lock- starter cable ...................... NUT, Starter cable ........................... GENERATOR ASSEMBLY ........................ SWITCH, Oil pressure .......................... .PLUG . .......................... SOLENOID ASSEMBLY, Engine stop ..... PLUG, Glow ........ .................. CONNECTOR, Glow plug ........................ SWITCH, Overheat warning ........................
Description
T.O. 38G1-1 27-1 TM1-2815-262-1 3&P SWP 998 01
v--19
.2
SEE FIG 13
Figure 17. Injection Pump Assembly.
Figure & Index No. 17-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11
Part Number 897147-5800 897170-8680 897083-3460 894128-9110 894128-9120 894132-7461 897083-3470 894128-9150 894128-9160 897083-3490 897083-3500 894128-9190
CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
Description PUMP ASSEMBLY, Injection .................... . PLUNGER ASSEMBLY .......................... . VALVE ASSEMBLY, Delivery ............. . SPRING, Delivery ............................ GASKET ............................ . HOLDER, Delivery ............................ . SEAT, Spring ............................ .O-RING ........................... . TAPPET ........ ................... . PIN ....... ..................... . RING, Snap ............................ . SPRING, Plunger ............................
Units Per Assy REF

1
SMR Code
Usable on Code
PAFFFP XB 1........ XB 1 XB 1 XB 1 XB 1 XB I PAFZZN 1 XB 1 XB 1 XB 1 XB
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. 17 -12 -13 -14 -15 -16 -17 -18 -19 Part Number CAGE 1234567 Description Units Per Assy SMR Code XB XB XB XB XB XB XB XB Usable on Code
894128-9200 894128-9210 894128-9310 897083-3551 894128-9230 897083-3480 894379-6920 894379-6910
4N530 . SEAT, Spring- upper .................... 1 4N530 .SEAT, Spring- lower .................... 1 4N530 . PLATE, T=2.60 .................... A/R I 4N530 . RACK, Control .................... 1 ............. 4N530 . SLEEVE, Control ...... 1 4N530 . SLEEVE, Flange .................... 2 4N530 . O-RING ................... 4N530 .BOLT .................... 2 2
Figure 18. Injection Nozzle Assembly.
Figure & IndexNo. 18-1 -2 -3 -4 -5 -6 -7 -8 -9 -10
Part Number 897079-9761 894130-5320 894104-9930 894128-9640 894128-9630 897083-3580 897084-6170 894129-0060 894176-9620
CAGE 1234567 S0226 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530
Description NOZZLE ASSEMBLY, Injection .................. .NOZZLE ....................... .HOLDER ASSEMBLY, Nozzle .................. .. GASKT. .. BODY, Nozzle holder .REF SPRING, Nozzle .1 . SEAT, Spring. ..SPACER ...... NUT, Retaining .1 NUT.1 ... SHIM, T=0.10. .
Units fPer AssyI REF 1 REF
SMR Code PAFZZN XB NSS XB NSS XB XB
Usable on Code
1 1
XB
XB XB
A/R
XB
T.O. 38G1-127-1 TMI-2815-262-1 3&P SWP 998 01
19
13
<-24 '21
17
17
Figure 19. Starter Assembly. Figure & Index No. 19-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 Part Number 897135-3430 897136-9090 897136-9080 894377-2400 897112-9540 897112-8700 897112-8710 897112-8720 897112-8730 897112-8800 897112-8750 897078-6490 897112-8790 581129-0990 894377-2460 CAGE 1234567 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 4N530 Description Units Per Assy SMR Code Usable on Code
........ REF PAFZZN STARTER ASSEMBLY, 12v-1.8kw ....... . YOKE ASSEMBLY .............................. 1 XA . ARMATURE ASSEMBLY .1........................ XA .. BEARING, Ball .1 XA .. BEARING, Ball. 1 XA 1 XA . CLUTCH SUB-ASSEMBLY ....................... 1 XA . HOUSING ASSEMBLY .......................... 1......... . SWITCH ASSEMBLY, Magnetic .......... XA 1........ . HOLDER ASSEMBLY, Brush .............. XA 4 XA .. SPRING, Brush. .FRAME, End ................. 1 XA 1 XA . PINION ................. . PINION ................. 1 XA 5 XA ............. . ROLLER, Clutch .... 1 XA . RETAINER .................
30
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01

Figure & Index No. 19 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 Part Number CAGE Description
1234567
4N530
. BALL,
Units Per ssy A:
SMR Code XA
Usable on Code
581129-0920 894377-2450 897112-8810 897136-9100 897112-8830 894377-2380 581119-0290 894109-7630 894170-2140 897041-4210
Steel ....................................
KA 4N530 . SPRING, Return ................................. 4N530 . BOLT, W/washer ................................ 2: KA 4N530 .BOLT, Through................................. 2: KA 4N530 . SCREW, W/o-ring ............................... 2: KA 4N530 .NUT .......................................... 4N530 . CAP, Terminal- rubber ............................ 4N530 .NUT .......................................... 4N530 . O-RING ...................................... 4N530 . BUSHING, Drain ................................ KA 1.: XA 1I KA 2:. XA 1 XA
Figure 20. Generator Assembly. Figure & Index No. 20-1 -2 -3 -4 Part Number CAGE 1234567 Description Units Per Assy SMR Code
PAFZZN XA XA XA XA
Usable on Code
897048-9681 897075-9650 894455-1540 897072-8390 897072-8380
4N530 GENERATOR ASSEMBLY, 12v-35amp ............. REF 4N530 . FRAME ASSEMBLY, Drive end .................... 1 4N530 .. PLATE, Retainer .1
4N530 .. SCREW. 4N530 . . BEARING, Ball ................ 4 1
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 01 Figure & Index No.
20 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26
Part Number
CAGE 1234567
4N530 .. STUD ...........
Description
Units Per SMR Assy Code

2
Usable on Code
894455-1560 897072-8410 897072-8420 894159-7810 894123-0560 894123-0570 894455-1600 897072-8430 897072-8350 894455-1660 894455-1640 894123-0610 894123-0640 894206-1860 897072-8400 894135-7530 894123-0510 897072-8340 897072-8360 894455-1630 894455-1620 894455-1610
4N530 4N530 4N530
FRAME, Rear end .1 . HOLDER ASSEMBLY, Rectifier .1 . HOLDER ASSEMBLY, Brush .1

.
4N530 .. BRUSH .... 4N530 .. SPRING .... 4N530 . REGULATOR ASSEMBLY .1 4N530 . COVER, Rear end .1 4N530 . NUT .1 4N530 . BUSH, Insulation .1 4N530 . BOLT, Flange. 4N530 . SCREW, W/washer.
2 2
2 2
4N530 .NUT.
4N530 . NUT. 4N530 . ROTOR ASSEMBLY. 4N530 .. BEARING, Ball ........... 4N530 .. COVER, Bearing ...........
2
I 1
1 1
4N530 .PULLEY .1
4N530 . COLLAR, Space .1 4N530 . BOLT. 3 6
4N530 .SCREW .1
4N530 . SCREW.
XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA XA
32
T.O. 38G1-127-1 TM1-281 5-262-13&P SWP 998 02
SUBORDINATE WORK PACKAGE

Total number of pages in this SWP is 6 Page No. 1-5 ..... 6 Blank . Change No. Page No. Change No. Page No. Change No
O
0
TABLE OF CONTENTS
Paragtph
1. Numerical Index ...........
P=
1
1. NUMERICAL INDEX
The numerical index on the following pages is a list of all of the part numbers shown on the master parts list of the illustrated parts breakdown (SWP 998 01).
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 02

Part Number FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. 1 1 10 10 12 12 13 13 15 15 16 16 18 18 19 19 2 2 3 3 4 4 5 5 6 6 7 7 9 9 Figure & Index No. 1-1 21-15 101-9 111-10 121-11 131-12 141-13 151-14 161-2 31-3 41-4 51-5 61-6 71-7 81-8 911-16 15-19 3-15 4-66 2-23 3-16 3-38 4-57 9-14 7-8 2-24 7-9 9-15 Part Number 028080-8160 028080-8160 028080-8200 028080-8200 028080-8300 028080-8400 028080-8450 028080-8450 028080-8500 028080-8700 028080-8800 028081-0300 028081-0700 028090-8450 028090-8600 028181-0200 028181-0250 028181-2300 028680-8300 091150-2060 091150-2060 091150-2080 091150-2080 091150-2080 091150-2080 091150-2100 091150-2100 091150-2100 109302-1070 109305-0050 109600-0051 109600-0112 109600-0112 109600-0121 109605-0040 109605-0190 109605-0190 109605-0500 109605-0500 109605-0500 109605-0500 109623-0550 109623-0550 Figure & Index No. 7-11 14-3 14-6 15-4 4-73 11-4 4-72 11-15 11-12 12-4 4-69 10-13 14-5 15-16 4-70 10-12 5-2 16-2 11-10 3-14 9-13 4-71 11-5 12-3 15-3 4-80 5-4 14-7 5-3 3-30 2-3 2-2 3-4 3-6 3-11 3-12 4-89 4-15 4-62 11-9 16-7 4-29 4-51 I Part Number 109623-0570 109623-4960 109701-0411 109747-0020 109747-0020 115739-0020 4LElPW14 509300-0650 509300-0650 509302-0081 509400-0480 509400-0530 509503- 1320 509503-1350 509503-1350 509600-0130 509604-0160 509605-0050 509605-0050 509605-0192 509625-0790 509625-0940 509674-0810 509707-0041 509707-0051 511119-0090 511129-0060 511321-0360 511321-0910 511322-0180 511599-0031 512211-0180 512251-0070 512535-0051 515419-0360 515669-0021 515729-2391 581119-0290 581129-0920 581129-0990 894104-6150 894104-9930 894106-0403 Figure & Index No. 6-3 7-12 11-27 4-17 4-22 4-86 12-11 3-32 4-79 4-44 15-11 4-43 4-30 4-52 3-5 3-25 2-13 11-2 4-59 4-91 3-36 10-7 15-22 13-7 2-4 4-64 4-77 4-76 4-78 8-2 8-9 8-8 15-15 11-28 4-46 4-38 19-21 19-15 19-13 7-3 18-3 13-5
020800-6120 028080-6120 028080-6140 028080-6140 028080-6200 028080-6200 028080-6200 028080-6200 028080-6250 028080-6300 028080-6450 028080-6500 028080-6500
T.O. 38G1-127-1 TM1-2815-262-1 3&P SWP 998 02

Part Number Figure & Index No. 13-2 19-22 2-12 8-10 20-21 20-9 20-10 20-16 20-17 2-21 4-75 17-3 17-4 17-7 17-8 17-11 17-12 17-13 17-16 17-14 18-6 18-5 18-9 4-11 18-1 17-5 10-3 10-4 2-20 8-15 8-20 20-20 13-12 10-10 8-21 20-8 3-2 19-23 18-10 3-27 8-16 20-18 I Part Number I 894216-2064 Figure & Index No. 8-6 8-7 3-3 7-2 9-20 11-24 9-19 13-3 13-4 4-34 2-18 3-18 11-7 3-42 4-25 11-21 19-20 19-3 19-16 19-14 13-11 17-19 17-18 8-19 8-13 4-74 4-27 20-2 20-5 20-11 20-26 20-25 20-24 20-15 20-14 10-1 2-15 11-19 9-8 10-2 4-39 4-48 4-50 Pa Number I 897016-9361 897016-9400 897023-2680 897031-7490 897034-5920 897034-5945 897034-6291 897034-6374 897034-6382 897034-6422 897034-6432 897036-9591 897038-4030 897038-8021 897039-2644 897039-4953 897039-5260 897039-5461 897039-5841 897041-4210 897042-0280 897045-3920 897045-4102 897045-6175 897046-7940 897047-0240 897047-0521 897047-0560 897047-1421 897048-9681 897048-9681 897049-3280 897062 0480 897063-4001 897064-6881 897069-5752 897070-6982 897072-8300 897072-8340 897072-8350 897072-8360 897072-8380 897072-8390 Figure & Index No. 4-47 4-24 8-14 2-5 8-17 4-4 9-18 4-9 4-5 4-10 4-19 2-16 11-11 4-26 4-63 3-21 9-4 4-49 4-36 19-24 12-6 2-7 9-17 4-1 13-10 8-5 4-88 3-7 3-8 16-5 204-28 15-6 11-13 4-56 9-22 9-10 4-67 20-22 20-13 20-23 20-4 20-3
894106-0551
894109-7630 894110-5591 894114-0491 894123-0510 894123-0560 894123-0570 894123-0610 894123-0640 894123-6231 894123-6231 894128-9110 894128-9120 894128-9150 894128-9160 894128-9190 894128-9200 894128-9210 894128-9230 894128-93 10 894128-9630 894128-9640 894129-0060 894130-4380 894130-5320 894132-7461 894132-9471 894132-9480 894133-2075 894133-3281 894134-7920 894135-7530 894144-5880 894148-3900 894156-0840 894159-7810 894167-4701 894170-2140 894176-9620 894200-8190 894201-6410 894206-1860
894224-2362 894229-8530
894235-5671 894239-5010 894241-9620 894251-0311 894257-5920 894257-5930 894317-6381 894329-5490 894343-8960 894365-6741 894368-5010 894369-5450 894370-8280 894377-2380 894377-2400 894377-2450 894377-2460 894379-6880 894379-6910 894379-6920 894386-0790 894419-6020 894425-6852 894454-6150 894455-1540 894455-1560 894455-1600 894455-1610 894455-1620 894455-1630 894455-1640 894455-1660 894456-7411 894463-7840 894466-3820 897010-4850 897014-2040 897016-4410 897016-4460 897016-4492
T.O. 38G1-127-1 TM1 -2815-262-13&P SWP 998 02

Part Number 897072-8400 897072-8410 897072-8420 897072-8430 897075-9650 897076-9040 897078-6490 897079-9761 897079-9761 897081 -9280 897083-3460 897083-3470 897083-3480 897083-3490 897083-3500 897083-3551 897083-3580 897083-5761 897083-7140 897084-6170 897085-1771 897085-3890 897085-3900 897093-5491 897094-6410 897102-1230 897102-1371 897102-2880 897102-3071 897102-3080 897102-3200 897102-5501 897102-8790 897106-4150 897106-5490 897109-3721 897109-6790 897111-5520 897111-5701 897112-2650 897112-8700 897112-8710 897112-8720 Figure & Index No. 20-19 20-6 20-7 20-12 20-1 4-12 19-11 13-1 184-84 17-2 17-6 17-17 17-9 17-10 17-15 18-7 7-1 4-20 18-8 4-58 14-1 14-2 4-8 2-9 9-16 13-6 15-10 7-5 11-22 11-20 3-20 11-18 3-39 16-9 8-18 7-7 10-11 15-21 4-16 19-5 19-6 19-7 Part Number 897112-8730 897112-8750 897112-8790 897112-8800 897112-8810 Figure & Index No. 19-8 19-10 19-12 19-9 19-17 19-19 19-4 7-4 2-1 8-11 2-8 9-6 9-7 7-10 12-1 9-1 2-17 9-2 3-13 2-22 9-21 16-11 4-55 2-6 12-2 13-9 15-2 15-13 15-14 6-5 16-1 192-14 19-2 19-1 19-18 6-6 16-10 8-4 F8-4 8-1 13-8 15-5 Part Number 897146-9960 897147-4890 897147-5800 897147-5800 897147-9990 897148-3430 897148-3450 897148-5480 897148-5500 897148-8650 897161-9690 897162-0810 897164-3340 897164-5300 897166-4750 897166-4820 897166-9600 897169-0150 897169-1920 897169-1941 897169-1971 897169-8890 897170-4010 897170-8680 897171-8380 897182-8530 897183-0130 897183-0140 897211-2090 897231-0300 900006-0070 900006-0070 900006-2070 900090-6100 900090-6570 Figure & Index No. 8-3 4-2 15-1 176-1 11-25 11-26 4-13 4-18 4-21 14-4 11-17 4-23 8-12 15-18 15-20 3-34 11-8 3-1 4-60 4-61 4-81 F8-3 17-1 5-1 11-1 15-17 16-8 11-6 3-35 4-82 4-85 4-83 15-8 15-9 2-19 3-17 3-19 12-5 2-10 3-31 3-33 4-32
897112-8830
897112-9540 897113-3320 897114-7130 897115-1770 897115-3150 897116-4480 897116-4500 897117-2990 897117-5900 897118-1964 897118-2052 897118-6561 897118-9891 897119-2990 897124-3690 897125-6001
897125-9740
897126- 1390 897126-1860 897126-1880 897126-3560 897129-7800 897129-7820 897135-1410 897135-3430 897135-3430
897136-3240
897136-9080 897136-9090 897136-9100 897137-8360 897138-6070 897141-2080
903910-4100 904110-6160 904110-6160 904110-8200 904110-8400 904110-8400 904110-8500 908160-4360
897141-2090 897141-2100 897144-7240 897145-1980
T.O. 38G1-127-1 TM1-281 5-262-1 3&P SWP 998 02

Part Number 908160-5160 908160-5450 908160-6160 908160-6160 908160-8160 908160-8500 908213-6250 909110-4060 909110-5080 909110-5080 909111-4060 909111-4060 909111-4080 909111-5060 909150-5080 909150-5080 909150-5080 909160-5040 909160-7040 909180-1620 909185-4030 909185-4040 909204-5 100 909524-6220 909561-2530 909565-2130 909571-4140 909571-4140 909571-4160 909572-0140 909572-0140 909664-0010 909878-5320 909878-6260 909906-3251 909915-2811 911129-0830 911229-0581 911229-0581 911229-0581 981325-4460 982720-0690 989136-4230 Figure & Index No. 9-5 4-14 3-24 7-6 3-22 4-3 4-6 4-37 4-31 4-53 4-35 4-45 16-4 9-9 4-33 4-54 16-3 4-40 4-41 15-12 4-42 4-7 3-10 3-41 4-65 4-90 9-12 10-9 3-40 3-26 10-6 3-9 3-29 15-7 10-5 11-23 9-3 3-23 3-28 4-68 4-87 16-6 11-14 Part Number I 999202-3140 999202-3140 Figure & Index No. 9-11 10-8 Part Number Figure & Index No.
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SERVICE AND OVERHAUL INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN

DIESEL ENGINE FOR SELF GENERATING NITROGEN SERVICING CART (SGNSC)

T.O. 38G1 -127-1 TMI-2815-262-1 3&P

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES

*Zero in this column indicates an original page

38G1 -127-1 TM1-2815-262-1 3&P

T.O. 38G1 -127-1 TM1-2815-262-1 3&P WP 001 00

WORK PACKAGE ALPHABETICAL INDEX

SERVICE AND OVERHAUL INSTRUCTIONS

LIST OF EFFECTIVE WP PAGES

Total number of pages in this WP is 2 Change No. Page No.

ALPHABETICAL INDEX OF EFFECTIVE WORK PACKAGES

............. 004 03 010 00 002 00 005 00 ............ 998 00

T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 002 00

WORK PACKAGE FOREWORD

SERVICE AND OVERHAUL INSTRUCTIONS

LIST OF EFFECTIVE WP PAGES

Fuel, Lubricant and Coolant .................

Notes On the Format of These Work Packages . 6

T.O. 38G1 -127-1 TM1-2815-262-1 3&P WP 002 00 1. GENERAL INFORMATION

1.1. ENGINE IDENTIFICATION

Figure 1. Engine Details.

T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 002 00

850 Engine modification Bosch, PFR type 135 (1920)

Variable speed, mechanical type Throttle type 0.4 (0.0157) 150

2.2 Isuzu Genuine Parts

3. FUEL, LUBRICANT, AND COOLANT

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE

-25C -2O@C -152C (-13F) (4F) (5F)

250C 30"C (770F) (86WFl

Figure 3. Recommended Oil Viscosity Grades.

T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 002 00

Figure 4. Example of Major Components Order of Disassembly and Reassembly.

T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 003 00

WORK PACKAGE MASTER LIST OF SPECIAL TOOLS AND CONSUMABLES

SERVICE AND OVERHAUL INSTRUCTIONS

LIST OF EFFECTIVE WP PAGES

Total number of pages in this WP is 4 Page No. Change No.

Table 1. Master List of Special Tools.

SWP 006 01 5-8840-0015-0

Bearing removal tool

Removing press fit bearings

5-8840-2061-0 5-8840-9004 5-8840-9007-0 5-8840-9015

S0226 S0226 S0226 S0226

Figure 2 Figure 3 Figure 5 Figure 9

Front Oil Seal Installation Tool

Injection Nozzle Tester

5-8840-9018-0 Commercial Tool

Piston Ring Compressor Valve Spring Compressor

T.O. 38G1-127-1 TM1-2815-262-13&P WP 003 00

x_}DFigure 1. Valve Spring Compressor. Figure 7. Compression Gauge.

Figure 2. Front Oil Seal Installation Tool.

Figure 8. Compression Gauge Adapter.

Figure 4. Drive Bar.

Figure 10. Injection Nozzle Tester.

Figure 5. Valve Guide Oil Seal Installion Tool.

Figure 11. Piston Ring Compressor.

Figure 6. Bearing Removal Tool.

T.O. 38G1-127-1 TM1-2815-262-1 3&P WP 003 00 2. CONSUMABLE MATERIALS

Sealing pipe threads Locking bolt and nut threads